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RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application Ser. No. 61/555,074 filed 3 Nov. 2011 under 35 U.S.C. 119(e).
FIELD
The field of the invention is a pressure mounted storage system with a locking friction clamp and a sliding container.
BRIEF DESCRIPTION
A pressure mounted storage system (PMSS) is a kitchen space optimization solution that reclaims unused storage space, reduces clutter, and delivers high-end functionality—without tools—at fraction of the price of existing systems. The PMSS is particularly beneficial in households that desire more kitchen storage space and improved organization, in contrast to professional kitchen remodeling which is expensive, and do-it-yourself (DIY) home improvement kits which are messy, time-consuming and require specific expertise, without nailing, screwing, drilling or expensive contractors—making kitchen upgrading a snap. The pressure mounting provides a friction mounting or a friction and pressure mounting of a storage apparatus to the inside of an existing kitchen cabinet or other enclosure. The drawer is one example of a shelf or other form of storage.
In one aspect, a pressure mounting apparatus comprises a platform and a locking friction clamp having at least two snap arms that are pivotally coupled at first ends to each other through a push/pivot buckle and each of the at least two snap arms being pivotally attached at second ends to a snap compression pad, wherein the plurality of snap arms have a locked position and an unlocked position wherein the locking friction clamp being mounted on the platform.
In a further aspect, an enclosure comprises a plurality of walls comprising an exterior of the enclosure, the plurality of walls forming an interior of the enclosure, a platform attached to the interior of the walls and having faces comprising a side, a front and a rear, and a plurality of locking bars protruding from at least one of the faces of the platform, wherein the plurality of locking bars have a locked position and an unlocked position wherein the plurality of locking bars being pivotally mounted on the platform, and wherein the locking bars create friction in the locked position against the plurality walls to hold the platform in place.
In another aspect, an enclosure comprises a platform, a plurality of walls coupled to the platform and at least one pivoting lever member that is mounted on the platform and operable to pivot into a position that creates force and friction against the walls.
Pressure mounting apparatuses of varying scope are described herein. In addition to the aspects and advantages described in this summary, further aspects and advantages will become apparent by reference to the drawings and by reading the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric diagram of a pressure mounted storage apparatus, according to an implementation;
FIG. 1B is an isometric diagram of a locking friction clamp integrated into a platform of a pressure mounted storage apparatus, according to an implementation;
FIG. 2 is a bottom view of a block diagram of a pressure mounted apparatus 100 of a pressure mounted storage system in an unlocked configuration, according to an implementation;
FIG. 3 is a bottom view of a block diagram of a pressure mounted apparatus of a pressure mounted storage system in a locked configuration, according to an implementation;
FIG. 4 is a bottom view of a block diagram of a pressure mounted apparatus of a pressure mounted storage system in an unlocked configuration, according to an implementation;
FIG. 5 is a bottom view of a block diagram of a pressure mounted apparatus of a pressure mounted storage system in an unlocked configuration, according to an implementation;
FIG. 6 is a bottom view of a block diagram of a pressure mounted storage apparatus of a pressure mounted storage system in an unlocked configuration, according to an implementation;
FIG. 7 is a bottom view of a block diagram of a pressure mounted storage apparatus of a pressure mounted storage system in a locked configuration, according to an implementation;
FIG. 8 is a bottom view of a block diagram of a lateral pressure mounted storage apparatus of a pressure mounted storage system in an unlocked configuration, according to an implementation;
FIG. 9 is a bottom view of a block diagram of a lateral pressure mounted storage apparatus of a pressure mounted storage system in a locked configuration, according to an implementation;
FIG. 10 is a bottom view of a block diagram of a pressure mounted storage apparatus of a pressure mounted storage system having a single actuating bar in an unlocked configuration, according to an implementation;
FIG. 11 is a bottom view of a block diagram of a pressure mounted storage apparatus of a pressure mounted storage system having a single actuating bar in a locked configuration, according to an implementation;
FIG. 12 is a bottom view of a block diagram of a lateral pressure mounted storage apparatus of a pressure mounted storage system in an unlocked configuration, according to an implementation;
FIG. 13 is a bottom view of a block diagram of a lateral pressure mounted storage apparatus of a pressure mounted storage system in a locked configuration, according to an implementation;
FIG. 14 is an isometric diagram of a pressure mounted child-proof lockable storage apparatus, according to an implementation;
FIG. 15 is an isometric diagram of a pressure mounted spice storage apparatus, according to an implementation;
FIG. 16 is an isometric diagram of a pressure mounted crisper storage apparatus, according to an implementation;
FIG. 17 is an isometric diagram of a pressure mounted wrap storage apparatus, according to an implementation;
FIG. 18 is an isometric diagram of a pressure mounted platform apparatus with no drawer, according to an implementation;
FIG. 19 is a top view of a block diagram of a lateral pressure mounted storage apparatus of a pressure mounted storage system in a closed configuration, according to an implementation;
FIG. 20 is a top view of a block diagram of a lateral pressure mounted storage apparatus of a pressure mounted storage system in an open configuration, according to an implementation; and
FIG. 21 is a flowchart of a method of installing the pressure mounted storage apparatus, according to an implementation.
DETAILED DESCRIPTION
In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific implementations that may be practiced. These implementations are described in sufficient detail to enable those skilled in the art to practice the implementations, and it is to be understood that other implementations may be utilized and that logical, mechanical, electrical and other changes may be made without departing from the scope of the implementations. The following detailed description is, therefore, not to be taken in a limiting sense.
The detailed description is divided into three sections. In the first section, apparatus described. In the second section, a method is described. In the third section, a conclusion of the detailed description is provided.
Apparatus
FIG. 1 is an isometric diagram of a pressure mounted storage apparatus 100 , according to an implementation. Apparatus 100 includes two notable features and attributes: a locking friction clamp 102 and a sliding container 104 . The sliding container 104 is moveably mounted or moveably attached to the locking friction clamp 102 through a platform 106 . In the example shown in FIG. 1-9 the sliding plastic container 104 is a sliding drawer, but in other examples shown in FIG. 14-13 , the sliding plastic container 104 is a lockable “child-proof” lockable drawer, a spice drawer, a crisper drawer, or a wrap drawer. In some implementations of the sliding drawer shown in FIG. 1 , the sliding drawer is collapsible container. Some implementations of the pressure mounted storage system include a level 108 that is integrated into the apparatus that can be used during installation to determine if the pressure mounted storage system is positioned level along an axis.
One particular benefit of pressure mounted storage apparatus 100 is that the pressure mounted storage apparatus 100 is not attached to the inside of a cabinet enclosure with screws, nails, tape, adhesive, or any other common attachment device. Instead, the pressure mounted storage apparatus 100 is simply “snapped” into place using an integrated clamp system of the locking friction clamp 102 (shown in FIG. 1-9 ). The integrated clamp system places outward pressure against opposing inside wall(s) of the cabinet, securely holding pressure mounted storage apparatus 100 in place within and inside the cabinet.
All cabinets in North America have standard sizes. Standard base kitchen cabinet sizes uniform in terms of depth and height (24″ deep, 34½″ tall). The widths are also predictable and standardized, with stock cabinets available in 3″ increments (9″, 12″, 15″, etc., usually up to 36″). The dimension makes ordering the right size no different than specifying a preferred size of shirt. Thus, the pressure mounted storage apparatus 100 is also manufactured in predictable and standardized dimensions, well-suited for mass production.
In some implementations, the sliding plastic container 104 includes an integrated pull stop (not shown in FIG. 1 ) so that the sliding plastic container 104 may not be completely pulled out of its housing (not shown in FIG. 1 ).
FIG. 1B is an isometric diagram of a locking friction clamp integrated into a platform of a pressure mounted storage apparatus 150 , according to an implementation; Apparatus 150 includes two notable features and attributes: the locking friction clamp 102 is integrated into the platform 106 and the sliding container 104 . The sliding container 104 is slideably mounted or slideably attached to the locking friction clamp 102 through the platform 106 .
FIG. 2 is a bottom view of a block diagram of a pressure mounted apparatus 100 of a pressure mounted storage system in an unlocked configuration, according to an implementation. The pressure mounted apparatus 100 includes a platform 106 and a locking friction clamp 102 . The locking friction clamp 102 includes at least one snap arm 202 that is pivotally coupled to at least one of the platform 106 (as shown in FIG. 4-5 and at least one other snap arm 204 . The at least one snap arm 202 has an unlocked (and an unlocked position as shown in FIG. 3 ). The at least one snap arm 202 is operable to hold the platform 106 in position in a cavity 206 by creating friction against at least on side of the cavity in the locked position, as shown in FIG. 3 . In some implementations of the snap arm, the snap arm is extendable or adjustable in reach. In one example of the extendable or adjustable snap arm, the snap arm 202 is adjustable through screws, where some portion of the snap arm 202 is threaded onto a base of the snap arm 202 or onto a lead screw and threading out the screw makes the snap arm 202 longer. In another example of the extendable or adjustable snap arm, the snap arm 202 is adjustable through discrete position adjustment, wherein the snap arms 202 are snapped into different positions using a spring loaded ball or pin and holes in a sliding outer member.
In some implementations, the platform 106 is adjustable or extendable in width, such as by a sleeve that is a part of platform 106 , and by a center piece that fits inside the sleeve and slides out to extend the width of the platform 106 . In some implementations, the adjustable or extendable platform 106 does not lock into a given width because the platform 106 takes only vertical loads. The locking friction clamp 102 is attached to the bottom of the adjustable or/extendable platform 106 and the snap arm(s) 202 are adjustable in length, but the locking friction clamp 102 is fixed in width and has a width that is not adjustable or extendable.
FIG. 3 is a bottom view of a block diagram of a pressure mounted apparatus 100 of a pressure mounted storage system in a locked configuration, according to an implementation. The at least one snap arm 202 is in a locked position as shown in FIG. 3 . The at least one snap arm 202 holds the platform 106 in a position in a cavity 206 by creating friction against at least on side of the cavity in the locked position
FIG. 4 is a bottom view of a block diagram of a pressure mounted apparatus 100 of a pressure mounted storage system in an unlocked configuration, according to an implementation. The pressure mounted apparatus 100 includes a platform 106 and a locking friction clamp 102 . The locking friction clamp 102 includes at least one snap arm 202 that is pivotally coupled to at least one of the platform 106 (as shown in FIG. 4-5 . The at least one snap arm 202 has an unlocked (and an unlocked position as shown in FIG. 5 ). The at least one snap arm 202 is operable to hold the platform 106 in position in a cavity 206 by creating friction against at least one side of the cavity in the locked position, as shown in FIG. 5 .
FIG. 5 is a bottom view of a block diagram of a pressure mounted apparatus 100 of a pressure mounted storage system in a locked configuration, according to an implementation. The pressure mounted apparatus 100 includes a platform 106 and a locking friction clamp 102 . The locking friction clamp 102 includes at least one snap arm 202 that is pivotally coupled to at least one of the platform 106 . The at least one snap arm 202 is a locked position as shown in FIG. 5 . The at least one snap arm 202 is operable to hold the platform 106 in position in a cavity 206 by creating friction against at least one side of the cavity in the locked position.
FIG. 6 is a bottom view of a block diagram of a pressure mounted storage apparatus 100 of a pressure mounted storage system in an unlocked configuration, according to an implementation. The pressure mounted storage apparatus 100 is shown in FIG. 6 in an unlocked configuration.
Each locking friction clamp 102 includes at least 2 snap arms (such as 202 and 204 ; or 602 and 603 ) that are rigid arms. When the snap arms are pushed outward by a push/pivot buckle 605 and 604 , the snap arms apply pressure through snap compression pads 614 , 616 , 606 and 608 upon and onto the inner walls of the cabinet enclosure 814 . Each pair of snap arms (such as pair 202 and 204 ) are identical in structure and function. The push/pivot buckles 605 and 604 rotatably connect the snap arms together and serve as the central connection and rotation point to the snap arms. The snap compression pads 614 , 616 , 606 and 608 are attached at the end of each snap arm to ensure snug and lasting fit.
Unlike conventional approaches which require tools and precision measurement, the pressure mounted storage apparatus 100 takes advantage of the rigidity and predictability of the size and space of standard kitchen cabinets in which the dimensions of the pressure mounted storage apparatus 100 is reasonably calculated to have a tight snug fit in a specifically sized cabinet when the snaps arms 202 , 204 , 602 and 603 are locked (such as in FIG. 7 ) yet the pressure mounted storage apparatus 100 is reasonably calculated to have a loose fit in the same specifically sized cabinet when the snaps arms 202 , 204 , 602 and 603 are unlocked (such as in FIG. 6 ).
The snap arms (e.g. 202 , 204 , 602 and 603 ) are also known as pivoting lever members.
The snap arms (e.g. 202 , 204 , 602 and 604 ) are also known as pivoting lever members. The snap compression pad (e.g. 614 ) is also known at a locking bar.
FIG. 7 is a bottom view of a block diagram of a pressure mounted storage apparatus 100 of a pressure mounted storage system in a locked configuration, according to an implementation. The pressure mounted storage apparatus 100 shown in FIG. 7 is a locked configuration.
The locking friction clamp 102 includes snap arms 202 , 204 , 602 and 603 that are rigid arms that when pushed outward by the push/pivot buckle 605 and 604 , as shown in FIG. 7 , applies pressure through snap compression pads 614 , 616 , 606 and 608 upon the outer walls of the cabinet enclosure 814 . The snap compression pads 614 , 616 , 606 and 608 is attached at the end of each snap arm to ensure snug and lasting fit. Note that in the locked configuration or position as shown in FIG. 7 , the snap arms 202 , 204 , 602 and 603 are not aligned in a straight line to each other, but have in fact been moved from the position as shown in FIG. 6 to a position further beyond straight alignment to each other to a position in which the push/pivot buckle 605 is closer to closest end 222 of the platform 106 than are the snap compression pads 614 and 616 and to a position in which the push/pivot buckle 604 is closer to closest end 702 of the platform 106 than are the snap compression pads 606 and 608 . The location of the snap arms 202 , 204 , 602 and 603 when not aligned in a straight line to each other after having been moved from the position as shown in FIG. 6 to a position further beyond straight alignment to each other is known as “negative space” helps ensure position of the locking friction clamp 102 remains locked in place, without risk of unintentional release. The negative space is an area on one side of the snaps arms 202 , 204 , 602 and 603 in which the snap arms move past 90 degrees into a locked position of about 3 degrees past 90 or so.
The snap arms can be positioned either from side-to-side as shown in FIG. 6-3 or from front-to-back as shown in FIG. 8-5 . In another example of the extendable or adjustable snap arm, each snap arm is adjustable through caps or compression pads 606 , 608 , 614 and 616 of different thicknesses can be placed on the ends of the snap arms, 202 , 204 , 602 and 603 , respectively. In some implementations, the snap arms (e.g. 202 , 204 , 602 and 603 ) have a threaded end that allows adjustment of the length of the snap arms.
FIG. 8 is a bottom view of a block diagram of a lateral pressure mounted storage apparatus 800 of a pressure mounted storage system in an unlocked configuration, according to an implementation. The pressure mounted storage apparatus 800 is shown in FIG. 8 in an unlocked configuration.
The locking friction clamp 102 includes snap arms 802 , 804 , 806 and 808 that are rigid arms. When the snap arms are pushed outward by a push/pivot buckle 810 and 812 , the snap arms apply pressure through snap compression pads 614 , 616 , 606 and 608 upon and onto the inner walls of the cabinet enclosure 814 . Each pair of snap arms (such as pair 802 and 804 ) are identical in structure and function. The push/pivot buckles 810 and 812 connect the snap arms together and serve as the central connection and rotation point to the snap arms. The snap compression pads 614 , 616 , 606 and 608 are attached at the end of each snap arm to ensure snug and lasting fit. Negative space ensures position of the locking friction clamp 102 remains locked in place, without risk of unintentional release.
FIG. 9 is a bottom view of a block diagram of a lateral pressure mounted storage apparatus 800 of a pressure mounted storage system in a locked configuration, according to an implementation. The pressure mounted storage apparatus 800 shown in FIG. 9 in a locked configuration.
The locking friction clamp 102 includes snap arms 802 , 804 , 806 and 808 that are rigid arms that when pushed outward by the push/pivot buckle 810 and 812 , as shown in FIG. 9 , applies pressure through the snap compression pads 614 , 616 , 606 and 608 upon the outer walls of the cabinet enclosure 814 . The snap compression pads 614 , 616 , 606 and 608 is attached at the end of each snap arm to ensure snug and lasting fit. Negative space ensures position of the locking friction clamp 102 remains locked in place, without risk of unintentional release.
FIG. 10 is a bottom view of a block diagram of a pressure mounted storage apparatus 1000 of a pressure mounted storage system having a single actuating bar in an unlocked configuration, according to an implementation. The pressure mounted storage apparatus 100 is shown in FIG. 6 in an unlocked configuration.
The single actuating bar 1002 provides a mechanism to apply mechanical pressure to all of the snap arms 202 , 204 , 602 and 603 simultaneously.
FIG. 11 is a bottom view of a block diagram of a pressure mounted storage apparatus 1100 of a pressure mounted storage system having a single actuating bar in a locked configuration, according to an implementation. The pressure mounted storage apparatus 100 is shown in FIG. 11 in a locked configuration.
The single actuating bar 1002 applies mechanical pressure to all of the snap arms 202 , 204 , 602 and 603 simultaneously. In another implementation of pressure mounted storage apparatus 1000 in FIG. 10 and pressure mounted storage apparatus 1100 in FIG. 1100 , at least two actuating bars are implemented, one actuating bar positioned towards the left side of the pressure mounted storage apparatus 1000 and 1100 and a second actuating bar positioned towards the right side of the pressure mounted storage apparatus 1000 and 1100 .
FIG. 12 is a bottom view of a block diagram of a lateral pressure mounted storage apparatus 1200 of a pressure mounted storage system in an unlocked configuration, according to an implementation. The pressure mounted storage apparatus 1200 is shown in FIG. 12 in an unlocked configuration.
The locking friction clamp 102 includes snap arms 202 and 204 that are rigid arms. When the snap arms 802 and 804 are pushed outward by a push/pivot buckle 810 , the snap arms 802 and 804 apply pressure through snap compression pads 614 , 616 , 606 and 608 upon and onto snap arms 802 , 804 , 806 and 808 that are rigid arms. When the snap arms are pushed outward by a push/pivot buckle 810 and 812 , the snap arms apply pressure through a snap compression pads 614 , 616 , 606 and 608 upon and onto the inner walls of the cabinet enclosure 814 . Each pair of snap arms (such as pair 802 and 804 ) are identical in structure and function. The push/pivot buckles 810 and 812 connect the snap arms together and serve as the central connection and rotation point to the snap arms. The snap compression pads 614 , 616 , 606 and 608 are attached at the end of each snap arm to ensure snug and lasting fit. Negative space ensures position of the locking friction clamp 102 remains locked in place, without risk of unintentional release.
FIG. 13 is a bottom view of a block diagram of a lateral pressure mounted storage apparatus 1200 of a pressure mounted storage system in a locked configuration, according to an implementation. The pressure mounted storage apparatus 1200 is shown in FIG. 13 in a locked configuration.
The locking friction clamp 102 includes snap arms 202 and 204 that are rigid arms. When the snap arms 202 and 204 are pushed outward by a push/pivot buckle 610 , the snap arms 202 and 204 apply pressure through snap compression pads 614 , 616 , 606 and 608 upon and onto snap arms 802 , 804 , 806 and 808 that are rigid arms. When the snap arms are pushed outward by a push/pivot buckle 810 and 812 , the snap arms apply pressure through a snap compression pads 614 , 616 , 606 and 608 upon and onto the inner walls of the cabinet enclosure 814 . Each pair of snap arms (such as pair 802 and 804 ) are identical in structure and function. The push/pivot buckles 810 and 812 connect the snap arms together and serve as the central connection and rotation point to the snap arms. The snap compression pads 614 , 616 , 606 and 608 are attached at the end of each snap arm to ensure snug and lasting fit. Negative space ensures position of the locking friction clamp 102 remains locked in place, without risk of unintentional release.
FIG. 14 is an isometric diagram of a pressure mounted child-proof lockable storage apparatus 1400 , according to an implementation. The pressure mounted child-proof lockable storage apparatus 1400 includes a sliding child-proof lockable drawer 1402 .
FIG. 15 is an isometric diagram of a pressure mounted spice storage apparatus 1500 , according to an implementation. The pressure mounted spice storage apparatus 1500 includes a sliding plastic spice drawer 1502 .
FIG. 16 is an isometric diagram of a pressure mounted crisper storage apparatus 1600 , according to an implementation. The pressure mounted crisper storage apparatus 1600 includes a crisper drawer with a top 1602 .
FIG. 17 is an isometric diagram of a pressure mounted wrap storage apparatus 1700 , according to an implementation. The pressure mounted wrap storage apparatus 1700 includes a drawer that is suitable for storing packages of aluminum foil wrap and plastic wrap. Some implementations of the pressure mounted wrap storage apparatus 1700 include dividers that separate the packages of aluminum foil wrap and plastic wrap.
FIG. 18 is an isometric diagram of a pressure mounted platform apparatus 1800 with no drawer or container, according to an implementation.
FIG. 19 is a top view of a block diagram of a lateral pressure mounted storage apparatus 800 of a pressure mounted storage system in a closed configuration, according to an implementation.
The locking friction clamp 102 includes the snap compression pads 614 , 616 , 606 and 608 that are attached at the end of each snap arm (not shown in FIG. 19 ) to ensure snug and lasting fit. The sliding plastic container 104 is in a retracted (closed) position.
FIG. 20 is a top view of a block diagram of a lateral pressure mounted storage apparatus 800 of a pressure mounted storage system in an open configuration, according to an implementation. The sliding plastic container 104 is in an extended (opened) position.
Method
FIG. 21 is a flowchart of a method 2100 of installing the pressure mounted storage apparatus, according to an implementation. Method 2100 includes positioning the pressure mounted storage apparatus inside a cabinet at block 2102 and locking the pressure mounted storage apparatus in the position by snapping the snap bars in a locked position.
In particular, one of skill in the art will readily appreciate that the names of the methods and apparatus are not intended to limit implementations. Furthermore, additional methods and apparatus can be added to the components, functions can be rearranged among the components, and new components to correspond to future enhancements and physical devices used in implementations can be introduced without departing from the scope of implementations. One of skill in the art will readily recognize that implementations are applicable to future drawers, different pivots, and new moveable mounts.
CONCLUSION
The terminology used in this application is meant to include all pivot arms and compression pads and alternate technologies which provide the same functionality as described herein.
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Systems, methods and apparatus are provided through which in some implementations an expandable or adjustable snap-in cam or other friction device having a mechanically lockable drawer, shelf or divider in a cabinet, pantry, kitchen cupboard mount includes no screws or other permanent mounting.
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FIELD OF INVENTION
[0001] The present invention relates to the development of low contact resistance joints on the solid bodies of HTSC (High Temperature Superconducting compound) of BiPbSrCaCuO for the transport of high currents below T c (critical temperature). The tube/rod conductors of HTSC Bi(2223) (BiPbSrCaCuO) are capable of carrying very high currents at 77 K and due to their low thermal conductivity they produce very low thermal load on system. Moreover if the contact resistance between HTSC and the current lead is low these tube/rod conductors become ideal high current transport leads for any system like cryogen free superconducting magnets/superconducting magnet generators etc.
BACKGROUND ART
[0002] Parameters in high current transmission in conventional conductors like Cu, Al, etc. are mostly due to the resistance of the conductors, which produces a significant amount of energy loss. Loss-less transport of current has been the main point of attraction in superconductors from the very beginning. The low T c conventional superconducting materials have been used in making high field magnets (˜20 tesla), which are now readily available. The operative temperature, i.e. 4.2 K (requiring a constant flow of liquid of helium) has hampered the growth of high current carrying leads and cables. The advancements in this field of high transport current are restricted up to prototype level only. The advent of high T c superconducting compounds (HTSC) has raised the hopes for high transport current leads as the operating temperature is raised to 77 K. However, poor ductility and low critical field had put restrictions on immediate applications. However the development of HTSC multifilamentary cables of Bi(2223) having J c ˜10 5 A/cm 2 at 77 K in a field 0.6T showed a good promise but again they are not a very conventional answer. In comparison, the tube conductors of high T c superconductors have shown good potential. HTS current-leads based on BSCCO tubes and rods are the first applications of ceramic superconductors in electrical power engineering where they offer a major advantage over both, the conventional superconductors as well as the traditional all-metal leads of good conductors such as Cu and Al. Conventional low T c superconductors embedded in copper were considered a better option over all-metal leads because of their zero resistance and their capacity to transport high currents defined by their critical current density J c (˜10 5 Amps/cm 2 ), but because of the restrictions of operation at 4.2 K these materials could not always replace Cu or Al.
[0003] In addition to the higher operational temperature of 77 K, the HTSC materials have their low thermal-conductivity, which reduces the heat-losses by more than a typical factor of 10. This reduces the heat load on the cryogenic system and results in a significant reduction in refrigeration cost and allows for new innovative cooling concepts. Their other applications are in the field of magnetic shielding and current-limiters.
[0004] All above utilization of HTSC tube conductors for high current application (Ic>1000 A) become ineffective and lossy if the contact resistance of the joints of the normal conductors (Cu, Al) feeding high currents to HTSC tube conductors are of the orders of 10 −4 -10 −3 Ω. The requirement to utilize the tube conductors to their optimum, the contact resistance of the normal conductors joining to HTSC tube conductors should be at least of the order of 10 −6 Ω.
[0005] Reference may be made to disclosure by K H Sandhage et al. in Journal of Materials Vol 43, pp21 (1991) wherein it is taught that among the HTSC family the Y-based superconductors suffer from many crystallographic limitations to synthesize tube and rod conductors and only thin film applications are commercialized. In yet another disclosure by E H Hellstorm in Materila Research Bulletin Vol XVII, pp45, (1992) it has been taught that T 1 based superconductors due to health hazards are not being used for bulk applications. Only Bi-based superconductors (Bi 2-x Pb x Sr 2 Ca 2 Cu 3 O x ) and Bi(2212) are commercially economical and suitable answers as reported by S X Dou and H K Liu in Supercond. Science and Technol Vol 6, pp297, (1993).
[0006] The contact resistance problem for high current electrical connection can only be solved using silver as normal conductors feeding the high current to Bi-based tube conductors. The major problem is to connect the silver feeder to Bi(2223) ceramic surface.
[0007] The problem has been tackled in parts in several ways:
[0008] U.S. Pat. No. 5,149,686 and a US Pat (publication No 20030132023) disclose sputtering the non-superconducting metal (Ag, Au) on small bar shaped HTSC of μm order for making the electrical contact.
[0009] Plasma spray technique of Ag/Au film on HTSC of μm order has been disclosed by Y Yamada in Bismuth Based High Temperature Superconductors Ed by H Maeda and T Togano pp277 (1996).
[0010] Then the high current feeders have been soldered on HTSC surface and a contact resistance of the order of 10 −6 Ω has been achieved at 77 K.
[0011] For small samples the sputtering technique has been successful but plasma deposition is used specially for bismuth based large samples like tube/rod conductors.
[0012] U.S. Pat. No. 5,506,199 and K K Michishita et al in Bismuth Based High Temperature Superconductors Ed by H Maeda and T Togano pp 253 (1996) disclose a process by partially encasing Ag tube, sheet or wire in large samples of Bi 2212 melt.
OBJECTS OF THE INVENTION
[0013] The main object of the present invention is to provide a process for the preparation of a low contact resistance contact on high transition temperature superconductors which obviates the drawbacks mentioned above.
[0014] Another object of the invention is to provide three layer process for the preparation of low contact resistance joint on high transition temperature superconductors.
[0015] Still another object of the present invention is to provide a low contact resistance to BiCaCuO superconductor.
[0016] A further object of the present invention is to provide a contact to a tubular HTSC.
[0017] A still further object of the present invention is to provide a contact to a rod HTSC.
[0018] Yet another object of the present invention is to provide a contact with a contact resistance in the range of 10 −7 to 10 −6 Ω.
SUMMARY OF THE INVENTION
[0019] The present invention describes a three layer process for making contact points to a high transition temperature superconductor (HTSC) particularly to (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 10+x with and without silver in the superconductor. The contact structure is a three layer configuration with a perforated silver foil sandwiched between two metal spray gun deposited silver layers and subsequent heat treatment in air. The contact has been made on tubes and rods. The silver contacts made have the characteristics of low resistance of 10 −6 Ω. Further, the contacts are capable of carrying a continuous current of 200 Amps without adding any substantial heat load to the cryogen used to cool the HTSC.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0020] In the drawings accompanying this specification
[0021] FIG. 1 . shows the structure of the contact on the HTSC tube or rod. ( 1 ) is a HTSC tube or rod with grooves at the ends, ( 2 ) is the first deposited silver layer ( 3 ) is the silver foil, ( 4 ) are the perforations in the silver foil, ( 5 ) is the second deposited silver layer, and ( 6 ) are the contacts for braded leads.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Accordingly the present invention provides a process for the preparation of a low contact resistance contact on high transition temperature superconductors which comprises making a groove at the end of the superconductor, depositing a first silver layer by metal spray gun at a temperature 120° C., heating the said deposited silver layer at a temperature in a range of 200-250° C. for a time period in the range of 2-5 hrs, wrapping a perforated silver foil on the said heat treated first silver layer, depositing a second silver layer by metal spray gun at a temperature of 120° C., heating the said combination of first silver layer, wrapped perforated silver foil and second silver layer at a temperature in a range of 830-850° C. in air for a time period in the range of 100-150 hrs resulting in a joint with a contact resistance in the range of 10 −7 to 10 −6 Ω,
[0023] In an embodiment of the present invention the high transition temperature superconductor may be a hollow cylindrical tube of length in a range of 200-300 mms
[0024] In another embodiment of the present invention transition temperature superconductor may be a solid rod of length 150 mms.
[0025] In still another embodiment of the present invention the wall thickness of the tube may be in a range of 2-3 mms.
[0026] In yet another embodiment of the present invention the outer diameter of the tube may be in a range of 12-30 mms.
[0027] In yet another embodiment of the present invention the high transition temperature superconductor may be pure (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 10+x .
[0028] In a further embodiment of the present invention the high transition temperature superconductor may be (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 10+x with 10 wt. % silver.
[0029] For making low contact resistance joints to the high transition temperature superconductors (HTSC), two types of samples were taken namely tubular and/or rod HTSC. FIG. 1 shows the HTSC sample ( 1 ). The dimensions of the tube ranged between 200 and 300 mms with an outer diameter in the range of 12-30 mm and wall thickness in the range of 2-3 mms. The ends of the tubes were machined to get a groove ( 2 ) of length of typically 20 mms. It is on these grooves that the contacts were made. Rod samples were of the dimensions of length of 150 mm and diameter in the range of 3-5 mm. HTSC samples used were (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 10+x pure and with addition of 10 wt % silver.
[0030] The process of making the contacts is described hereunder.
[0031] The structure of the contact is shown in FIG. 1 . First a layer of silver ( 3 ) metal was deposited on the groove ( 2 ) with the help of a metal spray gun with the temperature of the tube rising to about 120° C. This silver layer was heated to a temperature in the range of 250-300° C. for a time in the range of 2-5 hours in air. Next a silver foil ( 4 ) was taken and one surface was knurled and wrapped around the first spray deposited silver layer. The knurled surface was kept touching the first layer. The foil was perforated with equally spaced holes of diameter in the range of 1-1.5 mm and a maximum of 18 holes were used with three columns of holes. The strip was of width 2 cm with a length in the range of 4-6 cms. After the foil was wrapped completely leaving a small unwrapped portion ( 6 ) for making external contacts, a third layer ( 5 ) of silver was deposited with the help of metal spray gun with the HTSC sample temperature, maintained at 120° C. The final contact system was heated in air for a time in the range of 100-150 hrs at a temperature in the range of 830-850° C. The HTSC sample was then allowed to cool. External connections to all these samples were made to the silver metal ring by braded copper wires.
[0032] The resistivity of the contacts made by the procedure described above were measured by a four-probe method and are summarized in Table 1.
[0033] For four-probe method, the voltage taps were soldered directly to the superconductor close to the current contact. Two wires were attached to the current contact, one to carry current, and the other to detect voltage at the surface of the contact. The other voltage tap was soldered directly to the superconductor close to the current contact. Accuracy of the measurements was about ±10%. The measurements were taken both with and without magnetic field and at sample temperature of m77 K and 4.2 K.
[0034] Optionally a two layer structure was also prepared which essentially consisted of first layer deposited by metal spray gun and the perforated silver foil. The final assembly being heated inn air for a temperature in the range of 830-850° C. for a time in the range of 100-150 hrs. However, the contact resistance was observed to be in the range of 10 −5 Ω.
[0035] The low specific resistance materials and HTSC cables can be used to energize superconducting magnets and other non-superconducting devices requiring high current transport as at 77 K. Specific resistance of Cu is of the order of 10 −9 Ω-m. The specialty of the tube conductors is due to zero loss and very low thermal conductivity of material.
[0036] Especially devices which require very low power loss or low thermal load in current transport, tube conductors with low contact resistance are essential; like cryogen free magnetic systems where a close cycle system produces 10 K temperature, any thermal load more than 1 W becomes hazardous, only tube conductors are used.
[0037] The importance of low contact resistance joint is vital in these devices. Moreover low thermal conductivity is 1/10 th that of Cu makes it the first choice to avoid cryogen losses in conventional uses of high transport current.
[0038] Novelty of the invention lies in the low contact resistance of 10 −7 to 10 −6 Ω, and current carrying capacity of 200 Amps continuously for at least 2 hours. without adding any heat load to the cryogen.
[0039] The said novelty has been achieved due to the non obvious inventive steps of taking a three layer fabrication process and using a perforated silver foil sandwiched between the metal spray gun deposited silver layers.
[0040] Following examples are given by way of illustration only and should not be construed to limit the scope of the invention.
EXAMPLE 1
[0041] A tube of (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 10+x high temperature superconductor with 10 wt. % Silver was taken and groves at its ends were made. The length of the tube was 305 mm and the outer diameter of the tube was 12.4 mm with a wall thickness of 2.4 mm. First silver layer was deposited on the grooves by thermal metal spray gun at a temperature of 120° C. A silver metal foil of width 2 cm was taken and perforations with hole diameter of 1 mm and 18 holes were made in 3 columns each. One surface of the foil was knurled. This foil was then wrapped round the first silver layer with the knurled surface of the silver foil touching the first silver layer. After this a second silver layer was deposited by thermal metal spray gun at a temperature of 120° C. on the combination of first silver layer and the wrapped perforated silver foil. This entire three layered structure was sintered in air for 100 hrs. at 830° C. To establish electrical contacts to this silver contacts holes were made at the ends of the perforated silver foil at its end and high current leads were connected. Contact resistance was measured for this at a 77 K and in zero applied magnetic field and the value achieved was 5.1×10 −6 Ω.
EXAMPLE 2
[0042] A tube of (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 10+x high temperature superconductor with 10 wt. % Silver was taken and groves at its ends were made. The length of the tube was 300 mm and the outer diameter of the tube was 12.4 with a wall thickness of 2.4 mm. First silver layer was deposited on the grooves by thermal metal spray gun at a temperature of 120° C. followed by heating at a temperature of 250° C. for 2 hrs. A silver metal foil of width 2 cm was taken and perforations with hole diameter of 1 mm and 18 holes were made in 3 columns each. One surface of the foil was knurled. This foil was then wrapped round the first silver layer with the knurled surface of the silver foil touching the first silver layer. After this a second silver layer was deposited by thermal metal spray gun at a temperature of 120° C. on the combination of first silver layer and the wrapped perforated silver foil. This entire three layered structure was sintered in air for 100 hrs. at 830° C. To establish electrical contacts to this silver contacts holes were made at the ends of the perforated silver foil at its end and high current leads were connected. Contact resistance was measured for this at a 77 K and in zero applied magnetic field and the value achieved was 2.02×10 −7 Ω.
EXAMPLE 3
[0043] A tube of (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 10+x high temperature superconductor with 10 wt % Silver was taken and groves at its ends were made. The length of the tube was 300 mm and the outer diameter of the tube was 12.4 mm with a wall thickness of 2.4 mm. First silver layer was deposited on the grooves by thermal metal spray gun at a temperature of 120° C. followed by heating at a temperature of 250° C. for 2 hrs. A silver metal foil of width 2 cm was taken and perforations with hole diameter of 1 mm and 18 holes were made in 3 columns each. One surface of the foil was knurled. This foil was then wrapped round the first silver layer with the knurled surface of the silver foil touching the first silver layer. After this a second silver layer was deposited by thermal metal spray gun at a temperature of 120° C. on the combination of first silver layer and the wrapped perforated silver foil. This entire three layered structure was sintered in air for 100 hrs. at 830° C. To establish electrical contacts to this silver contacts holes were made at the ends of the perforated silver foil at its end and high current leads were connected. Contact resistance measured for this at 4.2 K and in zero applied magnetic field was 1.5×10 −8 Ω.
EXAMPLE 4
[0044] A tube of (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 10+x high temperature superconductor with 10 wt % Silver was taken and groves at its ends were made. The length of the tube was 300 mm and the outer diameter of the tube was 12.4 mm with a wall thickness of 2.4 mm. First silver layer was deposited on the grooves by thermal metal spray gun at a temperature of 120° C. followed by heating at a temperature of 250° C. for 2 hrs. A silver metal foil of width 2 cm was taken and perforations with hole diameter of 1 mm and 18 holes were made in 3 columns each. One surface of the foil was knurled. This foil was then wrapped round the first silver layer with the knurled surface of the silver foil touching the first silver layer. After this a second silver layer was deposited by thermal metal spray gun at a temperature of 120° C. on the combination of first silver layer and the wrapped perforated silver foil. This entire three layered structure was sintered in air for 100 hrs. at 830° C. To establish electrical contacts to this silver contacts holes were made at the ends of the perforated silver foil at its end and high current leads were connected. Contact resistance measured for this at 77 K and in applied magnetic field of 0.09 Tesla was 4.8×10 −7 Ω.
EXAMPLE 5
[0045] A tube of (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 10+x high temperature superconductor without Silver was taken and groves at its ends were made. The length of the tube was 300 mm and the outer diameter of the tube was 12.4 mm with a wall thickness of 2.4 mm. First silver layer was deposited on the grooves by thermal metal spray gun at a temperature of 120° C. followed by heating at a temperature of 250° C. for 2 hrs. A silver metal foil of width 2 cm was taken and perforations with hole diameter of 1 mm and 18 holes were made in 3 columns each. One surface of the foil was knurled. This foil was then wrapped round the first silver layer with the knurled surface of the silver foil touching the first silver layer. After this a second silver layer was deposited by thermal metal spray gun at a temperature of 120° C. on the combination of first silver layer and the wrapped perforated silver foil. This entire three layered structure was sintered in air for 100 hrs. at 830° C. To establish electrical contacts to this silver contacts holes were made at the ends of the perforated silver foil at its end and high current leads were connected. Contact resistance measured for this at a 77 K and in zero applied magnetic field was 6.09×10 −7 Ω.
EXAMPLE 6
[0046] A tube of (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 10+x high temperature superconductor without Silver was taken and groves at its ends were made. The length of the tube was 300 mm and the outer diameter of the tube was 12.4 mm with a wall thickness of 2.4 mm. First silver layer was deposited on the grooves by thermal metal spray gun at a temperature of 120° C. followed by heating at a temperature of 250° C. for 2 hrs. A silver metal foil of width 2 cm was taken and perforations with hole diameter of 1 mm and 18 holes were made in 3 columns each. One surface of the foil was knurled. This foil was then wrapped round the first silver layer with the knurled surface of the silver foil touching the first silver layer. After this a second silver layer was deposited by thermal metal spray gun at a temperature of 120° C. on the combination of first silver layer and the wrapped perforated silver foil. This entire three layered structure was sintered in air for 100 hrs. at 830° C. To establish electrical contacts to this silver contacts holes were made at the ends of the perforated silver foil at its end and high current leads were connected. Contact resistance measured for this at a 4.2 K and in zero applied magnetic field was 8.5×10 −8 Ω.
EXAMPLE 7
[0047] A tube of (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 10+x high temperature superconductor without Silver was taken and groves at its ends were made. The length of the tube was 305 mm and the outer diameter of the tube was 12.4 mm with a wall thickness of 1 mm. First silver layer was deposited on the grooves by thermal metal spray gun at a temperature of 120° C. followed by heating at a temperature of 250° C. for 2 hrs. A silver metal foil of width 2 cm was taken and perforations with hole diameter of 1 mm and 18 holes were made in 3 columns each. One surface of the foil was knurled. This foil was then wrapped round the first silver layer with the knurled surface of the silver foil touching the first silver layer. After this a second silver layer was deposited by thermal metal spray gun at a temperature of 120° C. on the combination of first silver layer and the wrapped perforated silver foil. This entire three layered structure was sintered in air for 100 hrs. at 830° C. To establish electrical contacts to this silver contacts holes were made at the ends of the perforated silver foil at its end and high current leads were connected. Contact resistance measured for this at a 77 K and in 0.03 Tesla applied magnetic field was 9.5×10 −7 Ω.
EXAMPLE 8
[0048] A tube of (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 10+x high temperature superconductor with 10 wt % Silver, was taken and groves at its ends were made. The length of the tube was 200 mm and the outer diameter of the tube was 30.8 mm with a wall thickness of 2.8 mm. First silver layer was deposited on the grooves by thermal metal spray gun at a temperature of 120° C. followed by heating at a temperature of 250° C. for 2 hrs. A silver metal foil of width 2 cm was taken and perforations with hole diameter of 1 mm and 18 holes were made in 3 columns each. One surface of the foil was knurled. This foil was then wrapped round the first silver layer with the knurled surface of the silver foil touching the first silver layer. After this a second silver layer was deposited by thermal metal spray gun at a temperature of 120° C. on the combination of first silver layer and the wrapped perforated silver foil. This entire three layered structure was sintered in air for 100 hrs. at 830° C. To establish electrical contacts to this silver contacts holes were made at the ends of the perforated silver foil at its end and high current leads were connected. Contact resistance measured for this at 77 K and in zero applied magnetic field was 3.8×10 −7 Ω.
EXAMPLE 9
[0049] A tube of (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 10+x high temperature superconductor with 10 wt % Silver, was taken and groves at its ends were made. The length of the tube was 200 mm and the outer diameter of the tube was 30.8 mm with a wall thickness of 2.8 mm. First silver layer was deposited on the grooves by thermal metal spray gun at a temperature of 120° C. followed by heating at a temperature of 250° C. for 2 hrs. A silver metal foil of width 2 cm was taken and perforations with hole diameter of 1 mm and 18 holes were made in 3 columns each. One surface of the foil was knurled. This foil was then wrapped round the first silver layer with the knurled surface of the silver foil touching the first silver layer. After this a second silver layer was deposited by thermal metal spray gun at a temperature of 120° C. on the combination of first silver layer and the wrapped perforated silver foil. This entire three layered structure was sintered in air for 100 hrs. at 830° C. To establish electrical contacts to this silver contacts holes were made at the ends of the perforated silver foil at its end and high current leads were connected. Contact resistance measured for this at 4.2 K and in zero applied magnetic field was 2.3×10 −8 Ω.
EXAMPLE—10
[0050] A rod of (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 10+x high temperature superconductor with 10 wt % Silver, was taken and groves at its ends were made. The length of the rod was 150 mm and the diameter 0.3 mm. First silver layer was deposited on the grooves by thermal metal spray gun at a temperature of 120° C. followed by heating at a temperature of 250° C. for 2 hrs. A silver metal foil of width 2 cm was taken and perforations with hole diameter of 1 mm and 18 holes were made in 3 columns each. One surface of the foil was knurled. This foil was then wrapped round the first silver layer with the knurled surface of the silver foil touching the first silver layer. After this a second silver layer was deposited by thermal metal spray gun at a temperature of 120° C. on the combination of first silver layer and the wrapped perforated silver foil. This entire three layered structure was sintered in air for 100 hrs. at 830° C. To establish electrical contacts to this silver contacts holes were made at the ends of the perforated silver foil at its end and high current leads were connected. Contact resistance measured for this at 77 K and in zero applied magnetic field was 3.7×10 −7 Ω.
EXAMPLE 11
[0051] A rod of (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 10+x high temperature superconductor with 10 wt % Silver, was taken and groves at its ends were made. The length of the rod was 150 mm and the diameter 3 mm. First silver layer was deposited on the grooves by thermal metal spray gun at a temperature of 120° C. followed by heating at a temperature of 250° C. for 2 hrs. A silver metal foil of width 2 cm was taken and perforations with hole diameter of 1 mm and 18 holes were made in 3 columns each. One surface of the foil was knurled. This foil was then wrapped round the first silver layer with the knurled surface of the silver foil touching the first silver layer. After this a second silver layer was deposited by thermal metal spray gun at a temperature of 120° C. on the combination of first silver layer and the wrapped perforated silver foil. This entire three layered structure was sintered in air for 100 hrs. at 830° C. To establish electrical contacts to this silver contacts holes were made at the ends of the perforated silver foil at its end and high current leads were connected. Contact resistance measured for this at a 4.2 K and in zero applied magnetic field was 4.05×10 −8 Ω.
EXAMPLE 12
[0052] A rod of (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 10+x high temperature superconductor with 10 wt % Silver, was taken and groves at its ends were made. The length of the rod was 150 mm and the diameter 5 mm. First silver layer was deposited on the grooves by thermal metal spray gun at a temperature of 120° C. followed by heating at a temperature of 250° C. for 2 hrs. A silver metal foil of width 2 cm was taken and perforations with hole diameter of 1 mm and 18 holes were made in 3 columns each. One surface of the foil was knurled. This foil was then wrapped round the first silver layer with the knurled surface of the silver foil touching the first silver layer. After this a second silver layer was deposited by thermal metal spray gun at a temperature of 120° C. on the combination of first silver layer and the wrapped perforated silver foil. This entire three layered structure was sintered in air for 100 hrs. at 830° C. To establish electrical contacts to this silver contacts holes were made at the ends of the perforated silver foil at its end and high current leads were connected. Contact resistance measured for this at a 77 K and in zero applied magnetic field. was 3.0×10 −7 Ω.
EXAMPLE 13
[0053] A rod of (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 10+x high temperature superconductor with 10 wt % Silver, was taken and groves at its ends were made. The length of the rod was 150 mm and the diameter 5 mm. First silver layer was deposited on the grooves by thermal metal spray gun at a temperature of 120° C. followed by heating at a temperature of 250° C. for 2 hrs. A silver metal foil of width 2 cm was taken and perforations with hole diameter of 1 mm and 18 holes were made in 3 columns each. One surface of the foil was knurled. This foil was then wrapped round the first silver layer with the knurled surface of the silver foil touching the first silver layer. After this a second silver layer was deposited by thermal metal spray gun at a temperature of 120° C. on the combination of first silver layer and the wrapped perforated silver foil. This entire three layered structure was sintered in air for 100 hrs. at 830° C. To establish electrical contacts to this silver contacts holes were made at the ends of the perforated silver foil at its end and high current leads were connected. Contact resistance measured for this at 4.2 K and in zero applied magnetic field was 4.7×10 −8 Ω.
[0054] The resistivity of the contacts made by the procedures described in the aforementioned examples were measured by a four-probe method and are summarized in Table 1.
[0055] For four-probe method, the voltage taps were soldered directly to the superconductor close to the current contact. Two wires were attached to the current contact, one to carry current, and the other to detect voltage at the surface of the contact. The other voltage tap was soldered directly to the superconductor close to the current contact. Accuracy of the measurements was about ±10%.
[0056] External connections to all these samples were made to the silver metal ring by braded copper wires.
TABLE 1 Sample in Temperature Magnetic Field Contact Resistance Example (K) (T) R c (Ω) 1. 77 0 5.1 × 10 −6 2 77 0 2.02 × 10 −7 3. 4.2 0 1.5 × 10 −8 4. 77 0.09 4.8 × 10 −7 5. 77 0 6.09 × 10 −7 6. 4.2 0 8.5 × 10 −8 7. 77 0.03 9.5 × 10 −7 8. 77 0 3.8 × 10 −7 9. 4.2 0 2.3 × 10 −8 10. 77 0 3.7 × 10 −7 11 4.2 0 4.05 × 10 −8 12 77 0 3.0 × 10 −7 13 4.2 0 4.7 × 10 −8
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Disclosed is a three layer process for making contact points to a high transition temperature superconductor (HTSC), particularly to (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 19+1 with and without silver in the superconductor. The contact structure is a three layer configuration with a perforated silver foil ( 3 ) sandwiched between two metal spray gun deposited silver layers ( 2,5 ) and subsequent heat treatment in air. The contact has been made on tubes and rods ( 1 ). The silver contacts are capable of carrying a continuous current of 200 Amps without adding any substantial heat load to the cryogen used to cool the HTSC. The contact resistance at 4.2 K is in the range of 1.5×10 (hoch −8 ) to 8.5″ 10 (hoch −8 ) OHM in zero applied filed.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This Application is a Continuation-in-Part of prior application Ser. No. 10/708,288, filed Feb. 23, 2004, now U.S. Pat. No. 7,100,320, issued Sep. 5, 2006 and incorporates the earlier application by reference.
COPYRIGHT NOTICE
[0002] A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent disclosure as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF INVENTION
[0003] The present invention relates to the field of reticules, and more particularly relates to a reticule for a telescopic sight system while being useful in both rapid target acquisition in close quarters combat and precise distance shooting situation
BACKGROUND OF THE INVENTION
[0004] Reticules are well known in the prior art. They are used in any situation where aiming any type of device is necessary, ranging from medical devices to weapons. Reticule types range from the traditional “crosshairs” to dots, circles, other geometric shapes, and moveable cross lines or any combination of the above. For example, U.S. Pat. No. 6,681,512 (2004) to Sammut; U.S. Pat. No. 6,591,537 (2003) to Smith; U.S. Pat. No. 6,453,595 (2002) to Sammut; U.S. Pat. No. 6,357,158 (2002) to Smith, III; U.S. Pat. No. 6,058,921 (2000) to Lawrence, et al.; U.S. Pat. No. 4,957,357 (1990) to Barnes, et al.; U.S. Pat. No. 4,618,221 (1986) to Thomas; U.S. Pat. No. 4,263,719 (1981) to Murdoch; U.S. Pat. No. 3,948,587 (1976) to Rubbert; U.S. Pat. No. 3,782,822 (1974) to Spence; U.S. Pat. No. 3,392,450 (1968) to Herter, et al.; U.S. Pat. No. 2,420,273 (1944) to West; U.S. Pat. No. 1,190,121 (1916) to Critchett; U.S. Pat. No. 1,088,137 (1914) to Fidjeland; U.S. Pat. No. 912,050 (1909) to Wanee; and U.S. Pat. No. 189,721 (1877) to Freund are all illustrative of the prior art.
[0005] While the aforementioned inventions accomplish their individual objectives, they do not describe a reticule that is useful for both rapid close range target acquisition and precision shooting at a distance. In this respect, the reticule according to the present invention departs substantially from the usual designs in the prior art. In doing so, this invention provides a simple reticule using an aiming point strategy in its design and functionality. The reticule according to the present invention also incorporates a plurality of aiming points represented as dots of different scales to facilitate use at various ranges, from 10 to 600 yards or beyond. Prior reticules attempt to compensate for drop of a bullet over distance by increasing the distance between provided reticule guidelines. While one embodiment of the reticule according to this invention does so, in general, the reticule according to the present invention does not attempt to do so. In the present invention, a set of smaller scale dots provides a reference point for a shooter to use after practicing with a particular weapon over time, thereby avoiding problems of translating the results of “average” weapons to a particular weapon. Simultaneously, the reticule according to the present invention covers less of a target area, decreasing uncertainty and having a corresponding increase in hit potential.
SUMMARY OF THE INVENTION
[0006] In view of the foregoing disadvantages inherent in the known types of reticule, this invention provides an improved reticule with varying scales for use in multiple range environments. As such, the present invention's general purpose is to provide a new and improved reticule that will allow a user to improve accuracy and time at a distance without being a hindrance at close range.
[0007] To accomplish this goal and still maintain a utility derived from simplicity, the reticule according to the present invention comprises a main aiming ring with a series of aiming dots extending from the ring in what would be considered the cardinal directions. The aiming ring is utilized for speed and accuracy in close targeting scenarios, providing a broad, easily identifiable aiming point. The “southern” portion of the targeting ring is empty, allowing for a series of aiming dots to extend from the center of the ring to the bottom of the reticule. As the southern dots extend from the ring, they gradually are reduced in size and are spaced at a lesser distance apart. Thin reference rings are positioned towards the bottom of the reticule for range estimation. The reticule may be made of a luminous material, or may be electronically or chemically induced to glow for night and low light use.
[0008] The more important features of the invention have thus been outlined in order that the more detailed description that follows may be better understood and in order that the present contribution to the art may better be appreciated. Additional features of the invention will be described hereinafter and will form the subject matter of the claims that follow.
[0009] Many objects of this invention will appear from the following description and appended claims, reference being made to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.
[0010] 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 the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0011] 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
[0012] FIG. 1 is a plan view of the reticule according to the present invention.
[0013] FIG. 2 is a plan view of an alternate embodiment of the reticule.
[0014] FIG. 3 is a plan view of an alternate embodiment of the reticule with caliber specific ranging.
[0015] FIG. 4 is a plan view of a further alternate embodiment of the reticule with caliber specific ranging.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] With reference now to the drawings, the preferred embodiment of the reticule is herein described. It should be noted that the articles “a”, “an” and “the”, as used in this specification, include plural referents unless the content clearly dictates otherwise.
[0017] Referring specifically to FIG. 1 , reticule 100 is has a central aiming ring 110 , a plurality of varying sized ranging rings 120 , 122 , 124 , 126 , and four sets of dots in linear patterns defining four cardinal directions, 130 N, 130 S, 130 E, 130 W. Throughout this application and in the claims, the term “dot” is used to define an indicator of the location of generic aiming points on the reticule. The term “dot” may be used of indicators of any shape, such as triangles, crosshairs, ovals and rectangles, and need not necessarily be circles. Aiming ring 110 is not a complete ring, as it is open towards the southern direction. Dot set 130 S initiates in the center of the reticule with central aiming point 135 and is comprised of dots of three different sizes and two different spacing intervals, as shall be described later in this specification. Labeled quick count lines 132 , 134 , 136 may be provided at any interval, though the shown preferred embodiment is an interval of 5. Ranging ring 120 is labeled “3” on the reticule.
[0018] The utility of the reticule 100 is found in the set spacing and sizes of the individual components relative to each other. The reticule uses the same basic perspective principles used in other ranging reticules, that is that objects appear smaller the further they are away from a viewer. Aiming ring 110 has a thickness of 4 Minutes Of Angle (“MOA”). 1 MOA is roughly equivalent to 1 inch at 100 yards. Its diameter is 18 MOA, leaving a 10 MOA window interior. Each of the dots in directional sets 130 N, 130 E, and 130 W are 0.75 MOA, and the central aiming point 135 is 1 MOA. The next highest dots in set 130 S are 0.75 MOA. Each of these dots has an interval spacing of 3.5 MOA. Staring with the dot labeled “5” in the southern set 130 S, the remaining dots are 0.5 MOA and have an interval spacing of 2 MOA. Ranging rings 120 , 122 , 124 , 126 have diameters of 3.33 MOA, 2.5 MOA, 2 MOA, and 1.67 MOA respectively. To maintain proper perspective of relative sizes of the reticule components with potential targets, the reticule should be positioned either on or next to the objective lens of any telescopic sighting devices, thereby magnifying the reticule in the same power as the target and maintaining proportion. It should be noted that aiming ring 110 may be of any shape, though depicted as round in the figures. The important characteristics of aiming ring 110 is that it is relatively broad compared to the rest of the reticule and that it has an incomplete perimeter at its bottom. Any reasonable shape may, therefore be used, be it ovular, rectangular, triangular, octangular, or any other polygonal shape. The term “ring” as used in this specification and the appended claims must, therefore, include such equivalent structures.
[0019] In use, the reticule according to the present invention provides a rapidly identified aiming point in close quarters combat situations, as the reticule provides an easily identified center target with aiming ring 110 . This is especially true if the sighting device is set at zero magnification, thus diminishing all other reticule components from view. The reticule also provides ranging capability for more accurate distance shooting. Aiming ring 110 and ranging rings 120 , 122 , 124 , and 126 are set to measure the equivalent of 10-inch targets at 100, 300, 400, 500, and 600 yards distance. Central aiming point 135 is the center of aiming ring 110 and therefore defines the diameter of a 5 MOA circle with any single point within the inner rim of the aiming ring 110 . This corresponds to a 10-inch target at 200 yards. While the four ranging rings are provided in the preferred embodiment, more or fewer rings may be employed in the practice of this invention. Likewise, different shapes may also be used, though in all embodiments the shapes should be mere outlines, allowing a user to see past the shape.
[0020] For distance shooting, it is important to consider the drop of a bullet over distance. The amount of drop will be determined by a number of factors, including barrel length, rifling, bullet weight, charge of ammunition, etc. Together, these factors are called a “package” and are usually uniform over time for a user's weapon. The scope can be zeroed so that the central aiming point 135 represents where a bullet will hit at 200 yards. Once this is set, a user merely practices with his or her particular weapon package to determine at which dot in the southern set 130 S a bullet will hit at specified yardage. Since the lower portion of southern set 130 S is used in distance shooting, the dots are smaller and the distance between them is smaller, so that less of a target is covered by a dot at greater distance from the shooter. With less of a target covered, there is greater accuracy in the shooting due to less uncertainty as to the actual spot where the bullet will hit. In the present embodiment, a 0.5 MOA dot will cover only 3 inches of a target at 600 yards. The distance between the dots in the lower range is 2 MOA, corresponding to 12 inches at 600 yards. The central aiming dot 135 would cover 6 inches at 600 yards, presenting double the uncertainty and a corresponding drop in accuracy.
[0021] Through practice, a user may note where a bullet will hit on the reticule at a determined distance. Afterwards, when a user picks a target of a known size, comparisons are made with ranging rings 120 , 122 , 124 , and 126 , as well as with the interior of aiming ring 110 , to determine distance. When aiming at the target, the user merely picks the appropriate aiming point from the dots in set 130 S and fires, hitting the target. The preferred embodiment attaches no external significance to the aiming points represented by the dots, unlike various other prior art reticules which attempt to compensate for the amount of drop a bullet will have over distance. The importance of the smaller dots and smaller distance between them is for better accuracy with a particular weapon. Remaining dot sets 130 N, 130 E, 130 W are ideally set to a uniform standard, for instance the standard military dot ranging system, and are useful as guides for windage and canting calculations and for ranging in horizontal and vertical planes.
[0022] In low light situations, the reticule may be illuminated through conventional means, or means to be discovered. Ideally, ranging rings 120 , 122 , 124 , 126 , dots sets 130 N, 130 S, 130 E, 130 W, and aiming ring 110 would have illumination capability. A highlighting ring, such as 311 in FIG. 3 , is used in those situations where illumination of the central aiming ring 110 is difficult or impossible.
[0023] In an alternate embodiment, shown in FIG. 2 , the aiming ring 210 is composed of a plurality of transparent cells 203 , allowing a user to see through a portion of the aiming ring 210 . Cells 203 may be of any shape, though regular polygons, such as the diamond pattern shown in FIG. 2 , circles and ovals are preferred. Ideally, the lines dividing aiming ring 210 should be thinner than cells 203 , allowing a user to see “through” over ½ of the area covered by the aiming ring 210 . This construction of the aiming ring 210 allows a user to look through the aiming ring 210 while still having the capacity to use it. It is also easier to illuminate aiming ring 210 when using the depicted or similar cell constructions, as uniform lines are easier to illuminate using current technology. Dots 207 and 235 and rings 220 , 222 , 224 , 226 , may be of any shape, and may actually mimic the construction of cells 203 . Some of the cells may be obscured 202 in a manner to provide greater contrast and increase acquisition speed. Obscured cells may demarcate a part of aiming ring 210 (as shown) or they may outline the perimeter of aiming ring 210 or they may be spaced at a regular pattern about the aiming ring. In either event, a user should still see through at least ½ of the aiming ring for this embodiment to maintain a good portion of its utility, though a greater percentage of obscured cells and different patterns would still be considered the purview of this invention.
[0024] In FIG. 3 , the reticule uses a caliber specific component for range shooting. In this embodiment, the CQB aspect of the reticule is maintained with aiming ring 310 while a customer may enjoy the convenience of a pre-set ranging system. The pre-set ranging system depicted is for an M4 rifle with a 14.5 inch barrel and a 62 grain bullet package (M855). The center dot 335 is set to correspond to the impact point at 100 yards. Since the drop between 100 and 200 yards for this package is only about 3 inches, a 200-yard impact point is not provided. Impact point 337 corresponds to 300 yards (and approximately a 12-inch relative drop from 100 yards). From this point, every successive range of 100 yards has an impact point set within a range indicator line 332 comprised of specially sized and spaced dashes 336 . The dashes 336 and the spacing between them are equal length and correspond to 10-inch spacing at that corresponding distance. Ranging rings 334 are provided with all of the range indicator lines and with the 300-yard dot 337 . Until the rings are small enough to not overlap, it is preferred they are set to the sides of the lines 336 , as shown in the 400 and 500-yard range lines, though wherever possible, it is preferred they are in the center of the line, as shown with the 600 and successive range indicator lines. A highlighting ring 311 may be used to circumscribe the entire reticule, as shown in FIG. 3 , or just the aiming ring 310 . In the event a highlighting ring is used to circumscribe the aiming ring alone, the highlighting ring should also be incomplete on the bottom. Highlighting rings should be significantly thinner than the aiming ring and may actually be comprised of a number of thin rings. The reticule shown in FIG. 3 can be further simplified, as shown in FIG. 4 , for shorter ranges and less clutter.
[0025] Although the present invention has been described with reference to preferred embodiments, numerous modifications and variations can be made, such as altering the shape of the dots or the cells, and still the result will come within the scope of the invention. No limitation with respect to the specific embodiments disclosed herein is intended or should be inferred.
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The present invention is a reticule featuring both rapid close-quarters target acquisition and precise distance shooting functionality. The reticule features a broad central aiming ring and four sets of aiming point-indicating dots. The lowest set comprises dots of differing dimensions and distances apart. Ranging rings are also provided. In an alternate embodiment the aiming ring comprises a plurality of varying transparent and opaque cells. The reticule can be illuminated through known or future discovered means for low-light or night shooting. A further alternate embodiment features a caliber specific ranging system.
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BACKGROUND OF THE INVENTION
[0001] The invention relates generally to toys, and more particularly to an animated toy doll and scooter assembly.
[0002] U.S. Pat. No. 3,574,969 to Cleveland and Wilson discloses a toy doll and scooter assembly wherein a doll is attached to a scooter and uses a walking motion to push the scooter along. However, Clevland lacks realistic animation of the doll. The scooter tilts from side to side, as in a walking motion, rather than remaining substantially vertical as do real scooters. Additionally, Cleveland is only able to travel forward and cannot be turned like a real scooter.
SUMMARY OF THE INVENTION
[0003] A general object of the present invention is to provide a more realistically animated toy doll and scooter assembly.
[0004] In accordance with an illustrative embodiment of the invention, a toy doll is articulated and removably attached to a toy scooter so that the doll's arms appear to steer the scooter and the doll's foot appears to propel the scooter. Additionally, the animated toy doll and scooter assembly is controlled by a radio remote control unit itself shaped like a scooter and having a toy foot attached to it. The remote control unit provides a highly intuitive method for controlling the animated toy doll and scooter assembly. By sliding the attached foot forwards or backwards, the animated toy doll and scooter assembly is commanded to travel forwards or backwards. By turning the attached left or right the animated toy doll and scooter assembly is commanded to turn left or right.
[0005] More specifically, an animated toy doll and scooter assembly is provided which includes a toy scooter having front and rear large size main wheels and several smaller stabilizing wheels. The scooter has a pivotal front wheel for turning, and handlebars linked to the front wheel. A doll is mounted on the scooter with its arms secured to the handlebars. The scooter has a motor mounted thereon for actuating at least one of the wheels for forward movement. The doll has a leg and foot assembly linked to the motor for movement up and down, or tilting, and front to rear to simulate scooter actuation motion. In addition, a second motor may be provided, or a coupler from the first motor may be provided, to turn the front wheel of the scooter.
[0006] These objects as well as other objects, features and advantages of the invention will become more apparent to those skilled in the art from the following description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Detailed description of the preferred embodiment of the invention will be made with reference to the accompanying drawings.
[0008] [0008]FIG. 1 is a top-perspective view of the animated toy doll and scooter assembly and remote control unit illustrating the principles of the present invention.
[0009] [0009]FIG. 2 is a bottom-perspective view of the scooter of FIG. 1.
[0010] [0010]FIG. 3 is a top view of the scooter of FIG. 1 with the top section removed to show the inside.
[0011] [0011]FIG. 4 is a perspective view of the toy doll of FIG. 1 showing the bending joints.
[0012] [0012]FIG. 5 is a semi-diagrammatic fragmentary partial side elevational view of the scooter showing the foot-pedaling mechanism.
[0013] [0013]FIG. 6 is a semi-diagrammatic partial side elevational view of the scooter showing the steering mechanism.
[0014] FIGS. 7 - 10 are semi-diagrammatic side elevational views showing the operating principal of the foot-pedaling mechanism.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] Disclosed herein is a detailed description of the best presently known modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention. The overall organization of the present detailed description is for the purpose of convenience only and is not intended to limit the present invention.
[0016] [0016]FIG. 1 shows an animated toy doll and scooter assembly 12 including a toy doll 14 positioned on a toy scooter 16 . Arms 18 are secured to scooter handlebars 20 . A foot 22 supports the doll on a floorboard 26 of the scooter. Another foot 24 is positioned on a foot movement actuating member 28 . Also shown are front 36 and rear 38 large size main wheels. The rear wheel 38 can be used to propel the scooter 16 while the front wheel 36 is used to steer the scooter 16 . A steering assembly 48 is made up of the handlebars 20 , a steering column housing 44 , a steering actuating assembly 46 and the front wheel 36 .
[0017] In one embodiment the animated toy doll and scooter assembly is controlled by a radio remote control unit 30 . The radio remote control unit 30 contains a radio transmitter as known in the art. The remote control unit 30 is shaped as a smaller version of the toy scooter 16 . The remote control unit can transmit radio signals through an antenna extending along the remote control unit 30 handlebars 34 . The remote control unit 30 can be two-thirds or less of the size of the toy scooter 16 so that it can be easily held by a child. Mounted on a sliding switch is a toy shoe 32 . By sliding the toy shoe forward and backward along a remote control floorboard 33 , a user can make the toy scooter 16 move forwards and backwards. Positioning the toy shoe to an intermediate position stops the scooter and moving the toy shoe further to the front or rear increases the forward or reverse speed of the toy scooter. By turning the foot 32 clockwise or counterclockwise, a user can similarly make the scooter handlebars 20 turn clockwise or counterclockwise, and turn a front wheel 36 , causing the forward moving scooter to turn right or left. Radio remote control units are known in the art, however, the remote control unit 30 of the present invention provides special advantages when included with the animated toy doll and scooter assembly of the present invention. The design of the remote control unit 30 makes its use in controlling the toy scooter 16 highly intuitive, allowing younger children to quickly comprehend how to use the remote control unit 30 to control the toy scooter 16 .
[0018] [0018]FIG. 2 shows the toy scooter 16 from a bottom perspective. Three small stabilizing wheels 40 are shown. The stabilizing wheels 40 can have diameters less than two-thirds the diameter of the main wheels 36 , 38 . The stabilizing wheels are mounted on opposite sides of the scooter. As illustrated in FIG. 1, the doll tends to move the center of gravity of the animated toy doll and scooter assembly 12 away from the center of the floorboard 26 and towards the foot movement actuating member 28 . It is therefore particularly important to have at least one stabilizing wheel positioned on the same side of the scooter as the foot movement actuating member 28 . Also shown is a battery compartment cover 42 for allowing insertion and removal of batteries. In one embodiment 6 AA batteries, providing approximately 9 V, can be used to power the animated toy doll and scooter assembly.
[0019] [0019]FIG. 3 shows a top view of the scooter with the top section and the steering assembly 48 removed from casing walls 49 to show the inner operating mechanisms. The scooter 16 is propelled by a drive motor 44 powered by the batteries or other power source. The motor 44 turns the rear wheel through a stepdown gear train 50 . The gear train 50 transfers the relatively fast spinning of the motor to a relatively slow, but more powerful, spinning of the wheel 38 . Included in the gear train 50 is a clutch 52 for preventing the burning out of the motor 44 when the wheel 38 experiences an excess amount of resistance to spinning. The speed of the motor is controlled by sliding the toy foot 32 of the remote control 30 forward and backward. As the toy foot 32 is slid further forward, the motor 44 spins faster in the forward driving direction. As the toy foot 32 is slid further backward, the motor 44 spins faster in the reverse driving direction. The motor 44 stops spinning when the toy foot 32 is positioned and an intermediate position approximately between the furthest forward and furthest back sliding positions.
[0020] Driven by the same motor 44 is a foot-pedal actuation mechanism 54 . The foot-pedal actuation mechanism 54 gives the foot 24 and leg segments 58 , 60 of the doll 14 (see FIG. 4) a pedaling motion whereby the foot is tilted and moved from front to rear, simulating a driving engagement of the foot with the ground. The motor 44 actuates the pedaling mechanism 54 through a step-down gear train 56 . The gear trains 50 , 56 share some of the same gears. Thus, the foot 24 pedaling motion corresponds to the speed of the scooter 16 . As the scooter 16 goes faster, the foot 24 pedals faster, and as the scooter 16 goes slower, the foot 24 pedals slower. Alternatively, separate motors can be used to propel the scooter 16 and move the foot movement actuating member 28 .
[0021] The foot-pedal actuation mechanism 54 is described with reference to FIGS. 3, 5 and 7 - 10 . The foot-pedal actuation mechanism 54 includes a pedal drive cam 62 rotated by a shaft 64 which is rotated by the gear train 56 . A peg 66 extends outwardly from the cam 62 to engage a linear cam follower 68 . The follower 68 has a vertical slot 84 along which the peg 68 rides up and down. On the face of the follower 68 opposite the slot 84 is a horizontal slot 86 into which a shelf 88 extends from the casing wall 49 . The horizontal slot 86 and shelf 88 limit the follower to substantially horizontal motion. Pivotally connected to the follower 68 at a pivot point 70 is a foot-tilting follower 72 . Rigidly connected to the follower 72 is foot tilting shaft 74 having a foot movement actuating member 28 and a foot securing pin 76 attached at the opposite end. The pin 76 is used to help removably secure the foot 24 to the foot movement actuating member 28 . Extending from the follower 72 is a peg 78 which rides inside a groove 80 within a caming groove piece 82 .
[0022] The operation of the foot-pedal actuation mechanism 54 is now described with particular reference to FIGS. 7 - 10 . The pedal drive cam 62 rotates about a fixed axis causing the peg 66 to ride up and down in the vertical slot 84 formed in the linear cam follower 68 . The follower 68 is constrained to substantially horizontal motion by the shelf 88 around which the horizontal slot 86 slides. Thus the rotation of the cam 62 leads to substantially linear horizontal motion of the follower 68 . As the follower 68 moves horizontally, the foot-tilting follower 72 moves forward and back and pivots relative to the follower 68 about the pivot point 70 . The peg 78 is driven around the groove 80 of the stationary camming groove piece 82 . The foot 24 , attached to the foot tilting shaft 74 , is thus tilted up and down and moved from front to rear, simulating a driving engagement of the foot with the ground. During forward motion the cam spins in the clockwise direction illustrated by arrows 90 , driving the peg 78 around the groove 80 in the clockwise direction illustrated by arrows 92 . During reverse motion the directions are also reversed.
[0023] [0023]FIG. 7 illustrates the foot-pedal actuation mechanism 54 with the foot 24 driven to its forward-most position by the cam 62 . At the same time, the foot is tilted downwards to a toe-down position by the peg 78 reaching the bottom-forward position in of groove 80 . This position simulates the foot 24 at the forward position with the toes down and ready to push back against the ground to drive the toy scooter 16 .
[0024] [0024]FIG. 8 illustrates the foot-pedal actuation mechanism 54 with the foot 24 driven to an intermediate position by the cam 62 with the peg 78 reaching the bottom-rear position of the groove 80 . This position simulates the foot 24 final position at which the toes have finished pushing back against the ground yet are still pointing down.
[0025] [0025]FIG. 9 illustrates the foot-pedal actuation mechanism 54 with the foot 24 driven to its rear-most position by the cam 62 . At the same time, the foot is returned to a raised, toe-up horizontal position by the peg 78 reaching the top-rear position in of groove 80 . This position simulates the foot 24 lifted up from engagement with the ground and ready to move forward.
[0026] [0026]FIG. 10 illustrates the foot-pedal actuation mechanism 54 with the foot 24 driven to an intermediate position by the cam 62 and with the peg 78 reaching the top-front position of the groove 80 . This position simulates the foot 24 returned to a forward position just before lowering the toes again in preparation for pushing back against the ground.
[0027] [0027]FIG. 5 diagrammatically shows a side view of the foot-pedal actuation mechanism 54 relative to the scooter 16 . The forward and back motion of the foot tilting shaft is illustrated within a slot 94 . Also illustrated is the motion of the peg 78 around the camming groove piece 82 . An optional spring 108 is shown attaching the follower 68 to a rearward fixed position. The spring is stretched as the foot 24 moves forward so that the foot will move faster during the backward motion than the forward motion giving the doll 14 an appearance of strongly pushing back against ground.
[0028] When the scooter 16 travels in the backward direction all directions illustrated FIGS. 3, 5 and 7 - 10 and described in the corresponding descriptions are reversed.
[0029] As illustrated in FIG. 4, the doll 14 is articulated with ankle joints 96 , knee joints 98 and hip joints 100 so that the foot 24 can be tilted down and lifted up and so that the entire leg can move forward and backward with the foot movement actuating member 28 .
[0030] The operation of the steering mechanism is now described with particular reference to FIG. 6. A steering motor 102 turns a drive train 104 comprising step down gears. The drive train 104 transfers spinning motion to a pinion 106 which then causes a rack 110 to turn a steering column 112 . The steering column 112 then causes the front wheel 36 and handlebars 20 to turn together. The step down gears 104 transfer the relatively fast spinning motion of the motor 102 to a relatively slow motion of the pinion 106 . The steering column 112 can be biased with a centering spring. In one embodiment, the front wheel 36 can be steered through a 74 degree range.
[0031] As shown in FIG. 4, the doll 14 is articulated with wrist joints 114 , elbow joints 116 , shoulder joints 118 and a waist joint 120 . When the doll 14 is placed on the scooter 16 , the foot 24 is removably secured to the floorboard 26 using two pegs 124 , 126 disposed to fit within two holes formed in the bottom of the foot 22 . Also, the peg 76 is fit within a hole formed in the bottom of the foot 24 . Hands 28 are then removably secured to the handlebars 20 as illustrate in FIG. 1. The shoulder joints 118 are used to raise the hands to the proper level. The wrist joints 114 are especially designed to generally pivot within a plane approximately formed between the elbows and the handlebars. The elbow joints 16 also pivot within the same plane as the wrist joints 114 . Thus, as the handlebars 20 turn the jointed arms 18 appear to be steering the scooter 16 in a life-like manner.
[0032] Returning to FIG. 3, within an electronics area 128 are conventional radio receiving circuits for receiving commands from the remote control 30 . Also within the electronics area 128 are circuits for controlling the motors 44 , 102 . The 6 AA batteries are located at the bottom of the electronics area 128 .
[0033] In one embodiment, the scooter is less than two feet long, and in particular approximately one foot long measured from the furthest forward part of the wheel 36 to the furthest rearward part of the wheel 38 . The floorboard 26 can have a length of approximately 7.5 inches and a width of approximately 3.5 inches. The scooter can have a height of approximately 9 inches from the bottom of the wheels 36 , 38 to the top of the handlebars 20 . The height from the bottom of the wheels 36 , 38 to the top of the floorboard can be approximately 1.5 inches. The wheels 36 , 38 can have diameters of approximately 2.25 inches. The stabilizing wheels 40 can have diameters of approximately 0.5 inches.
[0034] As for the remote control unit 30 , the total length can be approximately 7.5 inches, and the height from the bottom of the wheels to the handlebars can be approximately 5 inches. The width can be approximately 2.75 inches.
[0035] The present invention is not limited to scooters. The invention can take the form of other types of vehicles as well, such as skateboards or motorcycles, by way of examples, but not of limitation. For example, it can take the form of vehicles having one, three, four or other numbers of wheels. Also, instead of using wheels, slides can be used as the main or stabilizing structures. Furthermore, different types of dolls can be used to ride the vehicle. Also, the invention is not limited to use with a particular type of controller. Any kind of controller can be used or else the animated toy doll and scooter assembly can have a memory and processor onboard, for example, to lead the animated toy doll and scooter assembly on a particular predetermined or random course. Accordingly, the invention is not limited to the precise embodiments described in detail hereinbefore.
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A toy doll is articulated and removably attached to a toy scooter so that the doll's arms appear to steer the scooter and the doll's foot appears to tilt downward to push back against the ground and propel the scooter. Additionally, the animated toy doll and scooter assembly is controlled by a radio remote control unit itself shaped like a scooter and having a toy foot attached to it. The toy foot is slid forward or back to control the forward and reverse motion of the scooter and is turned to steer the scooter.
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BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates generally to a geometrical instrument for laying out and proportioning photographs and the like and more specifically, to a cropping device used, for example, in cropping from a photograph to a layout and from a layout to a photograph.
Cropping devices are generally old in the art. Most of these prior art devices are quite similar in that they each comprise a pair of angle members, usually right angle members, arranged in opposed overlapping relationship such that the inner edges of such angle members define a parallelogram, usually a rectangle. These angle members are usually connected together by a diagonally disposed bar or strut which adjustably connects the pair of angle members for movement toward and away from each other to vary the size of the parallelogram or other area defined therebetween. In some of the prior art cropping devices, the diagonal strut is connected to and extends between the apexes of the angle members; while in others, the diagonal strut is connected with and extends between the angle members at a point spaced to one side of the apex of the angle members so that the strut is parallel to, but spaced from, a line passing through the apex of the angle members. In this latter type of cropping device, the inside or included corner of the angle members is not obstructed from view. An example of the latter type of cropping device is described in U.S. Pat. No. 2,782,513.
The primary purpose of the geometrical instruments or cropping devices referred to above is for cropping from photographs to layouts or from layouts to photographs. In either event, the use of such a device involves an adjustment or movement of the angle members to a desired shape and size, and means for retaining the angle members in a fixed position such that only selected relative movement of the angle members is thereafter permitted. The relative movement permitted enables the user to transfer an area of that particular size and shape or an area of proportional shape, either smaller or larger, from a photo to a layout or vice versa. To accomplish the transfer of this area from one medium to another, crop marks were made with a pen or pencil at at least two of the inside or included corners of the resulting area. If the crop marks are made at the inside or included angles of each of the angle members, it is necessary that the diagonal bar or strut be disposed to one side of the apex to expose such angles visually, thereby permitting the crop marks to be made.
The making of such a crop mark in prior art cropping devices, however, gives rise to certain disadvantages of these prior art devices primarily because of the thickness of the crop mark itself and the space required to make such mark. In the prior art devices, the crop mark was made on the inside edge or corner of the resulting area. Thus, when the cropping device was removed, the crop mark actually reflected an area slightly smaller than that framed by the cropping instrument.
In contrast to the prior art, the present invention relates to a geometrical instrument or cropping device which includes a pair of angle members positioned in overlapping relationship and a diagonal bar or strut extending between and connecting said angle members together in adjustable relationship, with such diagonal strut connected to each of said angle members at a point other than at the apex of the angle members. The cropping device of the present invention further includes means for securing said angle members and strut together for selected relative movement and means by which crop marks may be made which account for and compensate for the thickness of such crop marks and the space required to make the same. Also, the present invention includes means for connecting the diagonal bar or strut with each of the angle members such that the bottom surface of such angle members remains relatively flush to avoid scratching or catching on photographs or layouts with which the device is used.
Accordingly, it is an object of the present invention to provide an improved geometrical instrument or cropping device which compensates for the thickness of the crop marks and the space required to make the same so that such crop marks accurately reflect the specific picture or photograph area desired.
Another object of the present invention is to provide a geometrical instrument or cropping device wherein the diagonal strut is connected to said angle members at a point other than the apex of the angle members and which includes means at the apex of the included angles of such angle members for making crop marks which accurately reflect the specific picture area framed by the cropping device.
A further object of the present invention is to provide a cropping device having a flush bottom surface to prevent such device from catching on photographs or layouts with which the device is used.
These and other objects of the present invention will become apparent with reference to the drawings, the description of the preferred embodiment and the appended claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the geometrical instrument of the present invention.
FIG. 2 is a perspective view of the geometrical instrument of the present invention showing such instrument in use.
FIG. 3 is a sectional view of one of the locking knobs of the device of the present invention as viewed along the line 3--3 of FIG. 1.
FIG. 4 is a sectional view of the other locking knob of the device of the present invention as viewed along the line 4--4 of FIG. 1.
FIG. 5 is a sectional view as viewed along the line 5--5 of FIG. 1.
FIG. 6 is a sectional view as viewed along the line 6--6 of FIG. 1.
FIG. 7 is a plan view of the underside of the bridge used in the device of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference first to FIG. 1, the cropping device of the present invention includes a pair of relatively thin, flat angle members 10 and 11 positioned in overlapping relationship. Each of the angle members 10 and 11 includes a pair of sides 12, 13 and 14, 15, respectively, connected at right angles with each other. In the preferred embodiment, the 90° angle member 10 is illustrated as being disposed on top of the 90° angle member 11. Each of the angle members 10 and 11 also includes a pair of inner, straight edges 16, 16a and 18, 18a respectively, which, in the preferred embodiment are disposed at right angles with each other to form an included angle 19 and 20, respectively, therebetween. Although the included angles formed by the edges 16, 16a and 18, 18a are normally right angles, it is contemplated that the advantages of the present invention could be utilized as long as such included angles are less than 180°.
Each of the corners 19 and 20 includes an inset edge or corner 19a and 20a respectively which is inset from the inner edges 16, 16a and 18, 18a of the angle members 10 and 11. As illustrated in FIG. 2, the primary purpose of such inset edges is to enable the user to make cropping marks 48, 48 (FIG. 2) which accurately reflect the specific area of the picture, photograph or the like framed by the device and intended to be cropped. The amount which each of the inset edges 19a and 20a is inset from the inner edges 16, 16a and 18, 18a should correspond to the space necessary to make the cropping mark. This distance normally would include the thickness of the crop mark itself as well as the distance between such mark and the drawing edge. The particular length of each leg of the inset edges 19a and 20a is not critical; however, such legs must be sufficiently long to make a proper crop mark, but should also be short enough to prevent distorting or misrepresenting the area to be cropped.
Each of the angle members 10 and 11 further includes graduations along both its inner edges 16, 16a and 18, 18a and along its outer edges 21 and 22 to aid the user in cropping areas having desired dimensions and to enable the user to arrange the angle members 10 and 11 so that they form the desired angles with the other. In the preferred embodiment, it is contemplated that the scales on each of the inner edges 16, 16a and 18, 18a and outer edges 21 and 22 should be different, thus giving the user alternative scales which he could use in his cropping process.
With further reference to FIGS. 1 and 2, it can be seen that the angle members 10 and 11 are adjustably connected in overlapping relationship by a slotted, diagonally disposed bar or strut member 24. Specifically, the strut 24 extends between the angle members 10 and 11 with one end pivotally connected with the angle member 11 by the connecting means 25, while the other end of the strut 24 is connected in sliding relationship with the angle member 10 by the connecting means 26. In the preferred embodiment the strut 24 is connected with each of the angle members 10 and 11 at a point other than the apex of the included angles 19 and 20 of said angle members, so that the apex of said included angles, specifically the inset edges 19a and 20a, are visually exposed. Preferably, the strut 24 is connected with the members 10 and 11 such that it is parallel to a line passing through the apexes of the included angles 19 and 20 of the members 10 and 11.
As illustrated best in FIG. 3 which is a sectional view of the means 25 for pivotally connecting the strut 24 with the angle member 11, it can be seen that the connecting means 25 includes a bolt 28 extending from the lower surface of the angle member 11 up through a hole in the strut 24 where it is threadedly secured by a locking knob 29. The bolt 28 includes a relatively thin, flat head portion 30 which is partially imbedded into the lower surface of the angle member 11 so that it is flush with the lower surface of the angle member, thereby minimizing the possibility that such bolt would scratch or catch the photograph being cropped. The bolt 28 also includes a square shoulder portion 31 disposed immediately above the flat head 30 which is adapted to fit into an opening in the angle member 11 of approximately the same shape and size to prevent the bolt 28 from turning when the locking nut 29 is tightened or loosened. As also illustrated in FIG. 3, as well as FIG. 6, the end of the strut 24 connected to the angle member 11 includes a spacing portion 32 integrally formed with the strut 24. The primary purpose of this spacing portion 32 is to allow free, unrestricted pivotal movement of the strut 24 relative to the angle member 11 and to compensate for the fact that the angle member 10 overlays the angle member 11. The locking knob 29 is adapted for threaded connection with the threaded portion of the bolt 28 such that when the locking knob is tightened, the strut 24 is held between the locking knob and the angle member 11, thus securing those elements in a relatively fixed position.
As illustrated in FIGS. 4, 5 and 7, the means 26 for slidably connecting the strut 24 with the angle member 10 includes a threaded bolt 34 having a relatively thin, flat head portion 35 and a square shoulder portion 36. As illustrated, the bolt 34 extends upwardly through the angle member 10, the strut 24 and the bridge member 38 at which point it is adapted for threaded connection with the locking knob 39. Similar to the connecting means illustrated in FIG. 3, the head portion 35 in FIG. 4 is partially imbedded into the lower surface of the locking member 10 to provide a relatively flush lower surface, thus preventing such elements from snagging or catching on photographs or other materials being cropped. Also, similar to the connecting means of FIG. 3, the square shoulder portion 36 of the bolt 34 is adapted for insertion into a square opening of approximately the same shape and size in the angle member 10 to prevent the bolt 34 from turning when the knob 39 is tightened or loosened. When the locking knob 39 is tightened over the bolt 34, the elements 38 and 10 are held in a relatively fixed position, permitting sliding movement of the elements 38 and 10 along the strut 24. When both locking knobs 29 and 39 are tightened, the angle members 10 and 11 are held in a fixed position such that only sliding movement of the angle member 10 is permitted along the strut 24. In this manner the size of the area cropped can be changed without affecting the proportions of the area.
As illustrated best in FIG. 7 which is a plan view of the underside of the bridge member 38, the bridge member 38 includes a pair of parallel ridges 40 and 41 which are spaced apart to permit the strut 24 to slide therebetween. The bridge member 38 also includes a center ridge portion 42 which is disposed within the elongated slot 23 of the strut member. The bridge 38 includes a hole 44 in its center portion to accommodate the bolt 34. To permit the above mentioned sliding movement of the angle member 10 when the knob 39 is tightened, it is necessary that the thickness of the ridges 40, 41 and 42 be slightly greater than the thickness of the strut 24.
Although the use of geometrical instruments or cropping devices of the general type to which the present invention relates is well known to those skilled in the art, a brief discussion of the operation of the present invention will be described as follows: First of all, as described above, the cropping device of the present invention, and specifically, the angle members 10 and 11 are adjustable to a variety of positions. The relative movement or adjustability of such members is accomplished by loosening the locking knobs 29 and 39 and positioning the angle members 10 and 11 with respect to each other as desired. When the members 10 and 11 are in position so that the desired cropping area is achieved, the locking knobs 29 and 39 are tightened, thus holding the members 10 and 11 in a fixed position with respect to each other and enabling that area, or a larger or smaller area of the same proportions, to be transferred to another medium.
To use the device of the present invention for cropping from layout to photo, the locking knobs 29 and 39 are first loosened. Next, the device is layed on the layout form with the inside edges 16, 16a and 18, 18a (FIG. 1) aligned with the specific picture area desired. When this is accomplished, the knobs 29 and 39 are tightened, thus securing the members 10 and 11 in a fixed position with respect to each other. The rigid device is then placed over the photo and the upper half of the device, the angle member 10, is moved along the slotted, diagonal strut 24 until the area of the photo desired to be reproduced is within the proportional area. The inset edges 19a and 20a are used as guides to make the crop marks 48, 48 as illustrated in FIG. 2.
For cropping from photo to layout, the locking knobs 29 and 39 are again loosened and the device is layed on the photo, enclosing the portion of the photo desired to be reproduced. The locking knobs 29 and 39 are then tightened, forming the cropping device into a fixed structure. The device is then placed over the layout form and the upper half of the device, angle member 10, is moved along the slotted, diagonal bar 24 until the reproduction size desired is within the proportional area. The inset edges 19a and 20a are then used as guides for drawing the picture area on the layout form similar to the manner illustrated in FIG. 2.
Although the description of the preferred embodiment of the present invention has been quite specific, it is contemplated that various changes and modifications could be made to such embodiment without deviating from the spirit of the present invention. Thus, the scope of the present invention is intended to be dictated by the appended claims rather than by the description of the preferred embodiment.
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An improved geometrical instrument for laying out and proportioning photographs and the like including a pair of angle members disposed in overlapping relationship, a diagonal strut connecting said angle members together for limited movement and means securing said angle members and strut together for selected relative movement between said angle members. The instrument of the present invention also includes an inset edge located at the apex of each of the included angles of the angle members to enable the user to make crop marks accurately reflecting the desired area.
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FIELD OF THE INVENTION
The present invention generally relates to collecting highly oriented flash-spun continuous backwindable fibers from a spinneret in the form of a rod-shaped batt, commonly referred to as a log.
BACKGROUND AND SUMMARY OF THE INVENTION
In the past, it has been desirable to collect flash-spun continuous fibers from a spinneret in the form of a rod-shaped batt, commonly known as a log, wherein the fiber in the batt may be unwound from the end opposite from which the fiber was fed into the batt. This is commonly referred to as being backwindable. For example, U.S. Pat. Nos. 3,413,185; 3,417,431; and 3,600,483 all disclose processes for forming such logs. In brief, the process for forming such logs generally comprises collecting the fiber from a spinneret in a tubular shaped perforated collecting conduit. As the fiber collects therein, it takes the shape of the conduit, i.e. a rod shaped batt. The solvent, which is discharged from the spinneret with the polymer fiber, flash evaporates and expands into the conduit compressing the fiber into the log, pushing the log forward in the conduit, and escaping through the gas release ports in the periphery of the conduit.
In the foregoing references, it should be noted that the spinneret does not include a tunnel at the exit thereof. As is disclosed in U.S. Pat. No. 3,081,519 (Blades et al.) and U.S. Pat. No. 3,227,794 (Anderson et al.), a tunnel has a significant effect on fiber tenacity. U.S. Pat. No. 4,352,650 (Marshall) discusses the optimization of tunnel configuration for increasing fiber tenacity from about 4.2 gpd to about 5.2 gpd, wherein fiber tenacity is described as being increased by as much as 1.3 to 1.7 times by using an appropriately sized tunnel at the exit of the spinneret. Accordingly, it would be very desirable to use a tunnel and obtain higher tenacity fiber for the rod-shaped batts.
However, when collecting the fiber into a log, it has long been believed that the expanding jet of solvent vapor must be allowed to expand fully and quickly so as to reduce or avoid the turbulence that is created by the high speed gases downstream of the spinneret. Such turbulence tends to randomly collapse the fibers prior to the fibers being collected into the log, and the fibers become disorganized as they are collected. The fibers are thereby sufficiently entangled to render the resulting lob difficult to backwind. It is much preferable for the fiber to be collected while still in the expanded state so as to form a more organized log which is far easier to backwind.
A further shortcoming of prior art logmaking methods is that quite frequently, fibers momentarily exit the gas release ports located along the fiber collection tube with the expanding gas. This condition damages the continuity of the plexifilamentary structure of the flash-spun fibers resulting in more frequent filament breaks during backwinding of the flash-spun fibers making up the log. Moreover, fibers exiting the gas release ports leave continuous marks in the form of heavy axial ribs on the surface of the resulting log. These axial ribs change the resistance of log motion through the collection tube in an unpredictable manner. Due to this condition, logs produced are not consistent in quality.
A further problem of prior art logmaking arrangements is the mechanical gate at the collection tube exit for initiating the logmaking process. The gate quite frequently catches fibers during start-up which results in start-up failures and adds to the cost of production.
Another problem with prior arrangements is the mechanical friction element such as rubber gaskets that provide resistance to the log passing out of the collection tube. Clearly, it is preferable for the logs to be discharged from the collection tube in a smooth, continuous and progressive manner. However, such mechanical devices are crude, unreliable and not adapted for adjusting or modifying the rate of discharge during operation of the collection arrangement.
Clearly, what is needed is an apparatus and method that overcome the problems and deficiencies inherent in the prior art. In particular, what is needed is a logmaking apparatus which will produce strong, highly oriented, flash-spun, continuous, backwindable fibers when formed into logs. Other objects and advantages of the present invention will become apparent to those skilled in the art upon reference to the attached drawings and to the detailed description of the invention which hereinafter follows.
The objects of the invention are achieved by the provision of an apparatus for collecting continuous fibers moving with a stream of relatively high speed gases therein into a collection tube. The fibers are formed into a rod-shaped batt in the central passage thereof and a constriction device is connected to the outlet of the collection tube for constricting the central passage to control the rate at which the rod-shaped bat moves therethrough.
BRIEF DESCRIPTION OF THE DRAWINGS
An understanding of the above and other objects of the invention will now be more fully developed by a detailed description of the preferred embodiment. The attached drawings, in conjunction with the following description, may provide a more clear understanding of the invention. In the drawings:
FIG. 1 is a longitudinal cross sectional view of a logmaking apparatus which would be typical of the prior art;
FIG. 2 is a longitudinal cross sectional view similar to FIG. 1 except of the preferred embodiment of the improved logmaking apparatus according to the present invention;
FIG. 3 is an enlarged longitudinal cross sectional view of the nozzle section of the apparatus of the present invention;
FIG. 4 is a transverse cross sectional view of the improved log making apparatus taken along line 3--3 in FIG. 2; and
FIG. 5 is a fragmentary perspective view of the end of the discharge section with parts removed to reveal particular features of the invention.
DESCRIPTION OF THE PRIOR ART APPARATUS
Referring to FIG. 1 of the drawings, the apparatus generally indicated by the number 50 is representative of prior art apparatuses. The apparatus 50 generally comprises a tubular collection chamber 55 including a plurality of gas release ports 57. Fiber is delivered from a spinneret 41 through a broadly diverging conically shaped transition portion 42 into the collection chamber 55. Fiber collection is initiated by a mechanical gate 61 which swings down to block the exit of the collection chamber 55. Once the fiber batt has formed, the gate 61 is opened to allow the batt to move out the exit of the collection tube 55. In practice, the formation of the batt is faster than the rate at which the mechanical gate 61 can be opened for satisfactory initiation of the batt.
Movement of the batt out of the tube 55 is slowed by a series of rubber gaskets 65 sized slightly smaller than the interior of the collection tube 55. However, depending on the size and smoothness of the log, the log may move at various rates from the collection tube 55.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now more particularly to FIGS. 2, 3 and 4 of the drawings, a preferred embodiment of the apparatus for making flash-spun continuous backwindable fiber is generally indicated by the number 100. The apparatus 100 is attached to the exit tunnel 92 at the spinneret 91 of a conventional flash-spinning device 90. The apparatus 100 generally comprises three portions: (1) a nozzle section, generally indicated by the number 120; (2) a collection section, generally indicated by the number 150; and (3) a discharge section, generally indicated by the number 180. The three sections 120, 150 and 180 are connected preferably coaxially end to end such that the fiber is spun at the spinneret 91, passes through the tunnel 92 and into the apparatus 100, through the nozzle section 120, through the collection section 150, and finally through the discharge section 180.
The nozzle section 120 comprises a generally open ended tube 121 having open interior 122 and oriented generally coaxial with the tunnel 92. The nozzle portion 120 is provided with suitable flanges 125 and 126 at the ends thereof for attachment to the flash-spinning device 90 and the collection section 150, respectively. The open interior 120 has a generally circular cross section along its length through the nozzle portion 120 and the interior 122 is larger at the exit end 132 than it is at the inlet end 131. The nozzle section preferably has a length of at least 1.5 times its diameter at the inlet end thereof and an internal contour that preferably diverges from the inlet to the outlet. As will be described below, the diverging contour is not necessarily continuous or always diverging, but preferably does not include any portions with reducing diameter.
The open interior 122 includes a particular geometry which has two stages 135 and 140. The first stage 135 is generally cylindrical and extends for about 0.5 to 10 times the diameter thereof. The diameter of the first stage 135 is preferably larger than the diameter of the tunnel 92 such that the fiber leaving the tunnel 92 "sees" a step change in the diameter of the passageway from the spinneret 91 into the nozzle portion 120. It should be noted that such a step change is preferably a 90° step as illustrated in the drawing. However, it may be acceptable to arrange a step change such that the angle to the axis or centerline of the device may be considerably less than 90 degrees. In other words, the step may comprise a short portion that has a shape extending perhaps 45° relative to axis of the apparatus 100.
The step change is preferably considered by comparing the cross sectional areas of the straight cylindrical first stage 135 to the tunnel exit. It has been found that the cross sectional area of the first stage 135 should be at least 1.05×, but not more than 3×, of the tunnel exit cross sectional area. It is preferred that the step increase in cross sectional area is 1.1× to 1.8× the tunnel exit cross sectional area.
It is hypothesized that the step increase between the tunnel 92 and the first stage 135 of the nozzle section 120 provides at least two advantages. First, it does not hinder the expansion of the jet exiting the tunnel. Occasionally, an under expanded jet condition occurs due to minor solution flow rate fluctuations over time. Any hindrance to this under expanded jet at the exit of the tunnel 92 may effect plexifilamentary structure of the spun fibers in a negative way, such as heavy and poorly fibrillated lines and short tie points in the plexifilamentary structure.
Secondly, it is believed that the pressure fluctuations down stream of the tunnel become dampened out by the step change prior to such fluctuations being transmitted back to the tunnel 92. Pressure pulses in the tunnel 92 tend to render irregular fiber quality. These two advantages result in making "logs" having consistent fiber quality without the undesired defects, such as, the above described heavy and poorly fibrillated lines in the plexifilamentary structure of the spun fibers.
Moving along the nozzle section 120, the straight cylindrical first stage 135 of the two stage nozzle section 120 conducts the jet of solvent vapor exiting the tunnel 92 to the second stage 140 of the two stage nozzle section 120 without disturbing the directionality and stability of the jet's axial motion. The length of the straight cylindrical first stage 135 is approximately 0.5× to 10× the exit diameter of the tunnel 92, and preferably 1× to 4× the exit diameter of tunnel 92.
The second stage 140 of the two stage nozzle section 120 comprises a diverging conical shape extending from the generally cylindrical first stage 135 to the exit end 132 of the nozzle section 120. The diverging angle α of the second stage 140 has been found to be suitable between one to about 20 degrees with respect to the axis or centerline of the apparatus 100 (also referred to as the half angle) but is preferably in the range of 4 to 12 degrees. The exit cross sectional area of the diverging second stage 140 (at the exit end 132) is at least 0.1× the cross sectional area of the collection section 150 down stream but not larger than the cross sectional area of the collection section 150. The preferred cross sectional area at the exit of the diverging section is 0.2× to 0.75× of the cross sectional area of the collection section 150. Also in the preferred embodiment, the angle of the diverging second stage 140 is such that, if the diverging second stage 140 were projected toward the tunnel 92, it would have approximately the same dimension as the exit of the tunnel 92 at the exit of the tunnel. In other words, the diverging second stage 140, in the preferred embodiment, is arranged so that an extension of the conical shape would intersect the tunnel exit with a cross sectional area that substantially corresponds to the cross sectional area of the tunnel exit.
The nozzle section 120 permits the continuation and completion of the flashing of the solvent while allowing for gradual deceleration of the jet. Under such an arrangement, it has been found that the turbulent forces are not as pronounced and the fiber may be formed into an acceptable log. In the improved design of the present invention however, there also includes an improvement in the collection section 150.
The collection section 150, as in the prior art arrangements, is a generally cylindrical tube 151 having a plurality of gas release ports 152 in the peripheral wall thereof. The ports 152 are suitably spaced and sized to permit the solvent vapor to exit while substantially preventing the fiber from exiting therethrough. However, in the present invention, the collection section 150 includes a wire mesh screen 155 lining the interior of the cylindrical bore so as to prevent fiber from easily exiting the interior of the tube 151. As such, the solvent vapor is permitted to exit through the ports 152 at substantially the same rate as in the prior art, but the fibers are less able to pass out therethrough because of the effective reduction in the size of the ports 152. The screen used is 10 mesh to 200 mesh, preferably 35 mesh to 100 mesh. Details about screens of specific mesh are given in Chemical Engineers' Handbook by R. H. Perry and C. H. Chilton, 5th Edition, Table 21-12. The screen 155 provides enough open area for gases to escape without any unacceptable pressure drop and at the same time prevents fibers from exiting through the openings in the screen 155 along with gases. This eliminates the mechanical damage to fibers that may occur in the absence of screen due to the fibers momentarily exiting the gas release ports on the collection tube. Preferably the screen is made of a Teflon impregnated nickel to provide a tough and low friction surface for the log moving through the collection section 150.
From the collection section 150, the now formed log of fiber passes into the discharge section 180. The discharge section 180 is comprised of a tubular section 181 having a generally imperforate elastomeric bladder 185 arranged to line the interior of the tubular section 181. The terminal edges of the tubular shaped bladder 185 are suitably sealed to the tubular section 181 so that the annular space 188 between the bladder 185 and the tubular section 181 may receive and hold air or other fluid through nipple 189 to change the dimension of the bladder 185 within the tubular section 181. As the annular space 188 is provided with fluid, the bladder 185 constricts the passage or essentially changes the interior dimension of the discharge section 180. To facilitate rapid evacuation of fluid, a network or matrix of grooves 191 are cut into the inner surface of the tubular section 181 so that fluid may move toward the nipple 189 even while the bladder 185 is pressed fully against the inner surface of the tubular section 181.
Log formation is initiated by collapsing the bladder by an impulse of high pressure air through nipple 189. Once the "log" formation is initiated, the bladder is allowed to quickly return to its initial dimension by releasing the air pressure. The resistance to "log" motion through the bladder is thereafter controlled by inflating the bladder to desired level during the process thus controlling the rate at which the log exits the collection section 150.
The gas pressure in the collection section 150 depends in some part on the size and number of ports 152 through which the solvent vapor may exit therefrom. The number of the ports 152 which are open depends on where the end of the log is in the collection section 150. If the beginning end (the end of the log into which the fibers are being fed) is close to the nozzle exit, the pressure (or back pressure) will be much higher than if the end of the log is closer to the discharge section 180. Accordingly, by controlling the rate at which the logs are permitted to exit from the collection section 150 essentially provides control of the back pressure in the collection section 150.
The back pressure has a significant effect on fiber quality and it is preferred to control the back pressure to desired level during the process to maintain the quality of the fiber. If the back pressure is too low, the "logs" produced are too soft to handle. If the back pressure is too high, flash spun fibers are not well fibrillated and also the process is more prone to fail due to fibers being blown out through the gas release ports on the collection tube.
Accordingly, the present invention provides a significant improvement over prior art arrangements in that the industry will now be enabled to produce backwindable fiber having higher tenacity and strength. Backwindable fiber logs can now be made using a tunnel of the type that has long been known to provide greater tensile strength.
Now that the apparatus 100 of the invention has been set forth, the process in which the apparatus is used will now be described. As noted above, the apparatus is to be substituted for prior fiber receiving and log forming arrangements. The apparatus for spinning the fiber strand is essentially the same as described in prior art patents. However, in contrast to the prior log making arrangements, the spinneret includes a tunnel at the exit thereof to enhance the acceleration of the flashing solvent vapors and provide enhanced tensile strength for the spun fibers. The fiber strand passes from the tunnel and into the nozzle section 120 where the lateral expansion continues in a diverging, continuously expanding arrangement gradually slowing the expanding jet of solvent vapor.
As the fiber strand passes out of the nozzle section 120 and into the collection section 150, the solvent vapor has slowed considerably so that the fiber can be collected. The collection section 150 includes the ports 152 which permit the solvent vapor to escape from the collection section. The fiber strand is collected into the log with sufficient force to form a stable and suitable log. Portions of the fiber which move to the periphery of the collection conduit are retained therein by the mesh screen while the mesh screen does not substantially create excessive back pressure in the nozzle and tunnel. The log then slowly moves out of the conduit and into the discharge section. The bladder is arranged to control the discharge of the log based on the physical qualities of the log and the fiber therein, and on the rate at which the fiber is being delivered into the apparatus.
While the invention has been described as a combination of at least three improvements to the prior apparatuses, it should be clearly understood that not all the described improvements are necessary together. While it is preferable that all are used in conjunction to form the preferred apparatus as described and illustrated in FIG. 2, each may be used independent of the others to improve the operation of prior apparatuses.
The above-described invention will now be illustrated by the following non-limiting examples.
EXAMPLE 1
A solution of 12%, by weight, of high density polyethylene (HDPE--melt index 0.75; stress exponent 1.45; rheology number 46; specific density 0.957; number average molecular weight 28000 and weight average molecular weight 135000) was prepared in Freon-11 solvent at 180° C. and 1500 psi. Solution pressure was then dropped to 930 psi to create two phase solution prior to flash spinning. Spinneret size was 0.047 in. and there was no tunnel at the spinneret exit. The spinneret was connected to the collection tube via a 120 degree flared opening (60 degree half angle) at the spinneret exit as shown in FIG. 1. The collection tube ID was 1.5 in. and was 10 in. long. Gas release ports were 0.125 in. diameter and were 18 degree apart around the circumference. Gas release port rows were 0.25 in. apart and were staggered along the length of the fiber collection tube as shown in FIG. 1. There was no screen inside the collection tube. Several rubber gaskets were used at the collection tube exit to achieve desired resistance to the log motion for log making process. A mechanical gate was used at the exit to initiate the logmaking process. The overall equipment assembly is generally as shown in FIG. 1.
During the test, polymer flow rate was 91 pph. Fibers momentarily projected out through the first 2 to 3 rows of gas release ports in the collection tube by about 0.25-0.75 in. This yielded heavy axial lines on the surface of the logs and damaged the continuity of the fibers. Also, fibers had heavy and poorly fibrillated regions. The web tenacity was 3.4 gpd.
EXAMPLE 2
The solution supplied and equipment set-up were the same as in Example 1 except an appropriately sized tunnel was used at the spinneret exit. The tunnel exit diameter was 0.423 and was 0.27 in. long. Tunnel diverging angle with respect to the center axis was 10 degrees. The tunnel opened into the collection tube.
During the test, significant difficulties were encountered while establishing initial "log" formation at the start-up. Even when "log" formation was established, the process kept failing almost instantaneously either due to blow out of the formed "log" from the collection tube or blow out of fibers from the gas release ports.
EXAMPLE 3
Solution supply and equipment set-up were same as Example 2 except collection tube diameter was 2.0 in. The process formed "logs". However, fibers in the "logs" were totally entangled and back winding of flash spun fibers from these "logs" was not feasible.
EXAMPLE 4
The solution supply and equipment set-up were same as in Example 2 except that a two stage nozzle, substantially as illustrated in FIG. 2, was added at the tunnel exit. Entrance diameter of the two stage nozzle was 0.51 in. creating a step increase in cross section area at the tunnel exit. The length of the straight portion of the nozzle was 0.93 in. The diverging section had a 4 degree diverging angle with respect to center axis. The exit diameter of diverging section was 1.00 in.
During the test, both "log" formation initiation at the start as well continuation of the "log" making process was without any difficulties. However, the process appeared to be more sensitive and unstable due to flash spun fibers momentarily projecting out from first few rows of gas release ports on the collection tube.
Due to the latter problem, the continuity of the plexifilamentary structure of flash spun fibers was damaged similar to Example 1. However, unlike Example 1, the web produced during this test was very well fibrillated and strong (5.1 gpd). Also, there were no defects, such as heavy and poorly fibrillated regions.
EXAMPLE 5
The solution supply and equipment set-up were same as in Example 4 except 100 mesh standard screen was used inside the collection tube as shown in FIG. 2. With the use of the screen, problems associated with the fibers projecting out of the gas release ports as in Example 4 were eliminated. However, the fiber was very poorly fibrillated. In order to improve fibers fibrillation, 30 mesh size screen was tried and was found have to have excessively large openings to retain the fibers. A screen size of 50 mesh was found to be optimum for this test. It retained fibers inside the collection tube at the same time screen opening size was large enough for the gases to escape without excessive pressure drop. The flash spun fibers were strong and the plexifilamentary structure was very well fibrillated similar to Example 4. At the same time, the backwindability of fibers from the logs produced during this test was extremely good and continuity of plexifilamentary structure of flash spun fibers was very good as well.
EXAMPLE 6
The solution supply and equipment set-up were the same as in Example 5 except an inflatable bladder was used instead of the rubber gaskets and the mechanical gate at the exit of fiber collection tube. The rubber bladder was made up of neoprene rubber. The thickness of bladder wall was 0.050 in. having durometer of about 70. The inside of the metal cylinder supporting the inflatable bladder was provided with a network of grooves 191 to facilitate the escape of the air through the air supply entrance hole. Air supply pressure was 45 psig.
A very short burst of 45 psig air was supplied to the bladder at the start to initiate log formation. The air inflated the bladder to constrict down on and close the exit of the fiber collection tube momentarily. Within a split second the bladder retracted back to its initial position by releasing the air pressure. Bladder diameter was matched with the diameter of "log" exiting the fiber collection tube in a way that no air pressure was applied to the bladder once the "log" formation had started. However, bladder was inflated slightly during the test whenever logs appeared to be too soft to handle.
Fibers quality and "logs" quality were extremely good as described in Example 5. In this example, both a straight tube and a short section of bicycle tube were tried as the bladder and both were found to function equally very well.
EXAMPLE 7
The solution supply and equipment set-up were the same as in Example 6 except the preferred two stage nozzle was replaced by single stage diverging nozzle at the tunnel exit. This nozzle did not have straight cylindrical section at the entrance and had only a conical diverging section. However, there was a step increase in cross section area at the tunnel exit due to nozzle entrance diameter 0.51 in. as compared to tunnel exit diameter 0.423 in. The diverging angle of the nozzle was 4 degrees with respect to center axis and exit diameter was 1.0 in. as in Example 6.
During the test, the process was not as stable as Example 6 (fluctuations in "log" motion velocity). Also, fibers in the "log" were not packed in a very backwindable manner as in Example 6.
EXAMPLE 8
The solution supply and equipment set-up were the same as in Example 7 except that the nozzle at the tunnel exit had neither a straight section (like Example 7) nor a step increase in cross sectional area at the tunnel exit (unlike Example 7). The entrance diameter of the nozzle was 0.450" as compared to tunnel exit diameter 0.423". The diverging angle was 4 degrees (half angle) and exit diameter was 1.0 in. similar to Example 7.
Plexifilamentary structure of flash spun fibers in logs formed during this test was very poorly fibrillated. This test was repeated with an increased diverging angle to the same angle as the tunnel diverging angle, i.e. 10 degrees. Fibrillation of plexifilamentary structure did improve, however, the process was still very unsatisfactory. Also, "log" formation process became unstable.
EXAMPLE 9
The solution supply and equipment set-up were the same as in Example 6 except that the collection tube had gas release ports 9 degrees apart in each row instead of 18 degrees apart. The screen size was 50 mesh.
During the test, fibers blew out through the screen and the gas release ports. As such, the logs produced during this test were unsatisfactory.
Although particular embodiments of the present invention have been described in the foregoing description, it will be understood by those skilled in the art that the invention is capable of numerous modifications, substitutions and rearrangements without departing from the spirit or essential attributes of the invention. Reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.
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This invention relates to making backwindable rod shaped batts or logs from highly oriented flash-spun continuous fibers. The fibers are conducted from the exit of a spinneret through a tunnel and into a two stage diverging nozzle to slow down the fibers for an organized collection in the collection section. The invention further includes an inflatable bladder in a discharge section for initiating the formation of the log and a mesh screen in the collection section for reducing the occurrence of fiber blow out through the gas discharge ports.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a Continuation-In-Part of co-pending U.S. Non-Provisional Patent Application Ser. No. 11/622,674 filed Jan. 12, 2007, entitled “BAR CONNECTING APPARATUS” which is hereby incorporated by reference. This application and application Ser. No. 11/622,674 both claim the benefit of co-pending U.S. Provisional Patent Application Ser. No. 60/860,434 filed Nov. 21, 2006, entitled “CLIP APPLYING APPARATUS” which is hereby incorporated by reference. The present application also claims benefit of co-pending U.S. Provisional Patent Application Ser. No. 60/911,401 filed Apr. 12, 2007 entitled “BAR CONNECTING APPARATUS” which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an apparatus and method for attaching clips to connect bars, wherein the bars are used to reinforce concrete. Reinforcing bars are commonly placed within a frame where cement is to be poured, so that the reinforcing bars will become encased in the poured cement. The reinforcing bars are placed in specified positions at specified heights within the frame, so the resulting concrete is strengthened. One method used to connect the reinforcing bars before the cement is poured is clips. These clips are attached at the intersection of two bars, so the bars are held together in a fixed position. The current invention provides an apparatus and a method for attaching clips to intersecting bars.
[0004] 2. Description of the Related Art
[0005] Supporting bars are commonly used to reinforce concrete. The supporting bars are laid out in a grid where the cement is to be poured. To maximize the effectiveness of the supporting bars, they are placed at specified heights, usually between about 2 and 6 inches from the ground. The bars are then connected so the grid is stable and will not move when the concrete is poured.
[0006] Many methods have been used to connect the bars, and many are done by hand. Rebar is the type of supporting bar most commonly used. When the rebar is connected by hand, it requires a laborer to bend over and connect the rebar at many points within the grid. This is labor intensive, slow, and tends to cause injuries from the repeated bending. In some instances, the rebar grid can be prepared first, and then placed into a form where the concrete will be poured. This can reduce the bending required, but does not address the time and labor needed to connect the rebar. To reduce the time needed to connect rebar and to minimize the time a laborer is working in a stooped over position, several applicators for connecting the rebar have been developed.
[0007] For example, in U.S. Pat. No. 5,881,452 Nowell et al. describes an apparatus for applying deformable metal fastener clips to concrete reinforcement steel. The Nowell device is a hand held applicator. It applies generally U-shaped deformable metal clips at the intersection of pieces of reinforcing rebar or wire mesh sheets. The apparatus is used to place the U-shaped metal clip around adjacent metal bars and then deform and close the U, thus connecting the bars.
[0008] West, in U.S. Pat. No. 5,826,629, describes a pneumatic wire tying apparatus for tying crossed reinforcing bars together. This device has a guide member which opens to receive intersecting bars, and then closes onto the bars. In the closed position a length of wire is guided around the bars. A feed mechanism feeds a wire to the guide member, and a twist member engages and twists the wire around the reinforcing bars.
BRIEF SUMMARY OF THE INVENTION
[0009] The current invention relates to an apparatus for applying clips to connect reinforcing bar as is typically used in concrete structures. The bar connecting apparatus as described is designed to fasten plastic clips as defined in U.S. patent application publication number 2006-0248844 A1, which is incorporated herein by reference. The clips are inserted into a barrel, and the apparatus is positioned over transverse supporting bars. A hammer reciprocates longitudinally within the barrel and strikes the clip. The hammer propels the clip out of the distal end of the barrel, which is positioned over the transverse bars, such that the clip engages and connects the bars. An alignment head at the distal end of the barrel is utilized to position the bar connecting apparatus relative to the transverse bars.
[0010] The clips are provided in a clip string, which is a plurality of clips connected together. In one embodiment, the clips are connected directly to each other, and in another embodiment the clips are connected to a common feed rod. The clip string is inserted into a clip feed assembly, which directs a clip into a clip receiving cavity in the barrel each time the hammer reciprocates. The clip feed assembly engages the hammer through a cam guide, so the motion of the hammer as it reciprocates provides the drive to cycle the clip feed assembly. Therefore, each time the hammer propels a clip from the barrel, the clip feed assembly inserts another clip from the clip string into the barrel, so the bar connecting apparatus can connect several pairs of transverse bars in rapid succession.
[0011] The clip feed assembly utilizes at least one finger to engage and advance the clip string into the clip receiving cavity. The finger has a pivot point and a sloped side so the finger can ratchet backwards along the clip string before engaging and urging the clip string forward into the clip receiving cavity. The backwards ratcheting motion and forward engaging motion allows the finger to advance clips into the clip receiving cavity as the clip feed assembly reciprocates laterally with each cycle of the hammer.
[0012] The clip feed assembly includes a clip track, which supports the clip string outside of the clip receiving cavity. In one embodiment, the clip track engages the clip from the top, and the clip track extends through the clip receiving cavity. The hammer has an indentation with legs, so the clip track is received in the indentation with the hammer legs passing beside the clip track. The legs contact and drive the clip from the barrel. In a second embodiment, the clip track terminates before entering the clip receiving cavity, and a resilient retainer is utilized to hold the clip in place until it is driven from the bar connecting apparatus.
[0013] The hammer is reciprocated by a drive, which can be powered by many sources, including manual and pneumatic sources. The power source first biases the drive and the connected hammer distally to drive a clip from the barrel. Next, the drive and hammer are biased proximally to reposition the hammer for the next clip, and to complete the associated cycling of the clip feed assembly. A handle and a biasing spring are used for the manual embodiment, and a trigger is used to actuate a pneumatic or other power source.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of the clip string.
[0015] FIG. 2 is a perspective view of a single clip engaged with transverse bars.
[0016] FIG. 3 is a perspective view of the clip string when the feed rod is utilized.
[0017] FIG. 4 is a perspective view of the clip string with teeth on the feed rod.
[0018] FIG. 5 is a side view of the manually driven embodiment of the bar connecting apparatus.
[0019] FIG. 6 is a side view of a distal portion of the bar connecting apparatus without the clip feed assembly.
[0020] FIG. 7 is a front view of a distal portion of the bar connecting apparatus without the clip feed assembly.
[0021] FIG. 8 is a side view of the manual drive portion of the bar connecting apparatus with an attached hammer.
[0022] FIG. 9 is a side view of the pneumatically driven embodiment of the bar connecting apparatus.
[0023] FIG. 10 is a side view of a distal portion of the bar connecting apparatus.
[0024] FIG. 11 is a top view of a finger of the clip feed assembly.
[0025] FIG. 12 is a top view of a clip string engaged by fingers of the clip feed assembly.
[0026] FIG. 13 is a side view of the hammer having an indentation.
[0027] FIG. 14 is a front view of a portion of the clip receiving cavity with resilient retainers.
[0028] FIG. 15 is a side view illustrating an alternate design for the cam plate.
[0029] FIG. 16 is a side view of an embodiment of the clip string.
[0030] FIG. 17 is a side view of an embodiment of the bar connecting apparatus showing the clip feed assembly.
[0031] FIG. 18 is a side view of an embodiment of the bar connecting apparatus with the barrel removed to display components within the barrel.
[0032] FIG. 19 is a side view of the distal portion of the bar connecting apparatus
[0033] FIG. 20 is a rear view of the distal portion of the bar connecting apparatus, with the clip feed assembly removed for clarity.
[0034] FIG. 21 is a side view of the hammer with the hammer plate.
[0035] FIG. 22 is a top view of the hammer with the hammer plate.
[0036] FIG. 23 is a top view of the cam plate for the hammer plate embodiment of the invention.
[0037] FIG. 24 is a side view of the cam plate for the hammer plate embodiment of the invention.
[0038] FIG. 25 is a rear view of the finger for the hammer plate embodiment of the invention.
[0039] FIG. 26 is a side view of the finger for the hammer plate embodiment of the invention.
[0040] FIG. 27 is a side view of the hammer plate embodiment of a manually actuated bar connecting apparatus with the safety plate removed for clarity.
DETAILED DESCRIPTION OF THE INVENTION
Clip String
[0041] The Bar Connecting Apparatus utilizes a clip string 2 as depicted in FIG. 1 . The clip string 2 is comprised of a plurality of connected individual clips 4 , wherein the last clip in the series is the terminal clip 6 . In the preferred embodiment, the clips 4 are comprised of plastic and each clip 4 has several components. Referring to FIG. 2 , the seat 8 is adapted to engage and position a first bar 9 . Below the seat 8 are a plurality of hooks 10 , preferentially four hooks 10 per clip 4 , which are adapted to engage and position a second bar 11 transverse to the first bar 9 . The first bar 9 is also positioned on top of the second bar 11 . The hooks 10 are joined by a joining portion 12 , and each hook 10 has an upper body 14 .
[0042] The upper body 14 combined with the upper portion of the joining portion 12 defines a cradle 15 for engaging and positioning another bar parallel to and above the second bar 11 . The clip 4 can position a bar parallel to the second bar 11 in the cradle 15 , or it can position a first bar 9 in the seat 8 , but not both at the same time because the seat 8 and the cradle 15 receive bars in areas which interfere with each other.
[0043] Each clip 4 in the clip string 2 is connected to at least one adjoining clip 4 at the connection point 16 , as seen in FIG. 1 . The connection point 16 can be defined anywhere on the portion of a clip that abuts an adjoining clip 4 , as long as the clips 4 are connected together. Each clip 4 has at least one connection point 16 , but multiple connection points 16 can be utilized if necessary. The clips 4 are connected such that every clip 4 in the clip string 2 has a consistent orientation. Preferably, the orientation is such that if a bar were received in the hooks 10 of the terminal clip 6 , the same bar could be simultaneously received in the hooks 10 of every other clip 4 in the clip string 02 . Therefore, there would be one axis defined by the hooks 10 of all of the clips 4 in a clip string 02 . Similarly, the cradles 15 defined by the upper bodies 14 of the clips 4 would also be aligned on a single axis.
[0044] In an alternative embodiment, the clips 4 as defined above are connected to a feed rod 18 , as depicted in FIG. 3 . If the feed rod 18 is utilized, the connection point 16 B connects each clip 4 to the feed rod 18 . The feed rod 18 can be positioned anywhere along the side of the clip string 2 B as long as the clips 4 are held in a consistent orientation as described above. It is possible for the feed rod 18 to have teeth 19 for advancing the clip string 2 B, as shown in FIG. 4 . Also, if the feed rod 18 is utilized, each individual clip 4 does not necessarily touch or directly contact the neighboring clip 4 . The clips 4 are connected to the feed rod 18 , and not to each other, so the clips 4 are not held in direct contact with other clips 4 in the clip string 2 B.
[0045] Every clip string 2 B has only one sized clip 4 , but every clip string 2 B does not necessarily have the same sized clip 4 . The clips 4 are sized to connect a certain size of reinforcing bar, and because there are several sizes of reinforcing bars, there are several sizes of clips 4 . Although the size of a clip 4 in different clip strings 2 B would vary, the feed rod 18 allows the spacing between neighboring clips 4 to be constant. That is, the distance from the front of a larger clip 4 to the front of a neighboring larger clip 4 in one clip string 2 B would be the same as the distance from the front of a smaller clip 4 to the front of a neighboring smaller clip 4 in another clip string 2 B. When a feed rod 18 is utilized, this consistent spacing is possible because the clips 4 do not have to touch to be connected together. The consistent spacing is desirable because it allows for a bar connecting apparatus to apply clips 4 of different sizes without having to adjust or change the clip feed mechanism.
[0046] A third embodiment of the clip string 2 C is shown in FIG. 16 . Similar components are given the same names, but the identification numbers are denominated by a “C,” for the sake of clarity. Every clip 4 C in a clip string 2 C is the same size, but the third embodiment allows for clips strings 2 C having different sized clips 4 C to maintain consistent spacing between the clips 4 C without the use of a feed rod.
[0047] The clip string 2 C has a length 3 C, with each individual clip 4 C having at least one adjacent clip. The terminal clip 6 C would only have one adjacent clip 4 C, whereas each clip 4 C in the middle of the clip string 2 C would have two adjacent clips 4 C. Each clip 4 C is oriented with the cradle 15 defined by the upper body 14 aligned perpendicular to the clip string length 3 C. When the cradle 15 is perpendicular to the clip string length 3 C, a bar received in the cradle 15 of the clip 4 C would be perpendicular to the length 3 C of the clip string 2 C. This orientation is ninety degrees from the orientation shown in FIG. 1 , where a bar received in the cradle 15 of each clip 4 would be parallel to the length of the clip string. In FIG. 16 each clip 4 C is still consistently oriented, but the orientation has shifted. It is also possible to orient each clip 4 C with the cradle 15 aligned parallel to the length 3 C of the clip string 2 C.
[0048] Consistent spacing between different sized clips 4 C in different clip strings 2 C is achieved by providing a connection point 16 C with a length 17 C. The connection point 16 C is also referred to as a tab 16 C, and the length 17 C of the tab 16 C varies between clip strings 2 C having clips 4 C of different size. By providing shorter tabs 16 C for clip strings 2 C with larger clips 4 C, the spacing between the clips 4 C can be kept consistent for clip strings 2 C having different sized clips 4 C. Therefore, the distance from the front of one clip 4 C to the front of an adjacent clip 4 C is the same for two different clip strings 2 C which have clips 4 C of different sizes. The length 17 C of the tab 16 C serves to hold adjacent clips 4 C apart, so they don't touch, with the adjacent clips 4 C separated by the tab length 17 C. When the clip string 2 C is flexed, adjoining clips 4 C may touch, but normally they would be apart.
[0049] The tab 16 C has an indent 13 C to facilitate breaking of the tab 16 C when the clip 4 C is applied to connect bars. The terminal clip 6 C becomes separated from the clip string 2 C when used to connect bars, and the indent 13 C provides a breaking point on the tab 16 C to aid in separating the terminal clip 6 C. Each clip 4 C is comprised of plastic, and preferably includes four hooks 10 , 4 upper bodies 14 , and two joining portions 12 which each connects two hooks 10 , as best seen in FIG. 2 . Each upper body 14 is connected to one other upper body 14 in each clip 4 .
Bar Connecting Apparatus
[0050] The clip string 2 is utilized in the bar connecting apparatus 20 as shown in FIG. 5 . Inside the bar connecting apparatus 20 is a barrel 22 with a clip receiving cavity 24 . The terminal clip 6 of the clip string 2 is received into the clip receiving cavity 24 of the barrel 22 , which can be seen more clearly in FIG. 6 . FIG. 6 does not include the clip feeding mechanism, to more clearly show the barrel 22 with the clip receiving cavity 24 . The clip receiving cavity 24 includes a hole in the side of the barrel 22 which is adapted to receive clips 4 from the clip string 02 . Inside the barrel 22 is a hammer 26 which reciprocates longitudinally within the barrel 22 . As the hammer 26 reciprocates distally, it contacts the terminal clip 6 and expels the terminal clip 6 out the distal end of the barrel 23 .
[0051] There is an alignment head 28 defined at the distal end of the barrel 23 , which aligns the clip applying apparatus 20 with the bars to be connected. When the terminal clip 6 is ejected from the barrel 22 , the alignment head 28 ensures the bar connecting apparatus 20 is properly aligned with the bars such that the terminal clip 6 connects the bars. After the terminal clip 6 is ejected the hammer 26 reciprocates proximally, the next clip 4 in the clip string 2 is advanced into the clip receiving cavity 24 and becomes the new terminal clip 6 , and the clip applying process is ready to be repeated.
[0052] The alignment head 28 has two pair of notches 30 , 30 B adapted to engage transverse bars, as seen in FIGS. 6 and 7 . For the sake of clarity, FIG. 7 also does not show the clip feeding mechanism. One pair of notches 30 is deeper than the other pair 30 B, so the first bar 9 , which is on top, is engaged in the deeper pair of notches 30 and the second bar 11 , which is underneath the first bar 9 , is engaged in the more shallow pair of notches 30 B. The notches 30 , 30 B in each pair are on opposite sides of the alignment head 28 , so the four points of contact between the notches 30 , 30 B and the transverse bars 9 , 11 prevent the bar connecting apparatus 20 from moving. The alignment head 28 , when engaged with the transverse bars, fixes the position of the bar connecting apparatus 20 in three dimensions.
[0053] The hammer 26 is reciprocated by a drive 32 , as seen in FIGS. 5 and 8 . FIG. 8 depicts the hammer 26 and the manual drive 32 , without the remainder of the bar connecting apparatus 20 . The drive 32 includes a drive rod 33 which is actuated either manual or automatically. The act of connecting the drive rod 33 to the hammer 26 can be aided by wrench flats in the drive rod 33 . In the manual embodiment, the drive 32 includes a handle 34 and a biasing spring 36 . The handle 34 is manually depressed to extend the hammer 26 distally for ejecting the terminal clip 6 from the barrel 22 . The biasing spring 36 then biases the handle 34 proximally and retracts the hammer 26 to a position such that the next terminal clip 6 can be introduced into the clip receiving cavity 24 .
[0054] FIG. 9 depicts the bar connecting apparatus 20 A with a trigger actuated automatic drive 32 A. For the sake of clarity, similar components in the manual and automatic embodiments are given the same name and number, but the component numbers in the automatic embodiment are designated with an “A.” The drive 32 A includes a trigger 38 for directing a power source to cycle the drive 32 A, such that the power source biases the drive 32 A distally when the trigger 38 is depressed and proximally when the trigger 38 is released. In the preferred embodiment, the power source is pneumatic; however, other power sources, such as an electric power source, could also be utilized. Additionally, an extension can be added to either the automatic or manual drive 32 , 32 A so an operator can stand upright while connecting bars.
[0055] The alignment head 28 includes two pair of notches 30 , 30 B, which are further designated as a first and second pair of notches 30 , 30 B, as seen in FIGS. 6 and 7 . The first pair of notches 30 are deeper than the second pair of notches 30 B. This allows the first transverse bar 9 , which is above the second bar 11 , to be engaged in the first pair of notches 30 , and the second, bottom transverse bar 11 to be engaged in the second pair of notches 30 B. The transverse bars 9 , 11 are perpendicular to each other, and the alignment head 28 C positions the barrel 22 C perpendicular to both bars 9 , 11 .
Clip Feed Assembly
[0056] The clip feed assembly 40 advances the clip string 2 into the clip receiving cavity 24 as the hammer 26 reciprocates, as seen in FIG. 10 . A cam guide 42 is connected to the side of the hammer 26 . The cam guide 42 passes through a straight slot and protrudes from the side of the barrel 22 . Therefore, the cam guide 42 reciprocates outside of the barrel 22 as the hammer 26 reciprocates inside of the barrel 22 . The cam guide 42 can include a bearing to make the motion of the cam guide 42 smoother.
[0057] The portion of the cam guide 42 which protrudes from the side of the barrel 22 is engaged in a slot type cam track 44 . The cam track 44 is defined in the cam plate 46 , and the cam plate 46 is pivotally connected to the bar connecting apparatus 20 at a pivot point 48 . The cam track 44 has an angled section such that as the hammer 26 and cam guide 42 cycle, the cam plate 46 pivots at the pivot point 48 and reciprocates laterally. The cam track 44 can also include straight sections, which are used for timing purposes to coordinate the clip feed assembly 40 operation with the cycling of the hammer 26 . The cam plate 46 reciprocates away from the barrel 22 as the hammer 26 reciprocates distally, and the cam plate 46 reciprocates towards the barrel 22 as the hammer 26 reciprocates proximally. With the slot type cam track 44 no return spring is needed for the cam plate 46 .
[0058] An alternate design for the cam plate, designated as 46 B is shown in FIG. 15 . Surrounding parts of apparatus 20 are not shown in FIG. 15 so as to aid in the ease of illustration of cam plate 46 B. The cam plate 46 B has an edge type cam track 44 B instead of the slot 44 of FIG. 10 . The edge type cam track 44 B is maintained in contact with the reciprocating cam guide 42 by a tension spring 47 , which is schematically illustrated in FIG. 15 . Any type of resilient return spring could be utilized in place of spring 47 to urge the cam track 44 B against cam guide 42 . With either the cam plate 46 of FIG. 10 or the cam plate 46 B of FIG. 15 the cam plate will reciprocate as the hammer 26 cycles.
[0059] A feed support block 50 can be positioned at the end of the cam plate 46 to facilitate the feeding of the clip string 2 into the clip receiving cavity 24 , as shown in FIG. 10 . At least one finger 52 , and preferably two fingers, is connected to the cam plate 46 through the feed support block 50 . Referring to FIGS. 10 , 11 , and 12 , the finger 52 has a flat end 51 for engaging the clip string 2 as the cam plate 46 reciprocates towards the barrel 22 , but the finger 52 also has a sloped side 53 for sliding past the clip string 2 as the cam plate 46 reciprocates away from the barrel 22 .
[0060] The finger 52 is pivotally connected to the feed support block 50 at a finger pivot point 57 , and a biasing spring 55 urges the finger 52 to engage an individual clip 4 of the clip string 2 as the cam plate 46 reciprocates towards the barrel 22 . The finger pivot point 57 allows the finger 52 to ratchet back past the clip string 2 as the cam plate 46 moves away from the barrel 22 . Therefore, the clip string 2 sits still as the cam plate 46 reciprocates away from the barrel 22 , but the clip string 2 is advanced into the clip receiving cavity 24 as the cam plate 46 reciprocates towards the barrel 22 . The clip feed assembly 40 does not utilize a spring or urging device at the back end of the clip string 2 to advance the clips 4 into the clip receiving cavity 24 . The above described mechanism engages the hammer 26 with the clip feed assembly 40 so the cycling of the hammer 26 provides the force to urge the clip string 2 into the clip receiving cavity 24 .
[0061] In one embodiment, the finger 52 has an angled back end 59 which can be pressed to disengage the finger 52 from the clip string 2 . When disengaged, the clip string 2 can be withdrawn from the clip receiving cavity 24 without the finger 52 retaining any of the individual clips 4 .
[0062] The clip string 2 is supported by a clip track 54 when inserted into the bar connecting apparatus 20 . The clip track 54 can engage the clip string 2 from either the top or the bottom. Referring now to FIGS. 1 , 9 , and 13 , the clip track 54 A can engage the clips 4 by the cradle 15 defined by the upper body 14 , or from the top. When the clip string 2 is engaged from the top, the clip track 54 A extends through the clip receiving cavity 24 A. The clips 4 are then released distally from the clip track 54 A. When the clip track 54 A extends through the clip receiving cavity 24 A, the hammer 26 A has an indentation 56 for receiving the clip track 54 A as the hammer 26 A reciprocates. The hammer 26 A has at least one, and preferably two, legs 58 on the side of the indentation 56 . The legs 58 contact the upper body 14 of the terminal clip 6 to propel the clip out of the barrel 22 A. As the legs 58 propel the terminal clip 6 out of the barrel 22 A, the clip track 54 A is received in the indentation 56 such that the legs 58 pass beside the clip track 54 A.
[0063] In the embodiment where the clip track 54 engages the clip string 2 from the bottom, the clip track 54 does not extend through the clip receiving cavity 24 , as shown in FIGS. 5 and 10 . The clip track 54 terminates at the clip receiving cavity 24 and the hammer 26 can be flat because there is no need to pass around the clip track 54 . Referring to FIGS. 5 , 10 , and 14 , because the clip track 54 does not hold the clip 4 in the clip receiving cavity 24 , at least one resilient retainer 60 can be used to secure the terminal clip 6 in the clip receiving cavity 24 . Preferably, four resilient retainers 60 comprised of ball bearing springs mounted in the clip receiving cavity 24 are used. The resilient retainer 60 releasably engages the terminal clip 6 in the clip receiving cavity 24 to prevent the terminal clip 6 from falling out of the barrel 22 before being expelled by the hammer.
[0064] Referring to FIGS. 1 and 9 , the clip track 54 A is further comprised of at least a first portion 62 and a second portion 64 . The second portion 64 is dimensioned to frictionally engage and lightly hold the clip string 2 . The first portion of the clip track 62 has smaller dimensions which do not frictionally engage or hold the clip string 2 , so the clips 4 will easily slide across the first portion of the clip track 62 . This allows the clips 4 to be easily engaged with the first portion of the clip track 62 , and yet still be frictionally engaged and held in position by a shorter second portion 64 . The second portion of the clip track 64 is between the barrel 22 A and the first portion 62 so that the clip string 2 is frictionally engaged when in a position to enter into the clip receiving cavity 24 A.
Clip Feed Assembly with a Hammer Plate
[0065] An alternate embodiment of the clip feed assembly is shown in FIGS. 17 , 18 , 19 and 20 . In the description of this embodiment, similar components are given the same name and number, but are denoted by the suffix “C.” In FIG. 18 , the barrel has been removed to better show the internal parts.
[0066] A barrel 22 C has a clip receiving cavity 24 C and a slot 25 C extending parallel to the length of the barrel 22 C. The hammer 26 C includes a hammer plate 27 C, which extends through the barrel slot 25 C. The hammer 26 C reciprocates longitudinally within the barrel 22 C, and the hammer plate 27 C reciprocates external and parallel to the barrel 22 C through the barrel slot 25 C. The hammer plate 27 C has an angled section 29 C, which is angled relative to the length of the barrel 22 C. This angled section 29 C works as an inclined plane. The hammer 26 C can be hollow and include holes to reduce weight, as better seen in FIGS. 21 and 22 . The cycling of the hammer 26 C provides the force to cycle the clip feed assembly 40 C, which urges a clip 4 C into the clip receiving cavity 24 C.
[0067] A cam plate 46 C is shown in isolation in FIGS. 23 and 24 . The cam plate has an inclined section 49 C, at least one running fit 66 C, and can include holes to reduce weight. The running fit 66 C has a spring pocket 68 C to receive and support a tension spring. The spring pocket 68 C has a larger diameter than the running fit 66 C. The inclined section 49 C faces the angled section 29 C of the hammer plate 27 C, as better seen in FIGS. 17 and 18 . The inclined section 49 C is positioned to be angled relative to the length of the barrel 22 C. A guide shaft 70 C is received in each running fit 66 C, and serves to guide the cam plate 46 C as the cam plate 46 C reciprocates. The guide shaft 70 C is fixed in one position, so the cam plate 46 C reciprocates parallel to the guide shaft 70 C. The running fit 66 C is dimensioned slightly larger than the guide shaft 70 C, so the cam plate 46 C will be held at a relatively constant angle to the guide shaft 70 C as the cam plate 46 C reciprocates up and down on the guide shaft 70 C. In this embodiment, the cam plate 46 C does not pivot on a pivot point.
[0068] As seen in FIG. 27 , a space 45 C between the hammer plate 27 C and the cam plate 46 C, when the hammer 26 C has reciprocated proximally, allows for the application of a smaller force to initiate the actuation motion of the hammer 26 C, as shown in FIG. 27 . This is because the hammer plate 27 C will have developed some momentum when contacting and initiating the cycling of the cam plate 46 C. This space 45 C between the hammer plate 27 C and cam plate 46 C is especially useful for a manually actuated bar connecting apparatus 20 D shown in FIG. 27 , because it requires less strength from the operator. Even though there is a space 45 C between the hammer plate 27 C and the cam plate 46 C, the angled section 29 C and the inclined section 49 C still face each other.
[0069] Referring again to FIGS. 17 and 18 , the guide shaft 70 C is received between the barrel 22 C and a guide shaft bracket 72 C. The guide shaft 70 C has a first end 74 C, which is connected and secured to the barrel 22 C, and a second end 76 C, which is secured to the guide shaft bracket 72 C. A compression spring 47 C is received about the guide shaft 70 C. The compression spring 47 C serves to urge the cam plate 46 C towards the hammer plate 27 C. The compression spring terminates on one end in the cam plate spring pocket 68 C, and on the other end in a guide shaft bracket spring pocket 78 C. The compression spring 47 C could be mounted in many alternative ways, and it could assume a form different than a coil spring, as long as it biases the cam plate 46 C towards the hammer plate 27 C.
[0070] As the hammer 26 C reciprocates distally, the angled section 29 C of the hammer plate 27 C pushes into the inclined section 49 C of the cam plate 46 C. The guide shaft 70 C forces the cam plate 46 C to only move parallel to the guide shaft 70 C, so the force of the hammer plate angled section 29 C on the cam plate inclined section 49 C is translated into a lateral motion of the cam plate 46 C along the guide shaft 70 C. Therefore, as the hammer 26 C reciprocates distally, the cam plate 46 C reciprocates laterally away from the barrel 22 C. When the hammer 26 C reciprocates proximally, the compression spring 47 C urges the cam plate 46 C towards the hammer 26 C, so the cam plate reciprocates laterally towards the barrel 22 C.
[0071] At least one safety plate 80 C is mounted to cover the workings of the hammer plate 27 C and the cam plate 46 C. Therefore, the safety plate 80 C is adjacent to the hammer plate 27 C and the cam plate 46 C. The safety plate 80 C is indicated by long and short dashed lines in FIGS. 17 and 19 , with the parts underneath the safety plate 80 C shown for clarity, even though the parts would not be visible underneath the safety plate 80 C. Preferably, there would be a safety plate 80 C on both sides of the bar connecting apparatus 20 C, to provide better protection from the workings of the hammer plate 27 C and the cam plate 46 C. The safety plate 80 C is connected to the barrel 22 C, and serves as a mount for the guide shaft bracket 72 C. It is also possible to connect a bracket 81 C between the safety plate 80 C and the handle 82 C of the bar connecting apparatus 20 C. The bracket 81 C can include a grip 83 C, if desired. The bracket 81 C and grip 83 C are shown in phantom lines in FIG. 17 .
[0072] A finger 52 C is pivotally connected to the cam plate 46 C at the distal end of the cam plate 46 C. The finger 52 C is for engaging and advancing a clip 4 C into the clip receiving cavity 24 C with each reciprocation of the cam plate 46 C. The finger 52 C is shown in isolation in FIGS. 25 and 26 . The finger 52 C has a flat end 51 C for engaging and advancing a clip. The finger 52 C also has a sloped side 53 C, to slide past a clip without engaging it. A catch portion 59 C serves to support the finger 52 C and prevent it from pivoting backwards, or towards the sloped side 53 C, when engaging a clip and advancing it forwards. An angled portion 61 C allows the finger to pivot forward, or towards the flat end 61 C, when the finger 52 C slides backwards past a clip to engage and advance a new clip forward. The finger 52 C has a pivot point 57 C, which is connected between two faces 69 C on the cam plate 46 C, as seen in FIGS. 23 and 26 . The catch 59 C abuts an edge of the cam plate faces 69 C as seen in FIG. 18 , which prevents the finger 52 C from pivoting backwards. The angled section 61 C abuts the edges of the cam plate faces 69 C after the finger 52 C has pivoted forward enough to allow the finger 52 C to slide away from barrel 22 C past a clip, so the forward pivoting of the finger 52 C is controlled by the angled section 61 C.
[0073] Referring now to FIG. 19 , the finger 52 C is received between finger brackets 84 C, which are mounted to the safety plate 80 C. When the hammer moves distally the cam plate 46 C moves away from the barrel 22 C, and the acceleration of the cam plate 46 C causes the finger 52 C to pivot towards the barrel 22 C on the finger pivot point 57 C. When the hammer moves proximally, the cam plate 46 C reverses direction and accelerates toward the barrel 22 C. This acceleration causes the finger 52 C to pivot away from the barrel 22 C on the pivot point 57 C. When the finger 52 C pivots away from the barrel 22 C, the flat end 51 C is positioned to engage and advance a clip 4 C towards the barrel 22 C.
[0074] A resilient catch 86 C is mounted in the finger bracket 84 C. The resilient catch 86 C is positioned to engage a clip 4 C received on the clip track 54 C and provide resistance to the clip 4 C sliding backwards, or away from the barrel 22 C. In particular, the resilient catch 86 C contacts a surface of a clip 4 C that is facing away from the barrel 22 C. The resilient catch 86 C is mounted in the finger bracket 84 C, but it could be mounted anywhere, as long as it is positioned adjacent to the clip track 54 C for contacting a surface of a clip 4 C that is facing away from the barrel 22 C. The resilient catch 86 C provides some resistance, but will allow motion past it if sufficient force is applied.
[0075] A clip track 54 C is connected to the barrel 22 C adjacent to the clip receiving cavity 24 C, but does not extend through the barrel 22 C. The clip track 54 C supports the clips 4 C in the seat 8 , so the connection point 7 between two upper bodies 14 is transverse to the clip track 54 C, as seen in FIGS. 19 , 2 , and 16 . The finger 52 C engages this connection point 7 , which provides a contact surface perpendicular to the motion of the finger 52 C. This broad contact surface facilitates the use of different sized clips 4 C in the same bar connecting apparatus 20 C, because different sized clips will still have the connection point 7 positioned above the clip track 54 C in the same manner. The finger 52 C moves a set distance with each reciprocation of the cam plate 46 C, so the consistent spacing of the clips 4 C in the clip string 2 C allows for different sized clips 4 C to be used in the bar connecting apparatus 20 C.
[0076] The clip track 54 C is parallel to the guide shaft 70 C, so the finger 52 C will move parallel to the clip track 54 C, as best seen in FIGS. 17 , 18 and 19 . The finger 52 C is connected to the cam plate 46 C, and the cam plate 46 C moves parallel with the guide shaft 70 C, so the finger 52 C also moves parallel with the guide shaft 70 C. The clip track 54 C can be perpendicular to the barrel 22 C, but it could also be at another angle, as long as it is parallel to the guide shaft 70 C.
Method of Connecting Bars
[0077] The current invention also includes a method of connecting bars, which is shown in FIGS. 1 , 5 , and 10 . The method includes providing a bar connecting apparatus 20 for applying clips 4 as described above. A clip string 2 is engaged with the clip track 54 of the bar connecting apparatus 20 , and then slid along the clip track 54 until at least one clip 4 is received in the clip receiving cavity 24 . The bar connecting apparatus 20 is then aligned with two transverse bars to be connected by an alignment head 28 . The alignment head 28 has two pair of notches 30 , so when the alignment head 28 is properly positioned each bar is engaged with one pair of the notches 30 . The bar connecting apparatus 20 is actuated, which reciprocates a hammer 26 in the barrel 22 . The hammer 26 contacts and expels the clip 4 received in the clip receiving cavity 24 such that the clip connects the bars. The cycling of the hammer 26 also cycles the clip feed assembly 40 to advance another clip 4 from the clip string 2 into the clip receiving cavity 24 for a subsequent clip application. The clip string 2 is advanced into the clip receiving cavity 24 in a direction transverse to the direction of reciprocation of the hammer.
[0078] The terminal clip 6 C of the clip string 4 C is inserted into the clip receiving cavity 24 C of the bar connecting apparatus 20 C, as seen in FIGS. 16 through 19 . After the terminal clip 6 C has been ejected to connect bars, the next clip 4 C becomes the new terminal clip 6 C, is advanced into the clip receiving cavity 24 C by the clip feed assembly 40 C, and the bar connecting apparatus is ready for a subsequent clip 4 C application.
[0079] The alignment head 28 C has two pair of notches 30 C, 30 D, wherein each pair of notches 30 C, 30 D has a different depth than the other pair, so the alignment head 28 C will engage two transverse bars 9 C, 11 C to be connected with one bar 9 C on top of the other 11 C. Each bar 9 C, 11 C is engaged in one pair of notches 30 C, 30 D.
[0080] The method includes the providing of at least a first and second clip string 2 C, wherein the size of the clips 4 C in each clip string 2 C is constant, but the clips 4 C in the first clip string 2 C are of a different size than the clips 04 C of the second clip string 2 C. The distance between the front ends of adjacent clips in the first and second clip string is the same. One clip string 2 C is selected such that the clips 4 C are sized properly for the bars to be connected. The selected clip string 2 C is then inserted into the clip receiving cavity 24 C for application of the clips 4 C.
[0081] Thus, although there have been described particular embodiments of the present invention of a new and useful BAR CONNECTING APPARATUS, it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims.
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A bar connecting apparatus applies clips to connect transverse bars used in reinforced concrete. A clip string is fed into the bar connecting apparatus by a clip feed assembly, so several pairs of transverse bars can be connected in rapid succession. A hammer reciprocates in the barrel of the bar connecting apparatus, and drives a clip from the barrel into engagement with the bars. An alignment head aligns the bar connecting apparatus with the transverse bars so the clips properly engage the bars.
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TECHNICAL FIELD
[0001] The present disclosure generally relates to aircraft display systems and methods for operating aircraft display systems. More particularly, the present disclosure relates to aircraft synthetic vision systems that utilize data from local area augmentation systems, and methods for operating such aircraft synthetic vision systems.
BACKGROUND
[0002] Many aircraft are equipped with one or more vision enhancing systems. Such vision enhancing systems are designed and configured to assist a pilot when flying in conditions that diminish the view from the cockpit. One example of a vision enhancing system is known as a synthetic vision system (hereinafter, “SVS”). A typical SVS is configured to work in conjunction with a position determining unit associated with the aircraft as well as dynamic sensors that sense aircraft altitude, heading, and orientation. The SVS includes or accesses a database containing information relating to the topography along the aircraft's flight path, such as information relating to the terrain and known man-made and natural obstacles proximate the aircraft flight path. The SVS receives inputs from the position determining unit indicative of the aircraft location and also receives inputs from the dynamic sensors. The SVS is configured to utilize the position, heading, altitude, and orientation information and the topographical information contained in the database, and generate a three-dimensional image that shows the topographical environment through which the aircraft is flying from the perspective of a person sitting in the cockpit of the aircraft. The three-dimensional image (also referred to herein as an “SVS image”) may be displayed to the pilot on any suitable display unit accessible to the pilot. The SVS image includes features that are graphically rendered including, without limitation, a synthetic perspective view of terrain and obstacles located proximate the aircraft's flight path. Using a SVS, the pilot can look at a display screen of the display unit to gain an understanding of the three-dimensional topographical environment through which the aircraft is flying and can also see what lies ahead. The pilot can also look at the display screen to determine aircraft proximity to one or more obstacles proximate the flight path.
[0003] The approach to landing and touch down on the runway of an aircraft is probably the most challenging task a pilot undertakes during normal operation. To perform the landing properly, the aircraft approaches the runway within an envelope of attitude, course, speed, and rate of descent limits. The course limits include, for example, both lateral limits and glide slope limits. In some instances visibility may be poor during approach and landing operations, resulting in what is known as instrument flight conditions. During instrument flight conditions, pilots rely on instruments, rather than visual references, to navigate the aircraft. Even during good weather conditions, pilots typically rely on instruments to some extent during the approach. Some SVS systems known in the art have been developed to supplement the pilot's reliance on instruments. For example, these systems allow pilots to descend to a low altitude, e.g., to 150 feet above the runway, using a combination of databases, advanced symbology, altimetry error detection, and high precision augmented coordinates. These systems utilize a wide area augmentation system (WAAS) GPS navigation aid, a flight management system, and an inertial navigation system to dynamically calibrate and determine a precise approach course to a runway and display the approach course relative to the runway centerline direction to pilots using the SVS.
[0004] The usefulness of these SVS systems for approach and landing is limited, however, by the accuracy of the topographical database, particularly in the terminal area of the airport. It has been discovered, for example, that in some instances, published terminal area topographical data may include unintended errors or biases in relation to the geographic position of certain features, such as runways, obstacles, etc. If these errors or biases are then introduced into the SVS topographical databases, then the 3-D rendered images presented to the pilot on the SVS may not match the aircraft's actual environment, which is problematic in the context of flying a precision approach to the airport supplemented by the SVS.
[0005] Accordingly, it is desirable to provide SVS systems and methods that are able to validate topographical information contained in a topographical database, in particular the geographical location of runways and obstacles in the terminal area of an airport. It is also desirable to provide such SVS systems and methods that are capable of correcting any errors or biases in the topographical database that may be determined by the validation. Furthermore, other desirable features and characteristics of exemplary embodiments will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background.
BRIEF SUMMARY
[0006] Provided are aircraft synthetic vision systems that utilize data from local area augmentation systems, and methods for operating such aircraft synthetic vision systems. In one exemplary embodiment, an aircraft synthetic vision display system (SVS) includes a topographical database including topographical information relating to an airport, a global positioning system receiver that receives a satellite signal from a global positioning satellite to determine a geographical position of the aircraft, and a ground-based augmentation system receiver that receives a ground-based signal from a ground-based transmitter associated with the airport, wherein the ground-based signal includes geographical information associated with the airport. The SVS further includes a computer processor that retrieves the topographical information from the topographical database based on the geographical position of the aircraft, that retrieves the geographical information associated with the airport, that validates the topographical information using the geographical information associated with the airport, and that corrects the topographical information using the geographical information associated with the airport to generate corrected topographical information. Still further, the SVS includes a display device that renders three-dimensional synthetic imagery of environs of the aircraft based on the corrected topographical information.
[0007] In another exemplary embodiment, a method of operating a synthetic vision system of an aircraft includes the steps of receiving a satellite signal from a global positioning satellite to determine a geographical position of the aircraft and receiving a ground-based signal from a ground-based transmitter associated with the airport, wherein the ground-based signal includes geographical information associated with the airport. The method further includes, using a computer processor, retrieving topographical information based on the geographical position of the aircraft, retrieving the geographical information associated with the airport, validating the topographical information using the geographical information associated with the airport, and correcting the topographical information using the geographical information associated with the airport to generate corrected topographical information. The method further includes rendering three-dimensional synthetic imagery of environs of the aircraft based on the corrected topographical information.
[0008] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present disclosure will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:
[0010] FIG. 1 is a functional block diagram of a synthetic vision system according to an exemplary embodiment of the present disclosure;
[0011] FIG. 2 is an exemplary image that may be rendered on the synthetic vision system of FIG. 1 ; and
[0012] FIG. 3 is a flow chart illustrating a method of operation for the synthetic vision system of FIG. 1 in accordance with exemplary embodiment of the present disclosure.
DETAILED DESCRIPTION
[0013] The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. As used herein, the word “exemplary” means “serving as an example, instance, or illustration.” Thus, any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. All of the embodiments described herein are exemplary embodiments provided to enable persons skilled in the art to make or use the invention and not to limit the scope of the invention which is defined by the claims. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary, or the following detailed description.
[0014] Embodiments of the present disclosure utilize ground-based data sources located at an airport, such as a local area augmentation system (LAAS), to validate the data from the topographical databases (particularly navigational database 108 , runway database 110 , and obstacle database 112 ). If the topographical database information does not match the information from the ground-based data source, then there is determined to be an error or bias in the data from the topographical databases. The error or bias is then corrected utilizing the information from the ground-based data source. The corrected topographical information is then utilized by the processor 104 to provide an accurate display on the display device 116 of the SVS 100 . The accurate display includes an accurate runway position, accurate obstacle positions, and accurate terrain renderings. With this verified and corrected display, the SVS 100 can be used as a supplement to the aircraft's instrument approach systems (e.g., ILS, VOR, GPS) until about 150 feet height above threshold (HAT).
[0015] As used herein, the term “synthetic vision system” refers to a system that provides computer-generated images of the external scene topography from the perspective of the flight deck, derived from aircraft attitude, high-precision navigation solution, and database of terrain, obstacles, and relevant cultural features. A synthetic vision system is an electronic means to display a synthetic vision depiction of the external scene topography to the flight crew. Synthetic vision creates an image relative to terrain and airport within the limits of the navigation source capabilities (position, altitude, heading, track, and the database limitations). The application of synthetic vision systems is through a primary flight display from the perspective of the flight deck or through a secondary flight display.
[0016] Referring to FIG. 1 , an exemplary synthetic vision system is depicted and will be described in accordance with various embodiments of the present disclosure. The system 100 includes a user interface 102 , a processor 104 , one or more terrain databases 106 , one or more navigation databases 108 , one or more runway databases 110 , one or more obstacle databases 112 , various sensors 113 , a multi-mode receiver (MMR) 114 , and a display device 116 . The user interface 102 is in operable communication with the processor 104 and is configured to receive input from a user 109 (e.g., a pilot) and, in response to the user input, supply command signals to the processor 104 . The user interface 102 may be any one, or combination, of various known user interface devices including, but not limited to, a cursor control device (CCD) 107 , such as a mouse, a trackball, or joystick, and/or a keyboard, one or more buttons, switches, or knobs. In the depicted embodiment, the user interface 102 includes a CCD 107 and a keyboard 111 . The user 109 uses the CCD 107 to, among other things, move a cursor symbol on the display screen (see FIG. 2 ), and may use the keyboard 111 to, among other things, input textual data.
[0017] The processor 104 may be any one of numerous known general-purpose microprocessors or an application specific processor that operates in response to program instructions. In the depicted embodiment, the processor 104 includes on-board RAM (random access memory) 103 , and on-board ROM (read only memory) 105 . The program instructions that control the processor 104 may be stored in either or both of the RAM 103 and the ROM 105 . For example, the operating system software may be stored in the ROM 105 , whereas various operating mode software routines and various operational parameters may be stored in the RAM 103 . It will be appreciated that this is merely exemplary of one scheme for storing operating system software and software routines, and that various other storage schemes may be implemented. It will also be appreciated that the processor 104 may be implemented using various other circuits, not just a programmable processor. For example, digital logic circuits and analog signal processing circuits could also be used.
[0018] No matter how the processor 104 is specifically implemented, it is in operable communication with the terrain databases 106 , the navigation databases 108 , the runway databases 110 , the obstacle databases 112 , and the display device 116 , and is coupled to receive various types of external data from the various sensors 113 (such as airspeed, altitude, air temperature, heading, etc.), and various aircraft position-related data from the MMR 114 , which receives signals from various external position-related data sources such as VOR, GPS, WAAS, LAAS, ILS, MLS, NDB, etc. The processor 104 is configured, in response to the position-related data, to selectively retrieve terrain data from one or more of the terrain databases 106 , navigation data from one or more of the navigation databases 108 , runway data from one or more of the runway databases 110 , and obstacle data from one or more of the obstacle databases 112 , and to supply appropriate display commands to the display device 116 . The display device 116 , in response to the display commands, selectively renders various types of textual, graphic, and/or iconic information. A brief description of the databases 106 , 108 , 110 , and 112 , the sensors 113 , and the MMR 114 , at least in the depicted embodiment, will be provided.
[0019] The terrain databases 106 include various types of data representative of the terrain over which the aircraft is flying, and the navigation databases 108 include various types of navigation-related data. These navigation-related data include various flight plan related data such as, for example, waypoints, distances between waypoints, headings between waypoints, data related to different airports, navigational aids, obstructions, special use airspace, political boundaries, communication frequencies, and aircraft approach information. It will be appreciated that, although the terrain databases 106 , the navigation databases 108 , the runway databases 110 , and the obstacle databases 112 are, for clarity and convenience, shown as being stored separate from the processor 104 , all or portions of either or both of these databases 106 , 108 , 110 , 112 could be loaded into the RAM 103 , or integrally formed as part of the processor 104 , and/or RAM 103 , and/or ROM 105 . The databases 106 , 108 , 110 , 112 could also be part of a device or system that is physically separate from the system 100 .
[0020] In one exemplary embodiment, the processor 104 is adapted to receive terrain data from the terrain database 106 and navigation data from the navigation database 108 , operable, in response thereto, to supply one or more image rendering display commands. The display device 116 is coupled to receive the image rendering display commands and is operable, in response thereto, to simultaneously render (i) a perspective view image representative of the terrain data and navigation data and (ii) one or more terrain-tracing lines. The perspective view image includes terrain having a profile determined by elevations of the terrain. Each terrain-tracing line (i) extends at least partially across the terrain, (ii) represents at least one of a ground-referenced range to a fixed location on the terrain and a aircraft-referenced range from the aircraft to a fixed range away from the aircraft, and (iii) conforms to the terrain profile.
[0021] Notably, the visibility of the terrain information displayed on the screen of visual display 116 may be enhanced responsive to one or more suitable algorithms (e.g., implemented in software) executed by the processor 104 , which functions to determine an aircraft's current position, heading and speed, and initially loads a patch of terrain data for a region that is suitably sized to provide a rapid initialization of the data. The processor 104 monitors the aircraft's position, heading, and speed (also attitude when pertinent) from sensors 113 and MMR 114 , and continuously predicts the potential boundaries of a three-dimensional region (volume) of terrain in the flight path based on the aircraft's then-current position, heading and speed (and attitude when pertinent). The processor 104 compares the predicted boundaries with the boundaries of the initially loaded terrain data, and if the distance from the aircraft to a predicted boundary is determined to be less than a predetermined value (e.g., distance value associated with the boundaries of the initially loaded data), then the processor 104 initiates an operation to load a new patch of terrain data that is optimally sized given the aircraft's current position, heading and speed (and attitude when pertinent). Notably, for this example embodiment, the processor 104 can execute the data loading operations separately from the operations that determine the aircraft's current position, heading and speed, in order to maintain a constant refresh rate and not interfere with the continuity of the current display of terrain.
[0022] One important aspect of situational awareness is to be aware of obstacles which pose a threat to the craft. This is particularly true for aircraft during take-off and landing or other low altitude operations and even more so in low visibility conditions. Some displays depict information on obstacles in or near the aircraft's travel path. Obstacle data should be presented in such a way that it will provide timely awareness of the height, location, and distance of possible threats without distracting from the other primary information on the display. The processor 104 generates data for display on the display 116 based on the position of the aircraft and obstacle data. Obstacles can be sought and displayed for different locations along one or more flight paths, thereby assisting an operator choose the safest path to follow. The obstacle database 112 may contain data regarding obstacles, wherein the processor 104 sends a signal to the display 116 to render a simulated graphical representation of the obstacle based on that data, or the obstacle database may contain actual images of the obstacles, wherein the processor 104 sends a signal to display the actual image based on the positional data.
[0023] The processor 104 analyzes the data received from the obstacle database 112 and determines if the obstacles are within a selected distance from the aircraft. Obstacles that are not within a selected distance are not displayed. This procedure saves processor load and reduces display clutter by only displaying obstacles that are of interest to the aircraft. Size, speed, and altitude of the aircraft and size of the obstacle may be considered along with distance in determining whether to display the obstacle.
[0024] The runway database 110 may store data related to, for example, runway lighting, identification numbers, position, and length, width, and hardness. As an aircraft approaches an airport, the processor 104 receives the aircraft's current position from, for example, the MMR 114 and compares the current position data with the distance and/or usage limitation data stored in the database for the landing system being used by that airport.
[0025] The sensors 113 may be implemented using various types of sensors, systems, and or subsystems, now known or developed in the future, for supplying various types of aircraft data. The aircraft data may also vary, but preferably include data representative of the state of the aircraft such as, for example, aircraft speed, heading, altitude, and attitude. The number and type of data sources received into MMR 114 may also vary. However, for ease of description and illustration, only a VHF data broadcast (VDB) receiver 118 functionality and a global position system (GPS) receiver 122 functionality are depicted in FIG. 1 , as these receivers are particularly relevant to the discussion of the present disclosure. As noted above, though, modern MMRs include the ability to receive many more signals beyond the illustrated GPS and VDB receiver functionalities.
[0026] The GPS receiver 122 functionality is a multi-channel receiver, with each channel tuned to receive one or more of the GPS broadcast signals transmitted by the constellation of GPS satellites (not illustrated) orbiting the earth. Each GPS satellite encircles the earth two times each day, and the orbits are arranged so that at least four satellites are always within line of sight from almost anywhere on the earth. The GPS receiver 122 , upon receipt of the GPS broadcast signals from at least three, and preferably four, or more of the GPS satellites, determines the distance between the GPS receiver 122 and the GPS satellites and the position of the GPS satellites. Based on these determinations, the GPS receiver 122 , using a technique known as trilateration, determines, for example, aircraft position, groundspeed, and ground track angle. These data may be supplied to the processor 104 , which may determine aircraft glide slope deviation therefrom. Preferably, however, the GPS receiver 122 is configured to determine, and supply data representative of, aircraft glide slope deviation to the processor 104 .
[0027] The VDB receiver 118 functionality is a multi-channel receiver configured to received VHF signals in the 108.0 to 117.975 MHz band from a ground station that is associated with a particular airport. The VHF data signals include corrections for GPS satellite signals. The VHF data signals also include broadcast information that is used to define a reference path typically leading to the runway intercept point. This data can include information for as many as 49 different reference paths using a single radio frequency. (Even more reference paths could be supported by using additional radio frequencies.) The VDB signal employs a differential 8-phase shift key (D8PSK) waveform. This waveform was chosen because of the relatively good spectral efficiency in terms of the number of bits per second that can be supported within a 25 kHz frequency assignment. Four message types are currently defined for VDB signals. Message Type 1 includes differential correction and integrity related data for the GPS satellites. Message Type 4 includes final approach segment definitions for each runway end or approach at the airport.
[0028] The display device 116 , as noted above, in response to display commands supplied from the processor 104 , selectively renders various textual, graphic, and/or iconic information, and thereby supply visual feedback to the user 109 . It will be appreciated that the display device 116 may be implemented using any one of numerous known display devices suitable for rendering textual, graphic, and/or iconic information in a format viewable by the user 109 . Non-limiting examples of such display devices include various cathode ray tube (CRT) displays, and various flat panel displays such as various types of LCD (liquid crystal display) and TFT (thin film transistor) displays. The display device 116 may additionally be implemented as a panel mounted display, a HUD (head-up display) projection, or any one of numerous known technologies. It is additionally noted that the display device 116 may be configured as any one of numerous types of aircraft flight deck displays. For example, it may be configured as a multi-function display, a horizontal situation indicator, or a vertical situation indicator, just to name a few. In the depicted embodiment, however, the display device 116 is configured as a primary flight display (PFD).
[0029] Referring to FIG. 2 , exemplary textual, graphical, and/or iconic information rendered by the display device 116 , in response to appropriate display commands from the processor 104 is depicted. It is seen that the display device 116 renders a view of the terrain 202 ahead of the aircraft, preferably as a three-dimensional perspective view, an altitude indicator 204 , an airspeed indicator 206 , an attitude indicator 208 , a compass 212 , an extended runway centerline 214 , a flight path vector indicator 216 , and an acceleration cue 217 . The heading indicator 212 includes an aircraft icon 218 , and a heading marker 220 identifying the current heading (a heading of 174 degrees as shown). An additional current heading symbol 228 is disposed on the zero pitch reference line 230 to represent the current aircraft heading when the center of the forward looking display 116 is operating in a current track centered mode. The center of the forward looking display 116 represents where the aircraft is moving and the heading symbol 228 on the zero-pitch reference line 230 represent the current heading direction. The compass 212 can be shown either in heading up, or track up mode with airplane symbol 218 representing the present lateral position. Additional information (not shown) is typically provided in either graphic or numerical format representative, for example, of glide slope, altimeter setting, and navigation receiver frequencies.
[0030] An aircraft icon 222 is representative of the current heading direction, referenced to the current ground track 224 , with the desired track as 214 for the specific runway 226 on which the aircraft is to land. A distance remaining marker 227 may be shown on the display 116 , in a position ahead of the aircraft, to indicate the available runway length ahead, and the distance remaining marker 227 may change color if the distance remaining becomes critical. Lateral deviation marks 223 and vertical deviation marks 225 on perspective conformal deviation symbology represent a fixed ground distance from the intended flight path. The desired aircraft direction is determined, for example, by the processor 104 using data from the navigation database 108 , the sensors 113 , and the external data sources 114 . It will be appreciated, however, that the desired aircraft direction may be determined by one or more other systems or subsystems, and from data or signals supplied from any one of numerous other systems or subsystems within, or external to, the aircraft. Regardless of the particular manner in which the desired aircraft direction is determined, the processor 104 supplies appropriate display commands to cause the display device 116 to render the aircraft icon 222 and ground track icon 224 .
[0031] As noted previously, the usefulness of the SVS system 100 for approach and landing is limited by the accuracy of the topographical databases 106 , 108 , 110 , and 112 , particularly in the terminal area of the airport. It has been discovered, for example, that in some instances, published terminal area topographical data may include unintended errors or biases in relation to the geographic position of certain features, such as runways (database 110 ), obstacles (database 112 ), etc. If these errors or biases are then introduced into the SVS topographical databases, then the 3-D rendered images presented to the pilot on the SVS may not match the aircraft's actual environment, which is problematic in the context of flying a precision approach to the airport supplemented by the SVS.
[0032] Embodiments of the present disclosure utilize ground-based data sources located at an airport, such as a local area augmentation system, to validate the data from the topographical databases (particularly runway database 110 ). If the topographical database information does not match the information from the ground-based data source, then there is determined to be an error or bias in the data from the topographical databases. The error or bias is then corrected utilizing the information from the ground-based data source. The corrected topographical information is then utilized by the processor 104 to provide an accurate display on the display device 116 of the SVS 100 . The accurate display includes an accurate runway position, accurate obstacle positions, and accurate terrain renderings. With this verified and corrected display, the SVS 100 can be used as a supplement to the aircraft's instrument approach systems (e.g., ILS, VOR, GPS) until about 150 feet height above threshold.
[0033] A LAAS at an airport generally includes local reference receivers located around the airport that send data to a central location at the airport. This data is used to formulate a correction message (Type 1), which is then transmitted to users via VDB. The VDB receiver 118 functionality on the aircraft uses this information to correct GPS signals, which then provides a standard ILS-style display to use while flying a precision approach. The LAAS VDB transmitters also transmit broadcast information that is used to define a reference path typically leading to the runway intercept point (message Type 4), which includes final approach segment definitions for each runway end or approach at the airport.
[0034] An aircraft on approach to the airport will begin receiving LAAS VDB signals once the aircraft enters within the usable range of the LAAS system, which is usually about a 25 nm radius from the airport. Prior to entering the usable range, the SVS 100 is receiving GPS data (receiver functionality 122 of the MMR 114 ). SVS 100 relies on the GPS data, and the topographical databases 106 , 108 , 110 , and 112 to display the image on display 116 . Upon entering the LAAS usable range, the aircraft begins to receive the VDB signal from the LAAS via the VDB receiver 118 functionality of the MMR 114 . Message Type 4 of the VDB signal includes final approach segment definitions, for example in terms of geographic reference coordinates. The topographical database information, particularly that of databases 108 , 110 and 112 , may then be validated using the message Type 4 information from the VDB signal. If the topographical database information does not match the message Type 4 information, then there may be determined to be an error or bias in the topographical database information. The message Type 4 information from the VDB signal is then used to correct the topographical information. The corrected topographical information is then used to render the SVS display on display device 116 , providing the flight crew with a high-fidelity SVS display that may be used as a supplement for use during an instrument approach, down to a HAT of about 150 feet.
[0035] The use of LAAS message Type 4 information as validation should not be understood to exclude the use of other validation data source. For example, in addition to the foregoing described validation, message Type 1 information may be used to validate and correct the GPS signal, which may then be used by the SVS 100 as part of its display/validation scheme. Moreover, satellite-based correction signals from a wide area augmentation system (WAAS) may be used for the same purpose. Still further, onboard validation means, such as inertial navigation systems (INS), may be used to validate and cross-check the received GPS signal for purposes of providing an accurate SVS display that is usable as a supplement with instrument approaches.
[0036] In some embodiments, it is proposed that that the VDB is modified to carry more information, e. g., runway closure NOTAM, runway occupancy status, hold short traffic information, etc., to facilitate a timely and improved visual situational awareness. This runway closure NOTAM, runway occupancy status, or hold short traffic information may be displayed to the flight crew as an appropriate graphical or textual indication on the display 116 of SVS 100 . For example, runway closure NOTAMs may be provided in text, runway occupancy status may be indicated by an aircraft symbol on the runway, and hold short traffic information may be indicated as an appropriate line or bar at the hold short point of the runway.
[0037] In further embodiments, the SVS 100 may include a “level of service” monitor to indicate the health of the SVS 100 . Various monitors may validate the information and allow the synthetic scene to be used for navigation and lower minimums. The level of service monitor may be provided on display device 116 , and may include green text that lists the type of approach, the unique identifier for the approach, and a label that indicates the health of the SVS 100 . When the label is written in green text, it means that the approach is usable, and that all of the validation scheme are operating properly (and that if any error or bias has been detected, it has been appropriately corrected using the VDB information). An audible signal or its accompanying text in an amber box in the level of service monitor means the approach must either be abandoned or flown as a normal ILS or other instrument approach. Below the normal ILS or other approach minimums, the box turns red and pilots must fly the missed-approach procedure.
[0038] FIG. 3 provides an exemplary flowchart of a method of operation 300 of the SVS 100 in accordance with an exemplary embodiment of the present disclosure. At step 301 , the SVS receives a GPS signal indicating a position of the aircraft. At step 303 , the SVS receives a VDB signal including final approach segment information from a ground-based augmentation system (i.e., a LAAS) at an airport. At step 305 , the SVS accesses one or more topographical databases (i.e., terrain, navigation, runway, and/or obstacle) and retrieved topographical information pertaining to the position of the aircraft. At step 307 , the SVS uses the VDB signal to validate the topographical information. Step 309 is a determining step wherein the SVS determines whether the topographical information has been validated, i.e., whether the topographical information matches the VDB signal information. At step 311 , if the topographical information has been validated, the SVS displays a synthetic vision image to the flight crew of the aircraft on a flight display based on the topographical information. At step 313 , if the information does not match, then the topographical information is corrected using the VDB information, namely the final approach segment information. Then, at step 315 , the SVS displays a synthetic image to the flight crew of the aircraft on the flight display based on the correct topographical information.
[0039] In this document, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Numerical ordinals such as “first,” “second,” “third,” etc. simply denote different singles of a plurality and do not imply any order or sequence unless specifically defined by the claim language. The sequence of the text in any of the claims does not imply that process steps must be performed in a temporal or logical order according to such sequence unless it is specifically defined by the language of the claim. The process steps may be interchanged in any order without departing from the scope of the invention as long as such an interchange does not contradict the claim language and is not logically nonsensical.
[0040] Furthermore, depending on the context, words such as “connect” or “coupled to” used in describing a relationship between different elements do not imply that a direct physical connection must be made between these elements. For example, two elements may be connected to each other physically, electronically, logically, or in any other manner, through one or more additional elements.
[0041] While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims.
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An aircraft synthetic vision display system (SVS) includes a topographical database including topographical information relating to an airport, a global positioning system receiver that receives a satellite signal from a global positioning satellite to determine a geographical position of the aircraft, and a ground-based augmentation system receiver that receives a ground-based signal from a ground-based transmitter associated with the airport, wherein the ground-based signal includes geographical information associated with the airport. The SVS further includes a computer processor that retrieves the topographical information from the topographical database based on the geographical position of the aircraft, that retrieves the geographical information associated with the airport, and that corrects the topographical information using the geographical information associated with the airport to generate corrected topographical information. Still further, the SVS includes a display device that renders three-dimensional synthetic imagery of environs of the aircraft based on the corrected topographical information.
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BACKGROUND OF THE INVENTION
Equipment is well-known for conveying the coiled hot rolled strip, especially non-ferrous metal strips, in a cold rolling mill. Such known transportation equipment for these strip coils usually consists mostly of cranes or trackless floor level transportation gear, such as fork lift trucks, by which means the strip coils are carried from the hot rolling mill and then unloaded and stored in a coil storage area. From the coil storage area, the coils are individually brought to a cold rolling train by this same type of transportation means and are then cold rolled. After being recoiled and again formed into cold rolled strip coils, they are carried to another coil storage area for cooling. Depending on the dimensional requirements of the strip, the chemical composition of the rolled metal, the capacity of the rolling mill, etc., this procedure is repeated one or more times before the coil finally enters the annealing furnace and, after annealing, is transferred elsewhere for further processing such as coating. This known method of transportation (with intermediate coil storage at the nonferrous cold rolling mills) is disadvantageous, because of the large space required for the intermediate storage of the hot rolled coils and because of the necessity of assuring that each coil is accurately deposited. Furthermore, because several cold rolling mills might have to be supplied with stock from the intermediate coil storage, several cranes are required for the intermediate storage area. This results not only in additional investment for those cranes, but also creates confusion in the order of treatment of the coils, because those cranes have to work side-by-side. Also, such handling of the strip coils is extremely labor intensive, and even partial automation of the work procedure is not possible.
It is, therefore, an outstanding object of the present invention to avoid to a great extent the disadvantages of the above-described transport system, by making possible an ordered storage of the coils in an intermediate storage area requiring relatively little space, by providing a rational procedure for the necessary movement of the rolled stock in a rolling mill, and arranging the above-mentioned specified equipment in order substantially to reduce the previously-required crane work and to make possible a partial automation of the transportation procedure.
SUMMARY OF THE INVENTION
In general, the present invention solves these problems, because the cold rolling train and the annealing furnaces can be charged by pallet-moving equipment arranged parallel to the rolling line and arranged perpendicular to an intermediate storage consisting of multi-level shelves. Preferably, the loading of the cold rolling train begins with pallet-advancing equipment at the vertically-arranged shelves positioned at the cold rolling mill entry end and ends with pallet-moving equipment located at the exit end of the cold rolling mill at the vertical shelf storage which is located there. Another desirable type of intermediate storage and rolling mill coil shipping area arrangement consists of terminating the tracks for the cars at vertical shelves positioned at the entry end of the cold rolling mill. This makes it possible to use the loading and unloading equipment on the front and the back sides of the vertical shelves of the storage area.
The pallet-moving equipment consists of a suitable transversely-moving platform arranged in an advantageous manner and connected to roller conveyors. Constructed inside the roller conveyors is a lowering mechanism preferably constructed in the form of lifting tables, the unloading equipment advantageously forming the end of a sectional roller table, each lifting table being equipped with a turntable.
Another improvement in accordance with this invention consists of the fact that traveling coil cars are positioned on tracks perpendicular to the roller conveyor of the cold rolling train that is being loaded by the pallet-moving equipment and in alignment with the reel mandrel of the cold rolling train. Strip coils can be conveniently transported by conveyors (preferably crane or trackless vehicles) lying between the pallet-moving equipment, which is located at the front of the cold rolling train (on the one hand) and in front of the annealing furnaces (on the other hand).
As a practical matter, the described pallet-moving equipment is positioned parallel to the longitudinal axis of the annealing furnaces, while the tracks for the loading and unloading of the annealing furnace are positioned perpendicular to the pallet-moving equipment.
There are special advantages to equipment constructed in accordance with the invention, if the mills are set with adjacent parallel roll passes and the cold rolling trains are consequently loaded from a common vertical shelf storage area, built up from an intermediate storage and, when the coils are rolled at the cold rolling train and annealed in annealing furnaces, the coils are brought to a common vertical-shelf storage area.
The advantages of the equipment for the transportation of the hot rolled strip coils in accordance with the invention, are especially noticeable, because the exact ordered arrangement of stored coils at the intermediate storage area (while waiting for their subsequent treatment) makes possible an orderly delivery in a relatively simple manner with investment costs which are not high. Because the intermediate storage needs relatively little space, the crane work is reduced, which means that at least a partial automation of the conveying procedure is possible. The result is a rational flow of the conveying steps, as is necessary in a cold rolling mill.
BRIEF DESCRIPTION OF THE DRAWINGS
The character of the invention, however, may be best understood by reference to one of its structural forms, as illustrated by the accompanying drawings, in which:
FIG. 1 is a plan view of a coil conveying apparatus constructed in accordance with the principles of the present invention,
FIG. 2 is a plan view of a portion of the apparatus, and
FIGS. 3 & 4 are plan views of the apparatus used for different purposes.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 show hot rolled aluminum strip coils 3 conveyed from a hot rolling mill (not shown) to a cold rolling mill by means of a driven car 1 on tracks 2. According to the example shown, the car 1 is contructed so as to convey five coils 3. Those coils 3 (which have not yet been cooled sufficiently from the hot rolling process, where they have been heated to a temperature of 450-550° C.) have to be cooled even further before they can be cold rolled. Therefore, along the extension of the tracks 2, an intermediate storage depot is positioned in the form of multi-level shelf storage 4 with individual compartments. The vertical shelf storage can be loaded or unloaded in the direction parallel to the tracks 2 by movable loading equipment 5 and by unloading equipment 6 on the opposite side of the vertical shelf storage 4.
After the coils 3 have been cooled, they are taken in the corresponding succession by the unloading equipment 6 from the vertical shelf storage 4. As shown in FIGS. 1 and 2, the two sets of tracks 2 are parallel to and spaced from each other and also each vertical shelf storage 4 is planned to be coordinated with the loading and unloading equipment 5, 6. This means that one car 1 can be unloaded without interruption, while another car 1 returns empty on the other track 2 to the hot rolling mill.
According to FIG. 1, a single strand cold rolling train 7 is positioned near the tracks 2 and the vertical shelf storage 4 and has a pass line that is perpendicular to the axis of the rolls 8, a roll stand 9 and a reel mandrel 10 being parallel. After a coil 3 is removed from the high shelf storage 4 by the movable unloading equipment 6, the coil 3 is placed at the end of the high shelf storage 4 on a turntable 11 which is positioned within a roller conveyor 11a. The coil 3 is rotated 90° on the rotating table 11, to turn the opening of the coil 3 parallel to the direction of the axis of the reel mandrel 10. Then, the coil 3 is deposited, at the cropping roller conveyor 11a, onto a pallet and is conveyed by it along the roller conveyers 11a and 12. The alignment of the reel mandrel 10 is parallel to that of movable coil cars 14 resting on tracks 13, which can enter at the side of the roller conveyor 12. The coil car 14 lifts a coil 3 from the pallet at the roller conveyor 12, brings it to a coil feeding machine 15 and is slipped onto the reel mandrel 10 of the uncoiler 16.
After the strip is passed between rolls 8 in the roll stand 9, it is coiled onto a reel mandrel 10 of a recoiler 17 and is tied into a new coil by a belt wrapper 18. The coil is removed from the reel mandrel 10 of the recoiler 17 by a coil-receiving equipment 19 and is deposited on another coil car 20.
If the strip is wound into a coil and need further rolling, i.e. a second pass, it is then unloaded from the coil car 20 onto a pallet at the roller conveyor 12, and is conveyed by this roller conveyor in the rolling direction to a rear cross transfer platform 21. On this cross transfer platform 21, the coil is conveyed by the roller conveyor 22 in a direction parallel to the roller conveyor 12 (but in the direction opposite to the rolling direction) to a front cross transfer platform 23 within the range of the high shelf storage 4. Another turntable 24 is positioned within this roller conveyor 22 to rotate the coil that has already been rolled once by 180° in order to turn the leading end of the strip in the direction of rolling.
At the front cross transfer platform 23, the coil is conveyed to the roller conveyor 12 arrives again at the coil car 14, roll stand 9, etc. After the strip has gone through the last rolling pass and after it has been coiled, it is conveyed by the roller conveyor 12 to the rear cross transfer platform 21, and is removed by a conveyor (not shown), such as a crane or a trackless vehicle.
With regard to the remainder of the installation, a lowering mechanism 25, preferably with lifting tables, is positioned within the roller conveyors 12, 22 between the high shelf storage 4 and the point where the coils are being removed from the roller conveyor 12 by the coil car 14. Within this lowering mechanism 25, the coils conveyed from the turntable 11 to the roller conveyor 11a are withdrawn and reach the roller table 12. The conveyor brings the coil to the cross transfer platform 21, lifts it on a pallet-moving equipment (not shown) positioned in the extension of the roller conveyors 12 and 22.
Referring to FIG. 4, the pallet-moving equipment 26, which is positioned parallel to the longitudinal dimension of a number of annealing furnaces 27, has front and rear cross transfer platforms 28 and 29, operating as the pallet turning equipment in front of the cold rolling train 7. Two roller tables 30, 31 are provided with opposite directions of movement. On the pallet turning equipment 26 and on the roller table 31, the coils, which are not annealed immediately after cold rolling, arrive at a high shelf storage 32 which is also formed as high shelves 33 and is positioned parallel to the high-shelf storage 4 at the entrance of the cold rolling mill.
As shown in FIG. 4, three rows of high shelves 33 are positioned behind each other. Between the outer and the middle row of the shelves 33, movable loading and unloading equipment 35 is carried on tracks 34 and works on both sides.
The coils to be annealed are conveyed by the roller conveyor 30 (which has a lowering mechanism 25 containing lifting tables) and a conveyor (not shown), such as a crane, to receive racks 36. From there, they are loaded into an annealing furnace 27 by means of a loading/unloading car 37 on tracks 37a. The tracks of the loading/unloading car 37 are also positioned perpendicular to the pallet-moving equipment 26. After the completion of the annealing process, the coils are removed from the annealing furnace 27 and are returned by the pallet-moving equipment 26 to the high shelf storage 32 for cooling.
From the high shelf storage 32, the annealed and cooled coils are conveyed by another pallet-moving equipment 38 (which is positioned parallel to the above-mentioned pallet-moving equipment 26) for further processing in a shearing line, strip stretching line, strip coating line, hardening (temper) line, or the like. The pallet-moving equipment 38 is only partly shown. Its end has a cross transfer platform 39 located between the high shelf rows 33, and extends out of the cold rolling mill bay.
In FIG. 3 the pallet-moving equipment 140 with the rear cross transfer platform 121, the front cross transfer platform, and the roller conveyors 112 and 122 is actually part of shown in use with a three-strand cold rolling train 108 with roll stands 109 positioned next to each other. Also, an uncoiler and a recoiler 116 and 117, respectively, are provided at the entry and at the exit of the roll stands 109. A turntable 124 and a elevator table 125 are also provided. Just as for the single strand cold rolling train 7 of FIG. 1, the traveling coil cars 114 and 120 on the tracks 113 are installed to more perpendicular to the roller conveyor 112 to deliver and to remove the coils which are to be rolled or which have been rolled. The pallet-moving equipment 140 of the three-strand cold rolling train 108 is installed parallel to the train in the same manner as with the single-strand cold rolling train 7 of FIG. 1. Another cold rolling train can be used in the same way having, for instance, five strands, to the single-strand and to the three-strand cold rolling trains. It is then also provided with another pallet-moving equipment that is positioned parallel to the above-described pallet turning equipment 140; similarly, high shelf storage 4 and 32 which are installed perpendicularly. The high shelf storage 4 and 32 for the suggested three-strand and five-strand cold rolling trains are then extensions of the entry end of the single-strand cold rolling train 7. The high shelf storage 4 is installed, relative to the high shelf storage 32, behind the annealing furnaces 27. That is to say, the single-, three- and five-strand cold rolling trains are arranged next to each other in parallel pass lines and are loaded from the same intermediate storage. After having been rolled in the cold rolling train and annealed in the annealing furnace 27, the coils are conveyed to the same high shelf storage 33.
It is obvious that minor changes may be made in the form and construction of the invention without departing from the material spirit thereof. It is not, however, desired to confine the invention to the exact form herein shown and described, but it is desired to include all such as properly come within the scope claimed.
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Apparatus for the transportation of coiled hot rolled strip, especially non-ferrous metal coils, such as aluminum coils, in a cold rolling mill, including an intermediate storage space at a cold rolling train, at the annealing facilities following cold rolling, and at further treatment installations.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This present application is a continuation of U.S. patent application Ser. No. 12/757,843, filed Apr. 9, 2010, which claims the benefit of 11/581,175, filed Oct. 16, 2006, which claims the benefit of PCT application no. PCT/IL05/00154 filed on Feb. 8, 2005, which claims the benefit of U.S. provisional application No. 60/542,843 filed on Feb. 10, 2004 all of which are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates in general to a device and method for substantially reducing the caloric efficiency of the digestive tract by capturing food being digested in the stomach and/or anywhere else in the GI tract, into entrapping members; moving the entrapping member containing said food down the GI tract, thus excluding at least part of the food intake from being absorbed in the small intestine and further down the GI tract.
BACKGROUND OF THE INVENTION
[0003] Obesity is a chronic disease due to excess fat storage, a genetic predisposition, and strong environmental contributions. This problem is worldwide, and the incidence is increasing daily. There are medical, physical, social, economic, and psychological comorbid conditions associated with obesity. There is no cure for obesity except possibly prevention. Non-surgical treatment has been inadequate in providing sustained weight loss. Currently, surgery offers the only viable treatment option with long-term weight loss and maintenance for the morbidly obese. Surgeries for weight loss are called bariatric surgeries. There is no one operation that is effective for all patients. Gastric bypass operations are the most common operations currently used. Because there are inherent complications from surgeries, bariatric surgeries should be performed in a multidisciplinary setting. The laparoscopic approach is being used by some surgeons in performing the various operations. The success rate—usually defined as >50% excess weight loss that is maintained for at least five years from bariatric surgery—ranges from 40% in the simple to >70% in the complex operations. The weight loss from surgical treatment results in significant improvements and, in some cases, complete resolution of comorbid conditions associated with obesity. Patients undergoing surgery for obesity need lifelong nutritional supplements and medical monitoring.
[0004] It is accepted that patients suffering from obesity are at a substantially increased risk of medical ailments and a range of diseases, including: Type II diabetes, heart disease, stroke, high blood pressure, high cholesterol, certain cancers, and other disorders. Furthermore, patients suffering morbid obesity have life expectancy that is significantly reduced, by at least ten to fifteen years.
[0005] For patients suffering from extremely severe obesity (morbid obesity), i.e. for patients whose weight exceeds the ideal weight by at least 50 kilograms, for example, it is absolutely essential to operate surgically on such patients in order to avoid not only a series of health problems that stem from such obesity, but also to avoid certain and imminent death of such patients.
[0006] It has also been observed that treatment based on a severe diet combined with a series of physical exercises associated with a change in behavior, in particular eating behavior, are relatively ineffective in such cases of morbid obesity, even though such methods of treatment are the most healthy.
[0007] Methods that have been used in the prior art to treat obesity include gastric bypasses and small-bowel bypasses such as described in U.S. Pat. No. 6,558,400 and U.S. Pat. No. 6,543,456. The number of these bariatric surgeries has skyrocketed from 40,000 per year back then to 120,000 in 2002. Many complications are associated with these procedures. Many patients have suffered serious side effects and regret having had it.
[0008] Other methods aim at reducing the effective volume of the stomach to induce a satiety feeling by the patient and hence reducing the calorie intake per meal.
[0009] One such method is the stapling of portions of the stomach has also been used to treat obesity, such as described in U.S. Pat. No. 5,345,949. This includes both vertical and horizontal stapling and other variations trying to reduce the size of the stomach or make a small stoma opening. Many problems have been associated with the use of staples. First, staples are undependable; second, they may cause perforations; and the pouch or stoma opening formed by the staples becomes enlarged over time making the procedure useless.
[0010] Another method that has been developed is the placement of an inflatable bag or balloon into the stomach causing the recipient to feel “full”. Such a procedure has been described in the patent to Garren et al U.S. Pat. No. 4,416,267. The balloon is inflated to approximately 80% of the stomach volume and remains in the stomach for a period of about three months or more. This procedure, although simple, has resulted in intestinal blockage, gastric ulcers, and even in one instance, death and fails to address the problems of potentially deleterious contact with the gastric mucosa which can result from leaving an inflated bag in the stomach for an extended period of time. Moreover, it also failed to produce significant weight loss for long periods of time.
[0011] Yet another method employs the placement of a band around a portion of the stomach thereby compressing the stomach and creating a stoma opening that is less than the normal interior diameter of the stomach for restricting food intake into the lower digestive portion of the stomach. Kuzmak et al in U.S. patent have described such a band. U.S. Pat. No. 4,592,339. It comprises a substantially non-extensible belt-like strap, which constrictively encircles the outside of the stomach thereby preventing the stoma opening from expanding. Kuzmak et al also describe bands, which include a balloon-like section that is expandable and deflatable through a remote injection site. The balloon-like expandable section is used to adjust the size of the stoma opening both intra-operatively and post-operatively.
[0012] Complications have been observed with both inflatable and non-inflatable gastric bands. In particular, obstruction of the stoma from edema and migration of the band has been observed. Such edema-caused obstruction of the stoma may be due to excessive vomiting. In these cases, the stoma must be enlarged either by deflating the expandable portion of a band or by removing the band altogether.
[0013] Yet another method is to impose satiety. U.S. Pat. No. 6,677,318, describing a swellable sponge-like structure. These structures are swallowed by the patient being collapsed inside a capsule. The capsule dissolves in the stomach and the polymer structure with super absorbing characteristics; absorb the gastric juices, which cause the structure to swell considerably. This patent aims to reduce food intake by causing the recipient to feel “full”, yet the absorbed content of the sponge is finally digested.
[0014] Lipase inhibition as a mean for reducing lipid intake is well known in the art, the major draw back is the oily stool as a side effect. To overcome this side effect, polymers capable of absorbing lipids where introduce, as in U.S. Pat. No. 4,432,968, but as the absorption is reversible and shifted backwards as a result of bile salt emulsifier, the overall entrapment was quite poor.
[0015] In order to overcome the a forth mentioned drawbacks, the present invention relates on a lipid absorption polymer having an prolonged equilibrium period in the range of 4-8 hours so as to keep the absorption step active during the relevant period in the digestion tract.
[0016] It is then the object of this invention to overcome these and other deficiencies described above.
SUMMARY OF THE INVENTION
[0017] The invention seeks to provide a successful and non-invasive alternative to existing approaches for controlling obesity.
[0018] The invention objective is to substantially reduce the caloric efficiency of the digestive tract by capturing food being digested in the stomach and/or anywhere else in the GI tract into entrapping members; moving the entrapping member containing the entrapped food ingredients down the gastrointestinal tract, thus excluding at least part of the entrapped food from being absorbed in the small intestine.
[0019] Another objective of this invention is to introduce a lipid absorption polymer having an prolonged equilibrium period in the range of 4-8 hours so as to keep the absorption step active during the relevant period in the digestion tract.
[0020] Another objective of this invention is to interfere with the micelles formation and capture the free lipids contained within.
[0021] Another objective of this invention is to provide a delivery system of the material via means of compressing the material so that it takes less space in the intake, and when the capsule, for example, opens up or dissolves, the individual particles of the material expand to accommodate the captured liquids.
[0022] In one embodiment, the device is comprised of a capsule system for oral delivery. The capsule system is comprised of an external capsule made of gelatin—as an example that dissolves in accordance with a temporal preset, which allows the food intake to be at least partially fluidic. The capsule system is further comprised of an internal permeable bag having a structure such as meshed, woven or fibers, made of disintegrable material such as gelatin for example, which bag contain expandable, super absorbent beads, which dry beads are larger than the pores of the bag, which bag is inflatable. When the bag comes in contact with the fluidic content of the stomach, fluids penetrate into the bag. The fluids are absorbed by the expandable, hydrogel beads enclosed. These beads expand partially or until they reach the absorption capacity limit. Optionally, the internal bag further contains a coating capsule, which dissolves at this time and coats the expandable beads, to seals and protects them from disintegration or prevent leakage of entrapped liquid, throughout their journey out of the GI tract.
[0023] For the sake of clarity, a capsule is a sealed container and a hag is a permeable containers.
[0024] In other embodiments, the external capsule contains folded mechanical structures, which open up to captures some of the stomach content and protects them from disintegration throughout their journey through and out of the GI tract.
[0025] Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The present invention will become more fully understood from the detailed description given herein below and the accompanying drawings, which are given by way of illustration only and thus not limitative of the present invention.
[0027] FIG. 1 is a view of the assembled device.
[0028] FIG. 2A is a view of the external capsule.
[0029] FIG. 2B is a view of the internal bag.
[0030] FIG. 2C is a view of an expandable bead.
[0031] FIG. 2D is a view of a coating capsule.
[0032] FIG. 3 illustrates a basic embodiment of this invention depicting an outer capsule containing super absorbent expandable beads.
[0033] FIG. 4A illustrates of the capsule system entering the stomach at t 1 .
[0034] FIG. 4B illustrates the external capsule dissolving at t 2 .
[0035] FIG. 4C illustrates the expandable beads expanding as they absorb stomach fluids.
[0036] FIG. 4D illustrates the expandable beads reaching the size limits of the internal bag at t 4 .
[0037] FIG. 4E illustrates the rupture of the coating capsule at t 4 .
[0038] FIG. 4F illustrates the internal capsule dissolving at t 5 .
[0039] FIG. 4G and FIG. 4H illustrate the draining stage of the coated at t 6 .
[0040] FIG. 5 is a temporal illustration of a full cycle of the process.
[0041] FIG. 6A - FIG. 6D illustrate another embodiment of the invention.
[0042] FIG. 7A - FIG. 7C illustrate another embodiment of the invention.
[0043] FIG. 8A - FIG. 8C illustrate yet another embodiment of the invention.
[0044] FIG. 9 illustrates an embodiment for loading the force into the small structures.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0045] Before explaining embodiments 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 the arrangement of the components set forth in the following description or illustrated in the drawings.
[0046] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples provided herein are illustrative only and not intended to be limiting.
[0047] In accordance with one basic embodiment of the present invention, illustrated in FIG. 3 , the device is in a form of a pill comprises an outer capsule 200 made of Gelatin for example, which capsule 200 is at least partly filled with cross-linked polymer beads, such as Hydrogels, supper absorbent polymers, cross-linked polymers, known in the art, which beads having a diameter in the range of microns to few mm and are made of non toxic and non digestible polymer and are capable of absorbing fluids at a ratio of at least 5:1 (W/W), (liquid\bead) by diffusion, osmotic force, ionic interaction, and\or capillary force, and\or magnetic force, or other physic-chemical mechanism, such as polyacryl amid derivatives, which absorbing beads may also act as ion exchanger, exclusion gel such as a cross-linked polydextran (or possibly Cellulose Ethers like material), which beads optionally may also contain functional groups that improves permeability when the ambient is acidic (low pH—at the stomach), yet the permeability is reduced when the ambient pH is neutral or basic (small intestine).
[0048] In practice, the pill is ingested, and the capsule 100 dissolves at a temporal preset, beads 300 which are now in contact with the content of the food being digested, absorbs caloric enriched liquid and swells. Next the beads along with content of the stomach 10 are moved into the small intestine, where the entrapped content of the beads are practically not involved in the digestion and absorbing steps in the intestine. It is plausible to design the beads such that they will continue to absorb digested food in the small intestine and further down the GI tract.
[0049] In another embodiment, similar to the first embodiment, the beads are pre coated or pre absorbed by a composition capable of forming at least a partial nutrient barrier on small intestine. The composition helps further to reduce the absorption of food in case of leaking from the bead.
[0050] FIG. 1 is a view of the assembled capsule system. It comprises an external capsule 100 which can be made of a biocompatible material such as gelatin, an internal bag 200 which can be made from gelatin with a net like structure, absorbing beads 300 which can be made from Hydrogels and coating capsule(s) 400 .
[0051] FIG. 2A illustrates the opened external capsule, which opens into two halves 201 and 202 at time t 2 (see FIG. 5 ). It cans also dissolve with control thickness or any other known technique.
[0052] FIG. 4A illustrates the assembled capsule being swallowed by the patient at time t 1 (see FIG. 5 ) which is a while after he started his meal at time t 0 (see FIG. 5 ). FIG. 2B is a view of the internal bag 200 , FIG. 2C is a view of an expandable bead 301 and FIG. 2D is a view of a coating capsule 400 .
[0053] FIG. 4B illustrates the dissolution of the external capsule in the stomach 10 at time t 2 . At this time the super absorbing expandable beads 300 are exposed to the stomach 10 fluids and start absorbing them, as illustrated in FIG. 4C and continue at time period t 3 (see FIG. 5 ).
[0054] Optionally, after the expandable beads 300 fill out the space allowed by the internal bag 200 , as illustrated in FIG. 4D , they press against the coating capsule(s) 400 . This triggers at time t 4 (see FIG. 5 ) the rupture, as illustrated in FIG. 4E , or dissolution of the coating capsule(s) 400 , which contains an agent that coats and seals (see FIG. 4F ) all the expandable beads such that they and their content remains untouched throughout their migration down the GI tract.
[0055] Once all the expandable beads 300 are coated, at time t 5 (see FIG. 5 ), the internal bag dissolves, all the expandable beads are free to move about the GI tract, at time period t 6 (see FIG. 5 ), and they are drained untouched through and out of the GI tract, as illustrated in FIG. 4G and FIG. 4H . The expandable beads 300 dissolve after a preset number of days, in case they were not able to clear out of the GI tract. In another option, the patient drinks a liquid that dissolves expandable beads 300 .
[0056] Thus the content of the expandable beads 300 which contains ingested food remains untouched, is not digested and absorbed by the body and hence reduces the calorie efficiency of the meal.
[0057] In another embodiment of this invention, time t 5 (see FIG. 5 ), when the internal bag 200 dissolves and the expandable beads 300 are free to move about the GI tract, occurs only after the fed mode of the stomach 10 is finished, and the stomach 10 goes into its maintenance mode.
[0058] In another embodiment (not shown) the fluids pass on their way to the super absorbable beads through a filter which is wide on the outer side and narrow in the inner side. This makes it easy for the fluids the flow inward the beads and hard to flow back.
[0059] In yet another embodiment of this invention, a polymer capable of absorbing lipid having an prolonged equilibrium period in the range of 4-8 hours so as to keep the absorption step active during the relevant period in the digestion tract, is provided. One such polymer for example is Polypore, having high absorption ratio of 13 gr lipid to 1 gr polymer.
[0060] Another embodiment of the present invention is to interfere with the micelles which are necessary for the lipid digestion activity. The purpose of the polymer is to disassemble the micelles and extract the lipids. Such a polymer is, for example, isss Gantrez® series, especially Gantrez 225 and Gantrez 425.
[0061] So when a mixture of Polypore and Gantrez are introduced to the small intestine, the Gantrez will interfere with the micelle formation equilibrium, and the polypore will absorb the free lipids without the highly competitive back extraction mechanism.
[0062] Another embodiment of this invention is illustrated in FIG. 6A - FIG. 6D in this embodiment the inner bag is in the form of a folded basket 202 which contains a stack of spheres 500 each of which is split into two halves 501 and 502 which are connected by a spring like connection 503 that the force embedded in it will close up the spheres to the poison 504 in a relaxed mode. When the external capsule 100 dissolves, the force embedded in the stacked up halve spheres 500 will cause the optional basket 202 to open up optionally locked into the position illustrated in FIG. 6D . This allows the half spheres to close up to position 504 which scoops up the food being digested while closing up. The sphere 504 is now small enough to leave the basket 202 through the opening 203 , being pushed by the next pair of half spheres. The last pair of half spheres in the stack may remain in the basket 202 , which dissolves after a preset time and dears out down the GI tract. The optional basket 202 is designed to avoid the possibility that the closing sphere will harm the stomach 10 inner walls. The spheres 500 are of a size appropriate to be able to travel through the GI tract. The closed spheres are made of a substantially ingestible biocompatible material and remain closed and untouched through the journey down and out of the GI tract. The spheres 500 dissolve after a preset number of days, in case they were not able to clear out of the GI tract. In another option, the patient drinks a liquid that dissolves spheres 500 .
[0063] Another embodiment of this invention is illustrated in FIG. 7A - FIG. 7C . In this embodiment, the capsule is filled up with number of folded stent like structures 600 . When the external capsule 100 dissolves, a force will cause the stents 600 to open up and lock into the position illustrated in FIG. 7C . The force can be embedded in the structures 600 , apply via external or internal spring (not shown) or generated internally or externally via chemical reaction with the stomach 10 content. While stents 600 open up inside the stomach 10 they will suck up some of the content into the stents. The stents 600 are built such that they have entry holes 604 through which the content is sucked up. Optionally, entry holes 604 are equipped with a directional valve such that the stomach 10 content can only enter into the stents but can not escape. The size of the opened stents 600 is designed to be able to travel through the GI tract. The stents are made of a substantially ingestible material and remain dosed and untouched throughout their journey down and out of the GI tract. The folded structures 601 , 602 , 603 can also he polymer beads and the force applied to them before delivery to compress the beads substantially so that they open inside the GI tract to capture various liquids. One such polymer, for example, is Polypore, having high absorption ratio of 13 gr lipid to 1 gr polymer and high ratio of its free form volume to its compressed form volume.
[0064] In another embodiment the force (such as spring force or elastic force) is being loaded into the small structures 700 before using the capsule. FIG. 9 shows a device 800 for compressing the small structures 700 and encapsulating them to form the pill to be swallowed. Turning the handle 802 in direction 806 moves the bar 804 in direction 808 . The capsule half 101 is pushed towards the second half 102 and the small structures 700 are compressed. This will overcome the possibility that the force will deteriorate over time.
[0065] Another embodiment of this invention is illustrated in FIG. 8A - FIG. 8C . In this embodiment, the capsule is filled up with a number of folded structures 700 . When the external capsule 100 dissolves, the force embedded within the structures will cause the structures 700 to open up into the position 702 illustrated in FIG. 8C . The force can be embedded in the structures 700 , in the manufacturing process by taking a semi rigid structure and forcing it into a collapsed form by applying pressure. The kinetic energy stored in the structures 700 will be used to restore the structures into their natural form once the capsule 100 has opened up. This force is designed so that it can over come the pressure inside the stomach 10 . While structures 700 open up inside the stomach 10 they will suck up some of the content into the structures 700 . The structures 700 are made up such that they have entry holes 703 through which the content is sucked up. Optionally, entry holes 703 are equipped with a directional valve such that the stomach 10 content can only enter into the structures 700 but cannot escape. The size of the opened stents 700 is designed to be able to travel through the GI tract. The full structures 700 are made of a substantially ingestible material and remain closed and untouched throughout the journey down and out of the GI tract.
[0066] In another embodiment the folded structures are polymer beads and the force applied to them before delivery to compress the beads substantially so that they take less space on the intake but open inside the GI tract to capture various liquids. One such polymer, for example, is Polypore, having high absorption ratio of 13 gr lipid to 1 gr polymer and high ratio of its free form volume to its compressed form.
[0067] The invention being thus described in terms of several examples and embodiments, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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Devices and methods for substantially reducing the caloric efficiency of the digestive tract by capturing food being digested in the stomach 10 and/or anywhere else in the gastrointestinal (GI) tract, absorbing or encapsulating the captured food into multiple capturing members and moving such multiple capturing members containing the ingestible encapsulated food down the GI tract, practically out of reach of the GI absorption organs, thus excluding the entrapped ingredients from being involved in the digestion and\or absorption process. The device is designed for oral delivery. The system can be comprised of liquid, food bars or a capsule system. The capsule system is comprised of an external capsule that dissolves in accordance with a temporal or ph dependent preset, which allows the food intake to be at least partially fluidic. The capsule system is further comprised of a mechanism designed to capture and isolate a portion of the food being digested.
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BACKGROUND
[0001] The present invention relates generally to the field of airbag modules and base plate attachments.
[0002] A conventional module for housing an airbag module in a vehicle has a cover or deployment door which attaches to a housing or base plate in which an air bag and inflator are housed. Commonly, a plurality of threaded studs extend from the base plate about its mouth and the cover has corresponding complementary holes which mate with the studs.
[0003] Conventional attachment designs may include rivets, rings, or rigid hooks to connect the base plate and cover. Other conventional airbag systems require the use of two separate base plates, which increase the costs associated with manufacturing the airbag system.
[0004] One drawback of such conventional designs is that the requirement of extra fasteners, rigid hooks or additional base plates increases the overall weight of the airbag module, cost and the difficulty in assembling the module.
[0005] Another drawback of using threaded studs to retain a cover to a base plate is that the studs can be inadvertently cross-threaded during assembly. The studs often require checking in order to verify proper assembly. Furthermore, the deployment of an airbag can be modified when the cover separates from the base plate during deployment, which varies the restraint performance from a designed and expected performance.
[0006] Additional drawbacks exist when utilizing fasteners to secure an air bag cover. For example, threaded fasteners are susceptible of loosening from vibration as a vehicle travels over a bumpy road and therefore require use of a thread binding agent or a lock washer to prevent loosening. This further increases the number of parts, complicates the assembly, and adds to cost and time required for assembly. As a result, such systems for attaching a cover to a base plate tend to be less feasible when constructing air bag modules for use in high volume and low cost applications.
SUMMARY
[0007] One embodiment of the invention relates to an airbag assembly. The airbag assembly comprises a base with a main plate portion and a bendable tab, a cover attachable to the base, an airbag stored between the cover and the base, and an inflator configured to inflate the airbag. The bendable tab is configured to attach to the cover.
[0008] According to another embodiment of the invention, a base for an airbag module is provided. The base includes a bendable tab that is configured to attach to a cover for an airbag.
[0009] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] These and other features, aspects, and advantages of the present invention will become apparent from the following description, appended claims, and the accompanying exemplary embodiments shown in the drawings, which are briefly described below.
[0011] FIG. 1 is an exploded side view of an airbag module.
[0012] FIG. 2 is a perspective view of an airbag assembly according to an embodiment of the invention.
[0013] FIG. 3 is a top perspective view of a base plate.
[0014] FIG. 4 is a detail view of a tab.
[0015] FIG. 5 is another detail view of the tab.
[0016] FIG. 6 is a detail perspective view of a tab on the base plate.
[0017] FIG. 7 is a cross-sectional view of the cover taken along line A-A of FIG. 2
[0018] FIG. 8 is another cross-sectional view of the cover taken along line B-B of FIG. 2 .
DETAILED DESCRIPTION
[0019] Hereinafter, embodiments of the present invention will be described with reference to the attached drawings.
[0020] FIG. 1 discloses an airbag module 10 for housing an airbag according to one embodiment of the present invention. The airbag module 10 comprises an airbag 18 , a cover 20 and a base plate 30 . The base plate 30 is configured to attach to the cover 20 , when the airbag module 10 assembled. The airbag module 10 may also include an inflator 15 . The inflator 15 provides the inflation gas to inflate and deploy the airbag during a collision.
[0021] The inflator 15 , shown in FIGS. 1 and 2 , may comprise a gas generant or propellant in order to provide inflation gas to the airbag 18 . In addition, the inflator 15 may include a decomposing type material as the source of the pressurized gas for the airbag 18 . The inflator 15 may include an igniter or initiator assembly (not shown). The igniter receives a signal from a controller in order to initiate operation of the inflator 15 when the controller determines a collision is occurring.
[0022] The airbag 18 is folded in the airbag module 10 in the uninflated state. The airbag 18 connects to a retainer (not shown) to retain the airbag 18 to the base plate 30 .
[0023] The airbag module 10 , as shown in FIG. 1 , may be mounted in the steering wheel of the vehicle or other suitable location. The airbag module 10 is positioned within the steering wheel of the vehicle in order to protect a driver in a collision, specifically a frontal collision. However, the airbag module 10 may be mounted along the dash, in a door, or any other suitable location for protecting a passenger or driver of a vehicle.
[0024] The cover 20 is generally formed of a plastic material, such as a soft resin, or any other suitable material. The cover 20 must be able to withstand any wear and tear derived from its position in the cabin of a vehicle and must also be able to break open upon deployment of the airbag 18 .
[0025] The cover 20 is attached to the base plate 30 such that an open area is created between the cover 20 and the base plate 30 . The airbag 18 is stored, in the uninflated state, in the open area between the cover 20 and the base plate 30 . The cover 20 forms the barrier between the airbag 18 and the inside of the vehicle passenger cabin area. For example, the cover 20 may form the center portion of a steering wheel.
[0026] The cover 20 includes an interior surface 21 that is adjacent the stored airbag 18 and away from the vehicle passenger cabin area. The cover 20 additionally includes side walls 22 that extend up from the interior surface 21 and create the open area or space for the airbag 18 and inflator 15 . The side walls 22 end at edges 25 that are generally flat.
[0027] The airbag module 10 is mounted to the vehicle by the base plate 30 . The base plate 30 holds the uninflated airbag 18 cushion in the open space between the cover 20 and the base plate 30 .
[0028] The base plate 30 can be made of metal. In addition, the base plate 30 should be of sufficiently high strength such that the base plate 30 can withstand the forces from a collision and from the inflation of the airbag 18 .
[0029] The base plate 30 of an airbag module 10 comprises a main plate portion 31 in a generally square plate shape with edges 35 as can be seen in FIG. 3 . An opening 34 is formed at the center of the main plate portion 31 for inserting an inflator 15 . Further, bolt through-holes 42 can be positioned at the periphery of the opening 34 for mounting the inflator 15 and/or the air bag. Mounting holes (bolt passing holes) 44 may also be disposed in the main plate portion 31 for mounting the base plate 30 and, thus, the airbag module 10 , to the vehicle.
[0030] The base plate 30 includes a plurality of tabs 36 on edges 35 of the main plate portion 31 , as shown in FIG. 3 . The tabs 36 are configured to be bendable. Each tab 36 includes a bendable portion 37 that folds or bends back from the surface of the main plate portion 31 at a crease portion 38 , shown in FIG. 4 . The tab 36 is generally planar with the main plate portion 31 of the base plate 30 when the tab 36 is in a starting, or original, position, such as shown in FIG. 3 . When the tab 36 is attached to the edge 24 of the cover 20 , the bendable portion 37 of the tab 36 is bent at an angle less than 90° from the main plate portion 31 . This allows for the tab 36 to securely attach over the edge 24 of the cover 20 . The tab 36 is bent or positioned such that it lies against the edge 24 of the cover when the base plate 30 is attached to the cover 20 .
[0031] The tab 36 is configured in a “T” shape, with a “T” section 26 b and two extending ends 26 a that are perpendicular to the bendable portion 37 . The “T” section 36 b, with ends 36 a, is bent 90° relative to the plane of the base plate 30 . This is to ensure that the flange 27 will be positioned with the base plate 30 during deployment of the airbag 18 .
[0032] Tab 36 fits into a corresponding notch 28 in flange 27 . A flat surface 54 of the flange 27 is adjacent the inside surface 33 of the base plate 30 . The tabs 26 bend around the top of the flange 27 and press against the top area 56 of the flange 27 . The ends 36 a of the tab 36 press against the upward extending portion 29 of the flange 27 .
[0033] In the embodiment shown in FIG. 2 , the base plate 30 includes a plurality of tabs 36 , such that each edge 35 of the base plate 30 includes at least one tab 36 . This configuration, having an attachment in every direction, can prevent the cover 20 from detaching from the base plate 30 . Of course, it will be recognized that any number of tabs 36 can be used, such as one, or any other suitable amount.
[0034] A lip 39 , as shown in FIGS. 4 and 5 , is positioned at an end of the bendable portion 37 . The lip 39 curves downward toward the cover 20 such that the lip fits over the receiving edge 24 of the cover 20 . The tab 36 can also fit over a flat portion 25 of the edge 24 , as can be seen in FIG. 5 . The lip 39 curves downward from the bendable portion 37 at an angle of approximately 90°.
[0035] When the base plate 30 and cover 20 are assembled, a user can lift up or bend back the bendable portion 37 of the tab 36 such that the base plate 30 can fit into position in the cover 20 . The tab 36 is then released, allowing for the bendable portion 37 to return toward its original position and fit over the edge 24 of the cover 20 .
[0036] The base plate 30 can further include a receiving edge portion 40 positioned along an edge 35 of the main plate portion 31 . The receiving edge portion 40 is configured to receive a flange 27 from the cover 20 . The receiving edge portion 40 is composed of a thickness configured to slide under the flange 27 . The flange 27 slides or fits over the receiving edge portion 40 , securing the cover 20 to the base plate 30 . The flange 27 extends up from the edge 24 of the cover 20 by an upward extending portion 29 . The edge 35 of the receiving edge portion 40 abuts the upward extending portion 29 of the cover 20 .
[0037] The base plate 30 , according to another embodiment, can be composed of any suitable material such as, for example, a high strength resin. Further, the base plate 30 can comprise any shape, such as oval, round, rectangular, etc. In addition, the position and number of mounting holes 44 and bolt through-holes can vary.
[0038] In another embodiment, the position and number of tabs 36 and receiving edge portions 40 may vary as suitable for the airbag module 10 . According to another embodiment, the lip 39 can extend down from the bendable portion 37 of the tab 36 at any angle suitable for fitting over the edge 24 of the cover 20 .
[0039] The “z” position of the module 10 is maintained for the base plate 30 by the top surface area of the cover 20 . In other words, the height of the walls 22 determines and maintains the “z” position of the module 10 .
[0040] The “x” position is made by utilizing an internal horizontal rib 92 in the cover 20 , as shown in FIG. 8 . The horizontal rib 92 is configured to have dimensions equal to the dimensions of one of a base plate notch 45 . The rib 92 fits in the notch 45 to maintain the module in the x direction.
[0041] The “y” direction is made by using a vertical internal rib 94 in the cover 20 . The vertical rib 94 has dimensions equal to the dimensions of one of the corresponding base plate notches 45 . The vertical rib 94 fits in the notch 45 and keeps the module 10 in the proper position by preventing any movement in the y direction.
[0042] Given the disclosure of the present invention, one versed in the art would appreciate that there may be other embodiments and modifications within the scope and spirit of the invention. Accordingly, all modifications attainable by one versed in the art from the present disclosure within the scope and spirit of the present invention are to be included as further embodiments of the present invention. It will be recognized that any combination of embodiments may be utilized. The scope of the present invention is to be defined with reference to the following claims.
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An airbag assembly includes an airbag, an inflator for inflating the airbag, a cover and a base plate. The base plate attaches to the cover such that the base plate is secured on each edge of the base plate and is prevented from detaching. The base plate and cover do not require fasteners or removable pieces. The base plate comprises a bendable tab. The bendable tab is configured to bend over an edge of the cover and secure to the cover by a lip on an end of the bendable tab.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to an inflator, especially to an inflator that indicates state and having simple structure.
[0002] Generally, water life saving equipment including life jackets, life vests, life rafts, etc. is connected to an inflator with a high pressure gas cylinder for fast inflation and providing gas required for generating buoyancy. The conventional inflator at least includes an inflator body, a pierce pin arranged at and movable with the inflator body, and a rotation arm. While in use, the pierce pin is driven by the rotation arm to pierce a seal of the high pressure gas cylinder. Thus compressed gas in the gas cylinder is released so as to inflation the life saving equipment mentioned above. The inflator is further arranged with an indicator for indicating the state of the inflator and the state of the high pressure gas cylinder. Users can learn the state of the inflator and the gas cylinder.
[0003] Refer to U.S. Pat. No. 7,854,347, a manual gas inflator is revealed. The shortcoming of the manual gas inflator is in that CO2 sensor and CO2 gas cylinder need to be replaced at the same time during rearming process. Moreover, the structure of the manual gas inflator is complicated and many components required increase the cost. The CO2 sensor is a special component and is not easy to get.
[0004] Refer to U.S. Pat. No. 3,809,288, an inflation manifold assembly is disclosed. The disadvantage of the inflation manifold assembly is in that an additional component (such as a color indicator) is required besides replacement of the gas cylinder during the reaming process. Once the rearming process is interrupted or the color indicator is lost, whether the gas cylinder of the inflator has been used is unable to be confirmed. Thus the gas cylinder needs to be removed and checked again.
[0005] Refer to U.S. Pat. No. 5,694,986, an automatic actuator with apertured housing and safety indicator is revealed. The shortcoming of the device is in that during rearming of the inflator operated manually, additional component (such as color indicator) is required. Once the rearming process is interrupted or the color indicator is lost, whether the gas cylinder of the inflator has been used is unable to be checked. The gas cylinder needs to be removed and checked again. When the inflator is operated automatically and the color indicator is not fallen off, whether the gas cylinder is fully-charged is unable to be quickly checked by the appearance. The gas cylinder needs to be removed for checking the state.
[0006] Refer to U.S. Pat. No. 6,589,087, an automatic inflator having a status indicator is disclosed. Besides the gas cylinder, a cylinder adapter also needs to be replaced during rearming of the inflator. Thus the cost is increased. Moreover, the status indicator that indicates whether the gas cylinder has been installed has complicated structure. Thus the assembly is time-consuming and the cost is further increased.
[0007] As to the inflators revealed in U.S. Pat. No. 5,643,030, and U.S. Pat. No. 6,422,420, they have the same shortcoming. Both devices have movement structure that needs more components. Thus more assembly processes are required and the defective rate is increased. Therefore the cost of the product is increased.
[0008] Thus the conventional at least has following shortcomings: complicated structure, too many components, time-consuming assembly and additional components required during rearming of the inflator. Moreover, users are unable to quickly check whether the gas cylinder of the inflator is replaced or not yet during rearming of the inflator.
SUMMARY OF THE INVENTION
[0009] Therefore it is a primary object of the present invention to provide an inflator that not only overcomes shortcomings of conventional ones but also features on simple structure, reliable performance, easy operation, convenient rearming and reduced cost.
[0010] In order to achieve the above object, an inflator of the present invention includes an inflator body, a needle-shaped shaft and a transmission arm. A top surface of the inflator body is disposed with a cylinder housing for mounting a gas cylinder. The inflator body further includes a first channel and a chamber therein. A through hole for connecting an object to be inflated is arranged at a side surface of the inflator body. A top end and a bottom end of the first channel are communicating with the cylinder housing and the chamber respectively while the through hole is communicating with one side of the first channel. A window is arranged at each of the two opposite side surfaces of the inflator body respectively. The needle-shaped shaft is moveable in the first channel of the inflator body and including a needle on a top end and a spring and a movable seat are disposed on a lower part thereof in turn. The needle is for piercing a seal of the gas cylinder. A first color area and a second color area are disposed around the needle-shaped shaft vertically. Through the windows of the inflator body, the color of the first color area or the second color area is displayed to indicate the state of the inflator including a non-inflated state and an already-inflated state. The transmission arm is pivotally disposed on the chamber of the inflator body and one end of the transmission arm is leaning against the bottom surface of the movable seat.
[0011] While in use, the transmission arm is rotated counterclockwise to chive the movable seat moving upward and further compressing the spring. Then the needle-shaped shaft is further pushed to move upward for piercing the seal of the gas cylinder. Thus compressed gas in the gas cylinder is released, passed the first channel and the through hole of the inflator body and entering the object to be inflated for inflation. Now the color of the first color area of the needle-shaped shaft representing non-inflated state and displayed through the window of the inflator body is changed into the color of the second color area that represents already-inflated state. Next the transmission arm is released. Due to the elasticity, one end of the first spring is elastically against the bottom surface of the needle-shaped shaft to keep the needle stay on the seal while the other end of the first spring is elastically against the movable seat to make the movable seat move downward. Thus the transmission arm is rotated in the opposite direction and moved back to the original position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view of an embodiment according to the present invention;
[0013] FIG. 2 is an explosive view of an embodiment according to the present invention;
[0014] FIG. 3 and FIG. 3A are a front view and a front cross sectional view of an inflator body respectively of an embodiment according to the present invention;
[0015] FIG. 4 , FIG. 4A , and FIG. 4B are a front view, a cross sectional view of an embodiment and a cross sectional view of another embodiment respectively according to the present invention;
[0016] FIG. 5 is a front view of a needle-shaped shaft of another embodiment according to the present invention;
[0017] FIG. 6 is a front cross sectional view of a movable seat of an embodiment according to the present invention;
[0018] FIG. 7 is a schematic drawing showing the embodiment in FIG. 5 and FIG. 6 assembled with a spring according to the present invention;
[0019] FIG. 8 , FIG. 9 and FIG. 10 are cross sectional views showing how an embodiment works according to the present invention;
[0020] FIG. 11 is a schematic drawing showing the embodiment in FIG. 8 connected to a handle by a rope according to the present invention;
[0021] FIG. 12 is a perspective view of another embodiment according to the present invention;
[0022] FIG. 13 is an explosive view of another embodiment according to the present invention;
[0023] FIG. 14 and FIG. 15 are a front view and a front cross sectional view of an inflator body respectively of another embodiment according to the present invention;
[0024] FIG. 16 , FIG. 17 , FIG. 18 , FIG. 19 and FIG. 20 are a front view, a side view, a longitudinal cross sectional view and two transverse cross sectional views of another embodiment according to the present invention;
[0025] FIG. 21 and FIG. 22 are a front view and a top view of a rod of another embodiment according to the present invention;
[0026] FIG. 23 and FIG. 24 are a perspective view and a longitudinal cross sectional view of an ammunition mechanism of another embodiment according to the present invention;
[0027] FIG. 25 and FIG. 26 are a perspective view and a longitudinal cross sectional view of an outer sleeve of another embodiment according to the present invention
[0028] FIG. 27 and FIG. 28 are front cross sectional view of another embodiment showing how the inflator works according to the present invention;
[0029] FIG. 29 is a schematic drawing showing the embodiment in FIG. 12 connected to a handle by a rope according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] Refer to FIG. 1 and FIG. 2 , an inflator 1 of the present invention includes an inflator body 10 , a needle-shaped shaft 20 and a transmission arm 30 .
[0031] Refer to FIG. 3 and FIG. 3A , a cylinder housing 11 with an opening facing upward for mounting a gas cylinder 40 (such as CO2 cylinder) is disposed on a top surface of the inflator body 10 . A seal 41 of the gas cylinder 40 is facing a bottom surface of the cylinder housing 11 . The inflator body 10 further includes a long first channel 12 , a chamber 13 therein, and a through hole 14 for connecting an object being inflated (not shown in figure) and located at a side surface thereof. A top end and a bottom end of the first channel 12 are communicating with the cylinder housing 11 and the chamber 13 respectively while the through hole 14 is communicating with one side of the first channel 12 . A window 15 is arranged at a front surface and a rear surface of the inflator body 10 respectively. The two windows 15 are arranged symmetrically and corresponding to each other.
[0032] Refer from FIG. 4 to FIG. 8 , the needle-shaped shaft 20 is mounted in the first channel 12 of the inflator body 10 and is moved along the length direction of the first channel 12 . The needle-shaped shaft 20 includes a needle 21 , a space 22 with an opening facing downward, a first spring 23 , a first color area 24 , a second color area 25 , a seal ring 26 , a groove 27 , and a movable seat 28 . The needle 21 is conical and arranged on a top end of the needle-shaped shaft 20 for piercing the seal 41 of the gas cylinder 40 . The first color area 24 and the second color area 25 with different colors such as green and red are disposed around the needle-shaped shaft 20 and adjacent to each other. The first color area 24 and the second color area 25 are corresponding to the windows 15 of the inflator body 10 respectively at different time so as to show the color through the windows 15 for indicating the state of the inflator 1 . The seal ring 26 is arranged around the needle-shaped shaft 20 , between the needle 21 and the first color area 24 and mounted in the groove 27 . The seal ring 26 is against an inner wall of the first channel 12 of the inflator body 12 so as to achieve sealing.
[0033] The first spring 23 and the movable seat 28 are disposed on a lower part of the needle-shaped shaft 20 in turn. The top end and the bottom end of the first spring 23 are leaning against the bottom surface of the needle-shaped shaft 20 and the top surface of the movable seat 28 . A space 22 with an opening facing downward for receiving the first spring 23 is arranged at a lower end of the needle-shaped shaft 20 (as shown in FIG. 2 ). Or a protrusion 29 is projecting downward from the bottom surface of the needle-shaped shaft 20 to be mounted in the top end of the first spring 23 , as shown in FIG. 5 . Moreover, a projecting pin 281 is formed on a top surface of the moveable seat 28 to be mounted in the bottom end of the first spring 23 . Or a space 282 with an opening facing upward for receiving the first spring 23 is arranged at the top surface of the movable seat 28 , as shown in FIG. 6 . The needle-shaped shaft 20 and the movable seat 28 are corresponding to each other and used in combination with each other. Refer to FIG. 7 , another embodiment of an assembly including the needle-shaped shaft 20 with protrusion 29 , the movable seat 28 having the space 282 and the first spring 23 according to the present invention is disclosed.
[0034] Refer to FIG. 2 and FIG. 4 , at least one long slot 211 with one end extending toward a head end of the needle 21 is disposed on a surface of the needle 21 of the needle-shaped shaft 20 . When there is a plurality of slots 211 on the needle 21 , the slots 211 are arranged at a certain interval. Due to the conical shape, the needle 21 pierces a central area of the seal 41 of the gas cylinder 40 to form a regular round hole. The movement of the needle 21 will not be interfered by the round hole. By the long slots 211 , the compressed gas in the gas cylinder 40 is released at a higher speed. In contrast, the hole formed by the conventional beveled needle tip piercing the seal 41 of the gas cylinder 40 is not located at the central area of the seal 41 . Moreover, the edge of the hole is irregular so that the movement of the needle 21 into or out of the seal 41 of the gas cylinder 40 is interfered.
[0035] The colors of the first color area 24 and the second color area 25 of the needle-shaped shaft 20 are coated over the needle-shaped shaft 20 by spray, electroplating or coating. Refer to FIG. 4B , a first covering body 241 that represents the color of the first color area 24 and a second covering body 251 that represents the color of the second color area 25 are made by colored plastic respectively. The first covering body 241 and the second covering body 251 are covered around the needle-shaped shaft 20 or covered over a first concave area 242 and a second concave area 252 disposed on the needle-shaped shaft 20 and correspondingly to the first covering body 241 and the second covering body 251 respectively. By the coating techniques, the color on the above color area is not easy to fade. Thus the operation state is checked easily and the service life is increased.
[0036] Refer to FIG. 2 , the transmission arm 30 includes a first end 301 at one end thereof, a second end 302 at the other end and a pivot hole 303 between the first end 301 and the second end 302 . A pivot shaft 31 is passed through the pivot hole 303 so as to pivotally connect the transmission arm 30 to the chamber 13 of the inflator body 10 . Thus the transmission arm 30 rotates around the pivot shaft 31 . The first end 301 is against the bottom surface of the movable seat 28 while the second end 302 is operated to rotate the transmission arm 30 .
[0037] When the needle-shaped shaft 20 pierces the seal 41 of the gas cylinder 40 , the first spring 23 is compressed into the space 22 of the needle-shaped shaft 20 or the space 282 of the movable seat 28 . At the moment, the top surface of the movable seat 28 is in contact with the bottom surface of the needle-shaped shaft 20 so as to prevent damages or elastic fatigue of the first spring 23 caused by over compression. Thereby the first spring 23 is protected by the design and the structure of the space 22 , 282 mentioned above.
[0038] The first color area 24 is used to represent non-inflated state while the second color area 25 is represented the already-inflated state. When the gas cylinder 40 is assembled with the cylinder housing 11 of the inflator body 10 , the needle-shaped shaft 20 is observed through the window 15 . Once the color of the first color area 24 such as green color is shown, it is learned that the inflator 1 can be used for inflation or is full-charged after being used. If the color of the second color area 25 such as red color is displayed, it means that the inflator 1 is unable to be used. The gas cylinder 40 needs to be replaced or rearmed so that the inflator 1 can be used again.
[0039] Two windows 15 on the inflator body 10 of the present invention allow users to check the state of the inflator 1 now easier and faster, compared with conventional device with a single window 15 .
[0040] Refer to FIG. 8 , FIG. 9 and FIG. 10 , how the inflator 1 of the present invention is manually operated is shown. As show in FIG. 8 , it shows the state of the inflator 1 before use. The first end 301 of the transmission arm 30 is against the bottom surface of the movable seat 28 and the first spring 23 is compressed. At the moment, the seal 41 of the gas cylinder 40 has not been pierced by the needle 21 of the needle-shaped shaft 20 . And the color of the first color area 24 of the needle-shaped shaft 20 is displayed through the window 15 of the inflator body 10 .
[0041] Refer to FIG. 9 , it shows the inflator 1 in use. The transmission arm 30 is rotated counterclockwise (the arrow A indicates) to drive the movable seat 28 moving upward and pushing against the first spring 23 . Thus the needle-shaped shaft 20 is further driven to move and the needle 21 thereof pierces the seal 41 of the gas cylinder 40 . The compressed gas in the gas cylinder 40 is released and used for inflation. Now the color of the second color area 25 of the needle-shaped shaft 20 is shown through the window 15 of the inflator body 10 .
[0042] As shown in FIG. 10 , release the transmission arm 30 after the seal 41 of the gas cylinder 40 being pierced by the needle 21 . The compressed first spring 23 is released. Due to elasticity, one end of the first spring 23 is elastically against the needle-shaped shaft 20 so as to keep the needle 21 stay on the seal 41 while the other end of the first spring 23 is elastically against the movable seat 28 to make the movable seat 28 move downward and push against the first end 301 of the transmission arm 30 . Thus the transmission arm 30 is rotated in the opposite direction and moved back to the original position.
[0043] Refer to FIG. 11 , the second end 302 of the transmission arm 30 is connected to a handle 33 by a rope 32 . The transmission arm 30 is driven to rotate counterclockwise by pulling the handle 33 downward and the operation is more convenient.
[0044] Under manual operation of the inflator 1 , how the inflator 1 works during rearming of the gas cylinder 40 is described in the following. The gas cylinder 40 is assembled with the cylinder housing 11 of the inflator body 10 . When the needle 21 of the needle-shaped shaft 20 is against the seal 41 of the gas cylinder 40 and the needle-shaped shaft 20 is moving downward, the color of the first color area 24 is completely shown through the window 15 of the inflator body 10 . This represents that the gas cylinder 40 has not been used yet and the inflator 1 can be used for inflation. Once the needle 21 of the needle-shaped shaft 20 has pierced the seal 41 of the gas cylinder 40 and the needle-shaped shaft 20 has not moved downward, the color of the second color area 25 is completely shown through the window 15 of the inflator body 10 . This means that the gas cylinder has been used and a new gas cylinder 40 is required for using the inflator 1 to inflate.
[0045] In another embodiment of the present invention, an automatic actuating device is used for automatic operation of the inflator 1 . Thus the inflator 1 can be operated manually/automatically and users have more options.
[0046] Refer from FIG. 12 to FIG. 26 , an inflator of the present invention further includes an automatic actuating device 50 that is composed of an inner sleeve 51 , a rod 52 , a second spring 53 , an ammunition mechanism 54 and an outer sleeve 55 .
[0047] The inner sleeve 51 is disposed under the inflator body 10 and is communicating with a second channel 16 of the inflator body 10 axially. At least two slots 511 are arranged with a certain interval axially at the inner sleeve 51 . A plurality of long grooves 512 is disposed on an inner wall of the inner sleeve 51 with an interval along the length direction of the inner sleeve 51 . An inner top surface 513 of the inner sleeve 51 is extended downward to form a circular projecting neck 514 . A threaded part 515 is set around on an outer surface of the inner sleeve 51 . At least one assembly hole 516 corresponding to an assembly hole 17 of the inflator body 10 is mounted on an upper part of the inner sleeve 51 . By at least one pin 18 being passed through the assembly holes 516 , 517 , of the inner sleeve 51 is assembled with the inflator body 10 . Moreover, the inner sleeve 51 and the inflator body 10 can be integrally formed. The second channel 16 and the first channel 12 of the inflator body 10 are positioned in parallel with an interval. The width of the long grooves 512 can be modified for alignment and preventing misplacement.
[0048] The rod 52 is mounted axially in the inner sleeve 51 . An upper part of the rod 52 is inserted into the second channel 16 of the inflator body 10 and is moveable along the length direction of the second channel 16 . A long hole 521 is disposed axially on an upper part of the rod 52 , allowing the second end 302 of the transmission arm 30 to pass through and move along the length direction thereof. A circular stopping part 522 is projecting from a lower part of the rod 52 while a circular groove 523 is mounted on a middle part of the rod 52 and a projecting flange 524 is disposed under the circular groove 523 . A seal ring 56 is mounted in the circular groove 523 and is against the inner wall of the circular projecting neck 514 of the inner sleeve 51 to achieve sealing. A plurality of projecting bodies 525 corresponding to and locked with the long grooves 512 is radially arranged on the projecting flange 524 .
[0049] The second spring 53 is arranged around the rod 52 . One end of the second spring 53 is elastically leaning against the inner top surface 513 of the inner sleeve 51 while the other end thereof is elastically leaning against a top surface of the projecting flange 524 of the rod 52 .
[0050] The ammunition mechanism 54 is mounted in the inner sleeve 51 and is located under the rod 52 . The ammunition mechanism 54 consists of a base 541 , a plurality of elastic pieces 542 and a circular wall 543 . A round hole 544 penetrating the base 541 is disposed on a center of the base 541 and the elastic pieces 542 are arranged evenly in the round hole 544 of the base 541 and is projecting a predetermined height from the round hole 544 . A bottom end of each elastic piece 542 is connected to the base 541 while a top end of the elastic piece 542 is disposed with a stopping surface 545 that is against the stopping part 522 of the rod 52 . The circular wall 543 is wrapped around the elastic piece 542 and is arranged at the top surface of the base 541 so as to restrict the elastic pieces 542 and prevent the elastic piece 542 from radial elastic deformation caused by axial pushing force from upward. The circular wall 543 is dissolved after in contact with aqueous solution. Corresponding to the slots 511 and the long grooves 512 of the inner sleeve 51 , the base 541 is radially disposed with at least two convex bodies 546 and a plurality of convex bodies 547 . The convex body 546 is locked with the slot 511 while the convex body 547 is locked with the long groove 512 correspondingly. The convex bodies 546 , 547 of the ammunition mechanism 54 and the slots 511 as well as the long grooves 512 of the inner sleeve 51 provide guidance and alignment while assembling the ammunition mechanism 54 with the inner sleeve 51 so as to prevent errors during rearming of the ammunition mechanism 54 . When the ammunition mechanism 54 is mounted in the inner sleeve 51 , the stopping surface 545 of the elastic piece 542 is against the stopping part 522 of the rod 52 and the elastic pieces 542 are stopped by the circular wall 543 . Thus the rod 52 will not move downward even under the action of elasticity of the second spring 53 .
[0051] As shown in FIG. 25 and FIG. 26 , the outer sleeve 55 is arranged around the inner sleeve 51 and having an opening 551 at one end while the other end thereof is disposed with a plurality of first water supply/vent hole 552 . A threaded part 553 corresponding to the threaded part 515 of the inner sleeve 51 is disposed inside the opening 551 of the outer sleeve 55 . Although the outer sleeve 55 and the inner sleeve 51 in this embodiment are connected by thread parts 553 , 515 engaged with each other, the connection way is not limited by threaded parts. The outer sleeve 55 and the inner sleeve 51 can also be fastened to each other. An inner surface of the bottom of the outer sleeve 55 is extended upward to form a projecting neck 555 . When the outer sleeve 55 and the inner sleeve 51 are assembled with each other, the projecting neck 555 of the outer sleeve 55 is against the bottom of the base 541 of the ammunition mechanism 54 . The size of the first water supply/vent hole 552 is not limited. For example, the first water supply/vent hole 552 in the center in FIG. 13 is in a larger size while other first water supply/vent hole 552 arranged circularly is in a smaller size. The arrangement way of the first water supply/vent hole 552 is also not restricted. At least one second water supply/vent hole 554 is disposed on an outer surface of the outer sleeve 55 .
[0052] Under the automatic operation of the inflator 1 , how the inflator 1 works during rearming of the gas cylinder 40 is described in the following. The steps are similar to those of the manual-operated inflator 1 but the difference is in that the ammunition mechanism 54 needs to be replaced. First disassemble the outer sleeve 55 of the automatic actuating device 50 . Then replace the used ammunition mechanism 54 with a new one. While assembling the new ammunition mechanism 54 , the convex bodies 546 , 547 on the base 541 of the ammunition mechanism 54 are locked with the slots 511 and the long grooves 512 of the inner sleeve 51 respectively. Then push the ammunition mechanism 54 inward until the stopping surface 545 of the elastic piece 542 of the ammunition mechanism 54 is against the stopping part 522 of the rod 52 . Next put the outer sleeve 55 back in place and the rod 52 is moved upward during the put-back process. At the same time, the second end 302 of the transmission arm 30 turns back to the original position due to elasticity of the first spring 23 .
[0053] Refer to FIG. 27 and FIG. 28 , the inflator 1 of the present invention is in the automatic operation mode and the inflator 1 is used to inflate automatically. When aqueous solution passes the first water supply/vent hole 552 and/or the second water supply/vent hole 554 of the outer sleeve 55 and enters the inner sleeve 51 , the circular wall 543 of the ammunition mechanism 54 is dissolved after in contact with the aqueous solution and the elastic restriction on the elastic piece 542 is released. By elasticity of the elastic pieces, the second spring 53 is against and pushing the projecting flange 524 of the rod 52 downward to make the rod 52 move downward. Thus the stopping part 522 of the rod 52 pushes against the elastic piece 542 of the ammunition mechanism 54 and the elastic piece 542 is bent outward to enter the round hole 544 of the base 541 until the projecting flange 524 is against an upper part of the elastic piece 542 . During the process, the inner top surface of the long hole 521 of the rod 52 is against the second end 302 of the transmission arm 30 so that the transmission arm 30 is driven to rotate clockwise around the pivot shaft 31 , as the arrow B indicates in FIG. 28 . Then the first end 301 of the transmission arm 30 is moved upward to push against the movable seat 28 . Thus the needle-shaped shaft 20 is further driven to move upward and toward the cylinder housing 11 of the inflator body 10 so as to pierce the seal 41 of the gas cylinder 40 . The compressed gas in the gas cylinder 40 is flowing through the first channel 12 and the through hole 14 of the inflator body 10 and entering an object (not shown in figure) to be inflated. Thereby the inflator 1 works automatically.
[0054] In summary, the inflator 1 can be operated manually, automatically, or both on the same inflator 1 , as shown in FIG. 29 . Users have more choices (options).
[0055] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, and representative devices shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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An inflator used for inflation of an object such as life jackets, life boats, etc is revealed. A needle-shaped shaft is driven by a transmission arm to pierce a seal of a gas cylinder on the inflator. Thus compressed gas in the gas cylinder is released and flowing through the inflator to inflate the object. The needle-shaped shaft is arranged with two color areas for representing state of the inflator. The color area is displayed through windows of the inflator to show the state now. The inflator features on simple structure, convenience in use, reduced cost and precise movement.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to composite containers for refrigerated dough products, wherein the container is opened by separating a body ply of the container along a helically extending butt joint between the edges of the body ply, so as to form an opening through the container body for removal of the dough products.
[0002] In conventional containers of this type, an outer label ply wound about and adhesively attached to the paperboard body ply holds the butt joint closed against the pressure of the expanded dough in the container until the consumer opens the container. The opening of the container is typically initiated by peeling the label off; in many cases, the pressure of the expanded dough in the container then forces the butt joint open. Ideally the label is supposed to peel off in one piece so that the container will open properly, and so that printing on the label, such as instructions for baking the dough products, can be read.
[0003] One of the difficulties often encountered in conventional dough containers is that the label may not peel off in one piece. The strength of the adhesive bond between the label and body ply is dependent on numerous variables, some of which (e.g., the humidity or other storage conditions for the container prior to opening) are not under the control of the container designer. If the label fragments when the consumer begins peeling it off, then the container may be harder to open. Once the label fragments, it is often difficult to grasp the label again to resume peeling it. Additionally, the fragmenting of the label can render any printing on the label difficult to read.
[0004] Dough containers have been developed that incorporate a narrow tear strip that covers the helical butt joint and is pulled to initiate opening of the container. The tear strip is often interposed between the body ply and the label. This approach entails additional costs for the tear strip. Such narrow strips are also difficult to handle with automated web-handling equipment, and thus pose significant manufacturing challenges in terms of manipulating and accurately placing the narrow tear strip into the container structure, in alignment with the container butt joint, as part of the spiral winding process.
BRIEF SUMMARY OF THE INVENTION
[0005] The present invention addresses the above needs and achieves other advantages. In accordance with one embodiment of the invention, a composite container for refrigerated dough products comprises a body ply helically wrapped about an axis to form a tubular body, opposite edges of the helically wrapped body ply being juxtaposed to form a butt joint therebetween, the tubular body having a radially inner surface and a radially outer surface. The container can include a liner attached to the inner surface of the tubular body to provide a barrier against transmission of liquids and gases. A pair of end closures are respectively affixed to opposite ends of the tubular body. A label is helically wrapped about the tubular body and adhered to the outer surface thereof, the label comprising an inner layer adhered to the outer surface of the tubular body and an outer layer adhered to a radially outer surface of the inner layer. The label has an integrated easy-open feature that is built into the label structure.
[0006] More particularly, the inner layer of the label defines a helically extending line of weakness positioned in alignment with the butt joint of the body ply. The outer layer is coextensive with the inner layer and comprises a removable peel strip that is peelable from the inner layer, the peel strip extending helically along the tubular body straddling the line of weakness and butt joint. The peel strip is peelably adhered to the inner layer so as to prevent the line of weakness from severing until the peel strip is peeled from the inner layer, whereupon internal pressure from expansion of the refrigerated dough products is able to assist in severing the line of weakness in the inner layer and forcing the butt joint open to create an opening in the tubular body for removal of the dough products.
[0007] In one embodiment, the peel strip is a die-cut or laser-cut portion of the outer layer that is detachable from the remainder of the outer layer. When the peel strip is peeled off the inner layer of the label, the remainder of the outer layer remains adhered to the inner layer. Alternatively, the entire outer layer can constitute the peel strip and can be peeled off in one piece.
[0008] When the outer layer is die-cut or laser-cut to define the peel strip, different adhesives can be used for adhering the peel strip and the remainder of the outer layer to the inner layer. For example, a first adhesive that is relatively easily peelable can be used to adhere the peel strip to the inner layer, while a second adhesive that is relatively less peelable can be used to adhere the remainder of the outer layer to the inner layer. The peelable adhesive can comprise a pressure-sensitive adhesive (PSA) or high shear-strength adhesive. The second adhesive can comprise a laminating adhesive. The outer layer can also be cut to define a tab for the peel strip that can easily be grasped and pulled to peel the peel strip off the container. The tab is preferably free of adhesive so that it can be easily grasped.
[0009] Alternatively, when the entire outer layer comprises the peel strip, the entire outer layer is adhered to the inner layer with a peelable adhesive such as PSA.
[0010] The inner layer of the label can comprise a polymer film, with or without a paper backing. The paper backing can facilitate adhering the label to the body ply of the container and can also act as a strength component of the structure. The outer layer can comprise a polymer film. Various polymer materials can be used in the manufacture of the label, including but not limited to polyester, polyethylene, polypropylene, polyamide, and the like. If desired, the polymer film can be metallized (i.e., having a thin vapor-deposited layer of substantially pure metal such as aluminum applied to a surface of the film) for barrier performance and/or for imparting a metallic appearance to the film.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0011] Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
[0012] FIG. 1 is a perspective view of a container in accordance with one embodiment of the invention;
[0013] FIG. 2 is a cross-sectional view through line 2 - 2 in FIG. 1 ; and
[0014] FIG. 3 is a cross-sectional view through a label in accordance with one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present inventions now will be described more fully hereinafter with reference to the accompanying drawings in which some but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.
[0016] With reference to FIGS. 1 and 2 , a composite container 10 in accordance with one embodiment of the invention is illustrated. The container includes a tubular container body 12 and a pair of end closures 14 affixed to the opposite ends of the container body. The end closures can comprise metal ends that are double-seamed or crimp (false) seamed onto the ends of the container body, or any other suitable type of end closures affixed in any suitable manner to the container body. The tubular container body is formed by helically or spirally winding various flexible materials in the form of strips about a forming mandrel and adhering the successive layers of the materials to one another with suitable adhesives. The container body comprises a body ply 16 that forms the main structural component of the container body. The body ply can comprise paperboard or the like. The body ply 16 is helically wound such that a butt joint 18 is formed between the opposite edges of successive helical turns of the body ply. The container body advantageously includes an impervious liner ply 20 adhered to the radially inner surface of the body ply. The liner ply prevents or substantially impedes the transmission of liquids and/or gases or vapors therethrough.
[0017] A label 30 is helically wrapped about the body ply 16 and is adhered to the body ply with a suitable adhesive. The label is positioned with respect to the body ply such that each edge 32 of the label is not aligned with the butt joint 18 but rather is axially offset from the butt joint. The label comprises an inner layer 34 that is directly adhered to the body ply 16 , and an outer layer 36 that is adhered to a radially outer surface of the inner layer. The inner layer has a line of weakness 38 along which the inner layer can be severed relatively easily. The line of weakness can comprise a line of spaced-apart perforations or slits extending at least partially through the thickness of the inner layer, or a continuous slit through the inner layer. The line of weakness extends lengthwise along the label 30 , parallel to and spaced from each of the opposite edges 32 of the label. The outer layer 36 in the illustrated embodiment has a pair of die-cut or laser-cut lines 40 that extend substantially or completely through the thickness of the outer layer and that are spaced on opposite sides of and parallel to the line of weakness 38 in the inner layer. The portion of the outer layer 36 between the cut lines 40 comprises a peel strip 42 that is severable from the remainder of the outer layer. The peel strip 42 straddles the line of weakness 38 in the inner layer. The peel strip is adhered to the inner layer using an adhesive that permits the peel strip to be peeled from the inner layer relatively easily and in one piece, as further described below.
[0018] The label 30 is helically wound about the body ply 16 such that the line of weakness 38 in the inner layer of the label is aligned with the butt joint 18 of the body ply, as best seen in FIG. 2 . Accordingly, the peel strip 42 straddles the butt joint 18 . As long as the peel strip is still adhered to the inner layer 34 of the label, the peel strip prevents the inner layer from severing along the line of weakness 38 , and thus prevents the butt joint 18 from coming apart. However, when the peel strip is peeled off, the internal pressure of expanded dough within the container body forces the butt joint apart and the line of weakness 38 fractures so that the body ply can be separated at the butt joint to create an opening through which the dough products are removed. Alternatively, removal of the peel strip exposes the line of weakness 38 in the inner layer 34 to allow the container to be opened by application of force to the line of weakness, such as by pressing a finger or implement against the inner layer at the line of weakness.
[0019] With reference to FIG. 3 , a particular label structure in accordance with one embodiment of the invention is illustrated. The label 30 has an inner layer 34 that includes a paper backing layer 44 that facilitates adhering the label to the paperboard body ply of a container body. The paper layer 44 can also supply structural strength to the label. The inner layer further comprises a polymer film layer 46 adhered to the paper backing layer using a suitable adhesive layer 48 . The line of weakness 38 extends through the thickness of the paper backing layer 44 and at least partially through the thickness of the polymer film layer 46 . The outer layer 36 comprises a polymer film, and a portion of the outer layer forms the peel strip 42 that is severable from the remainder of the outer layer. Suitable examples of polymer films for the outer layer include but are not limited to polyester such as polyethylene terephthalate (PET), metallized PET, oriented polypropylene (OPP), metallized OPP, or the like. If desired for barrier and/or appearance reasons, the outer layer can be metallized by vapor-depositing a thin layer of substantially pure metal such as aluminum onto one surface of the film.
[0020] The peel strip 42 is adhered to the inner layer using a peelable adhesive 50 . Advantageously, the peel strip 42 has a tab 52 that is die-cut or laser-cut through the thickness of the outer layer 36 . The tab 52 can be free of the adhesive 50 to permit the tab to be grasped and pulled to initiate peeling of the peel strip. The remainder of the outer layer 36 outside the peel strip can be adhered to the inner layer using an adhesive that differs from the peelable adhesive 50 , if desired. For example, the remainder of the outer layer can be adhered to the inner layer using a non-peelable adhesive.
[0021] A suitable peelable adhesive for the peel strip 42 can comprise a pressure-sensitive adhesive (PSA). Pressure-sensitive adhesives are often based on non-crosslinked rubber adhesives in a latex emulsion or solvent-borne form, or can comprise acrylic and methacrylate adhesives, styrene copolymers (SIS/SBS), and silicones. Acrylic adhesives are known for excellent environmental resistance and fast-setting time when compared with other resin systems. Acrylic pressure-sensitive adhesives often use an acrylate system. Natural rubber, synthetic rubber, or elastomer sealants and adhesives can be based on a variety of systems such as silicone, polyurethane, chloroprene, butyl, polybutadiene, isoprene, or neoprene. When the laminate of the invention is to be used for food packaging, the pressure-sensitive adhesive generally must be a food-grade composition. Various pressure-sensitive adhesives are approved by the U.S. Food and Drug Administration for use in food packaging, as regulated by 21 CFR Part 175. A preferred food-grade pressure-sensitive adhesive for use in the present invention is Jonbond 743 available from Bostik Findley. Additives (e.g., particulates or the like) can be added to the pressure-sensitive adhesive to reduce the tenacity of the bond, if desired.
[0022] A suitable non-peelable adhesive for the remainder of the outer layer 36 can comprise a laminating adhesive formulated to bond the layers together with a substantially higher bond strength than the first adhesive such that the layers bonded together by the second adhesive are not readily peelable from each other. The laminating adhesive can be, for example, a two-component polyurethane adhesive system, such as Tycel 7900/7283 available from Henkel. However, the invention is not limited to any particular adhesives, and various compositions can be used while still achieving the objectives and advantages of the invention.
[0023] To open the container 10 , the tab 52 of the peel strip 42 is grasped and pulled outwardly and generally in the helical direction along which the strip is wound, so as to peel the strip off the underlying layer 34 of the label. Once the peel strip is peeled off, the internal pressure of expanded dough within the container body forces the butt joint 18 of the body ply 16 apart and the line of weakness 38 in the inner layer 34 of the label fractures so that the body ply 16 can be separated at the butt joint to create an opening through which the dough products are removed. Advantageously, the majority of the label outer layer 36 remains intact on the can body so that baking instructions or other information printed thereon can still be read. The peel strength between the peel strip and the underlying inner layer of the label can be closely controlled by suitable formulation of the peelable adhesive 50 so that the peel strip can be easily peeled off in one piece. Thus, the invention provides a significant improvement over existing composite can constructions in which an attempt to peel off the entire label from the paperboard can body substantially in one piece often fails when the label fragments and it is then difficult to re-grasp the label to continue peeling.
[0024] Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
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A composite container for refrigerated dough products comprises a body ply helically wrapped about an axis to form a tubular body, opposite edges of the helically wrapped body ply being juxtaposed to form a butt joint therebetween. A label is helically wrapped about and adhered to the tubular body, the label comprising an inner layer adhered to the outer surface of the tubular body and an outer layer adhered to a radially outer surface of the inner layer. The inner layer defines a helically extending line of weakness positioned in alignment with the butt joint of the body ply. The outer layer comprises a removable peel strip that is peelable from the inner layer, the peel strip extending helically along the tubular body straddling the line of weakness and butt joint.
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RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. application Ser. No. 09/516,645, filed Mar. 1, 2000, now pending.
FIELD OF THE INVENTION
[0002] This invention relates generally to medical monitoring devices. More particularly the present invention is a system and method for monitoring physiologic variables of an individual in a wireless manner over the Internet.
BACKGROUND OF THE INVENTION
[0003] Monitoring devices of various types to monitor patient physiologic conditions have long been in the medical community. A plethora of testing and monitoring equipment have moved out of the hospital into the doctors' offices and, in some cases, have even progressed into home monitoring systems.
[0004] While these devices have clearly been extremely useful, many of these devices require that a patient be located at home, or in close proximity to a telephone system, such that results of the monitoring can be transmitted over the public switched telephone network (PSTN) to some form of analysis center. Such devices do not necessarily lend themselves to the mobile life style in which many individuals find themselves.
[0005] For example, it is difficult for a busy person to stop in the middle of the day, proceed to a monitoring station (whether it be at home or in some office) take the appropriate measurements, and then proceed with the business of the day. This simply is not possible and adds a level of stress to the already stressful situation of having to monitor physiologic signals.
[0006] What would truly be useful is a system for monitoring physiologic characteristics of an individual on a mobile basis. Such a system would require little if any interaction with a monitoring device. Signals that are collected would then be sent in an automated fashion to an analysis center or a physician's office. Alternatively, a physician could interrogate the system worn by a patient while the patient is mobile to obtain the physiologic signals of interest.
SUMMARY OF THE INVENTION
[0007] It is therefore an objective of the present invention to monitor remotely the physiologic variables from any patient.
[0008] It is a further objective of the present invention to monitor physiologic variables of a patient (regardless of whether the patient is ambulatory or stationary) when the physician is remote from the patient.
[0009] It is yet another objective of the present invention to monitor physiologic variables using the Internet.
[0010] It is a further objective of the present invention to monitor physiologic variables in a wireless manner within a generalized geographic area.
[0011] It is a further objective of the present invention to monitor physiologic variables without the patient having to proceed to any centralized location in a geographic area.
[0012] It is a further objective of the present invention to monitor a patient anywhere in the coverage map of a cellular- or satellite-based telephone network.
[0013] It is a further objective of the present invention to have data relating to physiologic variables automatically sent over a wireless network to a physician or other medical caregiver using the Internet.
[0014] It is a further objective of the present invention to allow a physician to interrogate the physiologic monitoring device in a wireless fashion whenever the physician needs to take such physiologic measurements.
[0015] It is a further objective of the present invention to provide voice communications in a wireless mode to and from a medical caregiver.
[0016] It is a further objective of the present invention to have a “panic” function which allows both a user to send a panic message to a physician or allows a physician, after monitoring physiologic signals, to send a voice “advice” message to the patient.
[0017] It is a further objective of the present invention to accomplish all the above objectives using a device that is worn by the patient in a relatively unobtrusive fashion.
[0018] These and other objectives of the present invention will become apparent to those skilled in the art from a review of the specification that follows. The words physician, doctor, healthcare provider, caregiver, medical care provider, care provider, etc. as used herein shall mean the person with responsibility for the care of the patient.
[0019] The present invention is a wireless Internet bio-telemetry monitoring system (WIBMS). The system makes use of a variety of bio-sensors which are generally used to detect signals or variables from the human body. One such sensor system is described in U.S. Pat. No. 5,673,692 whose characteristics are incorporated herein by reference in their entirety. However, this particular sensor is not meant as a limitation. Literally any type of bio-sensor or physical sensor generally known to those skilled in the art will find use in the present invention. Further, the sensor of U.S. Pat. No. 5,673,692 can be modified to include a microphone so that voice of the patient can be transmitted using the system of the present invention.
[0020] The sensors are connected to a combination data acquisition module and wireless transceiver which is worn by the patient. This combination sensor package and communication unit is known as the Multi-Variable Patient Monitor, or MVPM. The MVPM is battery-powered. The batteries that power the MVPM can be single use batteries or rechargeable batteries. Further, when the individual is in a mobile state, the batteries of the MVPM can be recharged by plugging them into a car or into normal wall current. This allows the individual to constantly keep batteries charged in the MVPM whether the individual is mobile or in an office.
[0021] As noted above, the MVPM is a patient-worn device which allows maximum mobility to the particular patient.
[0022] The MVPM has the ability, on a periodic basis, to interrogate bio-sensors worn by the patient and to store physiologic signals from the bio-sensors. On a periodic basic, the MVPM calls into a wireless network and transmits the bio-sensor information to the wireless network. The bio-sensor information then proceeds from the wireless network to the Internet and then to an analysis center or a data warehouse which receives and stores the information for subsequent analysis.
[0023] The MVPM also comprises emergency Panic buttons whereby a patient can direct the transceiver portion of the MVPM automatically to call 911 or a designated medical caregiver in the event of a medical emergency.
[0024] As noted above, the MVPM is connected to various sensors. Therefore, the MVPM has sensor condition detection circuitry, connected to a lamp and/or message display, which allows a user to determine that all sensors are operating correctly. When a sensor receives a particular signal which is out of the normal physiologic range for the particular patient, an “alarm” (sound, lamp, or display) is actuated such that the patient can understand that a significant medical event is occurring. Simultaneously with such an alarm, a time-tagged signal is sent to the medical care provider terminal notifying the caregiver of the event.
[0025] Thus, when the MVPM is functioning in a data acquisition mode, it receives information from the sensors, performs some limited analysis on that information, and notifies the patient and caregiver of any non-standard conditions.
[0026] When the MVPM periodically sends stored signals from the sensors over the network, a unique identifier is encoded with any such data that are sent such that the data can be directly associated with a particular patient.
[0027] Once data are received at the Host server, the data are stored with appropriate privacy and security issues dealt with in a manner known to those skilled in the art.
[0028] The MVPM also comprises circuitry for self-testing its various sub-systems and sensors and for communicating any trouble shooting information directly to the patient in the event that the sensor becomes dysfunctional. Further, such trouble-shooting data can also be sent in a wireless manner to the central server such that trouble-shooting can take place remotely, or in the alternative, a new MVPM unit can be sent to the patient.
[0029] The MVPM also can be preset before giving it to a patient. In addition, and depending upon the biological signals being monitored, “Alarm” variables can be set remotely by the health care provider over the Internet and subsequently via the wireless network and can be based upon the caregiver's knowledge of the condition of the patient. Such remote setting also occurs via the two-way communication of the transceiver portion of the MVPM.
[0030] Communication rates of the WIBMS are optimized to fit wireless telephone communications calling and rate plans and to minimize the cost and air time usage.
[0031] Using the WIBMS, the following types of monitoring can take place:
[0032] digitally sampled electrocardiogram
[0033] patient body temperature
[0034] pulse oximetry
[0035] pulse rate
[0036] other physiologic variables, such as blood glucose, respiration, etc.
[0037] various pre set alarm conditions or physiologic variables
[0038] event occurrences per patient action/input.
[0039] As also noted above, the MVPM has bi-directional communication capability and has the capability to transmit a “panic” signal over wireless network, to initiate 911 calls, to allow patient-initiated voice-calling over a cellular telephone link, and to allow medical provider voice-calling to the patient over a cellular telephone link.
[0040] Other characteristics of the present invention will become apparent to those skilled in the art by review of the detailed description of the invention that follows.
BRIEF DESCRIPTION OF THE FIGURES
[0041] [0041]FIG. 1 illustrates the Wireless Internet Bio-telemetry System.
[0042] [0042]FIG. 2 illustrates the Multi-Variable Patient Monitoring portion of the WIBMS.
[0043] [0043]FIG. 3 illustrates a front panel drawing of the multi-variable patient monitor portion of the WIBMS.
DETAILED DESCRIPTION OF THE INVENTION
[0044] As noted above, the present invention is a Wireless Internet Bio-telemetry System comprising a patient monitoring device which is conveniently worn by a patient and which comprises sensors together with a combination network that allows biologic and physical signals to be reviewed and acted upon by a health care provider who is located remotely from the patient. Data from the monitoring system are then sent in a wireless mode over a cellular network to the Internet and then to a data analysis center (Host) for retrieval and review by a medical care provider.
[0045] In FIG. 1, the Wireless Internet Bio-telemetry System (WIBMS) is illustrated. Patient 10 wears a Multi-Variable Patient Monitor (MVPM) 12 . This MVPM monitors a variety of bio-signals as further noted below. The MVPM 12 has the capability of communicating bi-directionally via voice 14 in much the same manner as a normal cellular telephone. However, in addition, the MVPM sends data 16 on a periodic basis, or in some cases on a continuous, Real-time basis, over a cellular network to the Internet and then to the Host. It also receives requests for data 18 which may be made by a medical care provider over the Internet using wireless or PSTN connections to the Host.
[0046] Wireless Network 20 is the normal digital cellular telephone network currently in use. This type of network is not however meant as a limitation. For example, PCS networks and other types of wireless loop networks are also suitable for transmission of the voice and data envisioned by the present invention. It will be apparent to those skilled in the art that such other networks can satisfy the requirements for transmission of voice 14 , data 16 , and request for data 18 to and from patient 10 .
[0047] Once physiologic data is transmitted over network 20 , it is then transmitted via an Interworking Function (IWF)® 24 (for example), preferably to the Internet 26 for subsequent retrieval and review by a medical care provider at the medical care provider terminal 28 . In addition, data can be archived (again via the Internet 26 ) to a data archiving and distribution facility 30 (“Host”). Data that are archived are stored in a private and secure fashion using techniques known in the art that allow secure transmission and access limitations.
[0048] In the event that voice traffic is being transmitted from the patient, a cellular network 20 connects to the public telephone network 22 to communicate with the medical care provider (or 911 operator). Although network 22 will usually be a PSTN, other non-switched connections, such as ISDN, DSL, satellite, and cable modem connections can also be used. Again, in this fashion, the medical care provider can receive voice information from the patient 10 and provide voice feedback to the patient as well. Similarly, the medical care provider terminal 28 can both receive traffic from the WIBMS as well as transmit requests for data and configuration changes to the Host 30 . In turn, the Host 30 communicates these requests to the MVPM 12 , receives data, and provides it back to the caregiver over the Internet 26 and PSTN 22 . All data that are received from the MVPM (and the network) can be archived by the Host 30 so that the data from the specific patient can be monitored over time and so that data can be analyzed for trends that can be used for alarm setting and data collection protocols. All such data are transmitted in an encrypted and possibly non-attributable form with limited access using methods known in the art so that patient privacy and confidentiality is maintained.
[0049] In FIG. 2, the Multi-Variable Patient Monitor (MVPM ) is further illustrated. The MVPM (initially noted as 12 in FIG. 1) comprises, without limitation a number of sensors. For example, blood oxygen saturation level (Sp02) 32 , pulse rate 34 , body temperature 36 , and Electrocardiogram (ECG) 37 can all be measured by sensors associated with the appropriate measurement. Signals from the sensors are picked up and stored by the Data Acquisition Module 42 . This information from the sensors 44 is then sent to the CDMA (although other module types may also be used) telephone module 56 of the MVPM for subsequent transmission.
[0050] In addition simply to acquiring data, the Data Acquisition Module 42 also notes any Alarm condition 46 and transmits that information via CDMA module 56 over the Internet 26 to the Host 30 where it can be used to notify a medical care provider terminal 28 . Also, Data Acquisition Module 42 transmits the time of day 48 with any transmission of alarm information or sensor information. As noted earlier, the various alarm conditions can be reconfigured by the health care provider over the internet and the wireless network without any patient interaction.
[0051] The CDMA module is, for example, one manufactured by Qualcomm® for use within a cellular telephone. That information, in connection with 3Com QuickConnect® Internet connection software and 3Com Interworking Function® (IWF) device are all used to connect to, for example, the Sprint PCS® digital cellular telephone network. The characteristics of the Qualcomm® CDMA cellular phone module, the 3Com QuickConnect® Internet connection software and the 3Com IWF® device are all incorporated herein by reference in their entirety.
[0052] The CDMA module 56 allows for digital cellular communications at 14.4 kbps which is sufficient for the transmission of the bio-sensor information contemplated by the present invention. This is not however meant as a limitation, since faster wireless modulated speeds surely will become available. All of these faster connections will be suitable for transmission of the data and voice of the present invention.
[0053] Data that are collected are encrypted to prevent eavesdropping or tampering with any commands. All information and data are Internet Protocol (IP) compatible and contain error checking to insure data accuracy.
[0054] The Data Acquisition Module 42 continuously monitors, for example and without limitation, Sp02 32 , pulse rate 34 , body temperature 36 , and ECG 37 , and transmits that information from the MVPM to the Host over the Internet. Data can be transmitted in real time and/or can be stored and forwarded depending upon the collection protocol ordered by the medical service provider. Similarly, temperature measurement, pulse oximetry, and pulse rate all can be collected and transmitted continuously during various periods of time or can be collected stored and burst transmitted over the wireless network as required.
[0055] The Data Acquisition Module contains logic that allows an “Alarm” 45 condition to be transmitted at any time whenever the alarm criteria are fulfilled. Further, any alarm condition can be reset by the health care provider via the Host over the Internet and thence over the wireless network. Any “Alert” 47 signals that, for example, a sensor is turned off, broken, or has become disconnected is used to alert the patient to take appropriate action to replace or repair the sensor. While such information is transmitted by the Data Acquisition Module 42 to the CDMA module 56 and thence to the wireless network, a voice synthesizer contained in the Data Acquisition Module 42 also provides a voice alert via speaker 60 to the patient that a particular Alarm 45 or Alert 47 condition has occurred.
[0056] As noted earlier, the patient also has the ability to speed dial 911 38 as needed. Data Acquisition Module 42 also processes this information and passes it over a voice connection 50 to the CDMA module 56 and thereafter to the Wireless Network 20 for communication. The patient also has the ability to call the medical care provider on a non-emergency basis. This is accomplished by a dedicated function speed dial “button” 40 on the MVPM. Again, Data Acquisition Module 42 processes voice information 50 and passes that information to the CDMA module 56 .
[0057] As noted above, the medical service provider or other organization that is responsible for monitoring and maintaining the MVPM can interrogate the Data Acquisition Module of the MVPM through the Host. A request for information flows from the medical care provider terminal over the Internet to the Host. The Host initiates a voice call to the MVPM which triggers the MVPM to establish a data call back to the host. Alternatively, the Data Acquisition Module can be reconfigured 54 to update communications capabilities, or to change the protocol for monitoring physiologic data and to change or modify alarm limits.
[0058] The system of the present invention includes the network and can allow any number of MVPMs. In the same fashion that a cellular telephone has a roaming capability, so does the MVPM, therefore allowing the continual transmitting and updating of physiologic data.
[0059] In FIG. 3, a front panel for the MVPM is illustrated. The MVPM has a time of day 72 , battery capacity 74 and signal strength 75 indicators which allow the wearer to determine if recharging or battery replacement is required and if the signal strength of the communications channel is adequate to support reliable communications. The panel 70 is dimensioned to be small and unobtrusive so that the wearer will not be disproportionately burdened by carrying the MPVM. The panel has several speed dialing preset buttons that allow emergency calls to 911 76 to be made and to call the care provider 78 simply by pressing a button. Similarly, if the wearer determines that an “Event” has occurred such as faintness, shortness of breath, irregular heartbeat, or other symptoms, this event button 80 can be pressed causing data be stored and transmitted for a preset period of time. A power indicator 82 , such as a flashing green LED, is part of the panel so that the user can determine that power is “On.” Sensor lamp 86 , such as a yellow LED, is on the panel as well to inform the user when a sensor has potentially become disconnected or has otherwise malfunctioned. An Alarm lamp 84 , such as a red LED, together with an audible signal is also present on the control panel so that the patient can have both a visual and audible warning of any Alarm condition that might exist.
[0060] The panel design shown in this FIG. 3 is by way of illustration only. It will be apparent to those skilled in the art that other panel designs are possible so long as the information is presented in an easy and usable way for the patient.
[0061] As noted above, the communications link between the MVPM and the care provider via the PSTN or the Internet is a bi-directional link. Thus, requests for data from a workstation located at the care provider's facility can be transmitted through the Internet to the Host which contacts the MVPM. Data transfer (real time or stored) can be transferred from the MVPM through the Internet to various data bases for analysis or storage. Data from the MVPM can be transferred in real time to or from the storage site through the Internet to other authorized users such as insurance providers. Alarm information is transferred from the MVPM to the care provider through the Internet. When a sensor malfunctions or becomes disconnected from the wearer, a “sensor off” signal is sent from the MVPM and transferred over the Internet to the medical care provider terminal so that such information is available and so that the caregiver can know when and if it is repaired. Event occurrences, as described earlier, may also be transferred to the Medical Care Provider through the Host. The medical care provider terminal can transmit a communication to disarm or reset alarms in the MVPM through the Internet as necessary. Further, protocols relating to when and the type of bio-signal to be measured can be sent from the medical provider over the Internet to the Host which transmits this information to the MVPM. The personal emergency button for use by the user to activate a call to the Medical Care Provider gives voice communication from the MVPM to and from the care provider. Real-time clock resets or any other variations in configuration of the MVPM can be transmitted from the Medical Care Provider over the Internet to the Host which transfers this information to the MVPM using the Internet and the Wireless Network.
[0062] A Wireless Internet Bio-telemetry System has now been illustrated. It is important to note that, while a particular wireless protocol was described in the preferred embodiment (i.e., CDMA) this is not meant as a limitation. For example, other protocols for communication in a digital wireless network (such as a GSM or a TDMA network) will be equally suitable for use with the present invention. It is also anticipated that other types of wireless networks will also be suitable such as satellite networks and wireless local loop networks. The requirement is that there be two-way communication with the MVPM and that Internet connectivity flow as part of the communication system to allow interaction between health care provider and the patient through voice and data links using the Internet. It will be apparent to those skilled in the art that other variations in, for example and without limitation, the type of network, the types of sensors, and the configuration of the patient monitor can be accomplished without departing from the scope of the invention as disclosed.
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The patient worn monitoring device wirelessly monitors patient variables and connects to a variety of sensors with at least one microphone and speaker for voice communications. The patient-worn device connects to a wireless network and thence to the Internet for transmitting data to a Host for access by a health care provider. The health care provider communicates with the patient worn device via the Host over the Internet and the wireless network to send instructions to the patient-worn monitoring unit and to communicate over the wireless network via voice with the patient. The health care provider can also flexibly reconfigure the patent-worn monitoring device to change data collection parameters for the sensors worn by the patient. When an alarm limit is exceeded and detected by the sensors, it is transmitted over the wireless network and thence over the Internet to the Host computer for use by the health care provider.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an information signal selecting apparatus for transmitting an electrical video signal from a plurality of transmitting means to each of a plurality of receiving means and for selectively receiving the transmitted video signal by each receiving means.
2. Description of the Prior Art
In a monitoring television system used as an information transmission system, at least one television monitor and one video recorder are connected through an electronic matrix switch to a plurality of television cameras and a plurality of transmission lines, for selectively connecting at least one camera for display through the monitor and record another camera signal onto the video recorder. The electronic matrix switch is used also for sequentially connecting a plurality of the television cameras to a monitor and independently recording other camera signals in sequence onto the video recorder. Such electronic matrix switch uses a centralized controller for the selection of all the outputs, be it a single television camera or sequencing multiple television cameras, for displaying on the monitor or recording independently any single or multiple camera signals in sequence onto the video recorder.
However, in a well known electronic matrix switching used for a system of this kind, as the number of television cameras and monitors or video recorders increase, the centralized switching and coordination become more complex, requiring larger software and hardware capacity to control the multiple individual independent outputs. Thereby, as the system grows, the matrix switching control becomes costly and inefficient.
Further, well known electronic matrix switches do not employ synchronized switching and the selected images displayed on a monitor are often disturbed during and immediately after the switching-over from one television camera to another.
In such an information switching system, it is preferable to mutually lock the internal synchronizing signals of a plurality of television cameras and the electronic switching time to an external synchronizing signal, in order to prevent the picture image on the monitor from being disturbed during and immediately after the switching operation from one television camera to another.
As the one of the devices for synchronizing a plurality of television cameras, there is known an apparatus for transmitting a vertical synchronizing signal and a horizontal synchronizing signal or composite synchronizing signal used in a television system. Another known apparatus is an apparatus for transmitting a vertical drive signal and a horizontal drive signal, and driving the television camera and its deflection circuits by the transmitted vertical drive signal, and the horizontal drive signal.
In any of the above known devices of the type under discussion, as the transmitted synchronizing signal itself is a train of pulses, which can be easily influenced by noise, the transmission of a synchronizing signal requires the use of a coaxial cable with its high shielding effect, which makes it costly for systems with a plurality of television cameras.
Another known apparatus for synchronizing a plurality of television cameras, is an apparatus for transmitting an external synchronizing signal from an external synchronizing generator to the television cameras by injecting the external synchronizing signal into the video signal transmission line and locking an internal synchronizing signal generator of the television camera by means of the transmitted external synchronizing signal. Such an apparatus is disclosed in U.S. Pat. No. 4,603,352 the contents of which are incorporated herein by reference.
SUMMARY OF THE INVENTION
An object of the present invention is to eliminate the centralized controller from controlling all the switching operations of all the independent outputs and to make it simple and easy to control the selection independently from any of the outputs by providing each independent output with individual controller. Another object of present invention is to provide smooth synchronized switching over from one transmitting means to another without any disturbance to the reproduced images, even when a large number of transmitting means and receiving means are involved.
Yet another object of the present invention is to provide each individual controller with individual remote controlling of any and all television cameras connected to the matrix switcher.
An apparatus for selecting information signals according to the present invention comprises a plurality of transmitting means, each processing an electrical information signal including a video signal a plurality of receiving means for selectively receiving the information signal, a plurality of information transmission lines for connecting each receiving means with the plurality of transmitting means, and an external synchronizing signal generating means for generating an external synchronizing signal and applying the same to the plurality of transmitting means and to the plurality of receiving means.
Each transmitting means includes a circuit for feeding the information signal to the plurality of receiving means through the corresponding information transmission lines. Each receiving means includes a selection circuit for selecting one of the plurality of corresponding information transmission lines or switching over from one information transmission line to another. The selection and the switching-over timing of the information signals in the plurality of the receiving means is synchronized with the external synchronizing signal.
Each information transmission line corresponds to a combination of the receiving means and transmitting means, and each transmitting means transmits an information signal to the plurality of receiving means through the corresponding information transmission lines. The information signals from the plurality of transmitting means are inputted to each receiving means. Therefore, each receiving means can be connected to any one of the plurality of transmitting means for receiving an information signal by selecting one of the plurality of corresponding information transmission lines.
The switching-over of the information signals is timed by an external synchronizing signal to occur precisely along with the vertical synchronizing timing, thereby providing an uninterrupted synchronizing process and the reproduced video images are not disturbed during and immediately after the switch-on or switch-over operation.
According to the present invention, each receiving means is connected to a plurality of transmitting means through a plurality of corresponding information transmission lines, and the switch-over timing of the information signals in the plurality of receiving means is synchronized with the external synchronizing signal. Therefore, even though a large number of transmitting means and receiving means are involved, any of the information transmission lines connecting the transmitting means and the receiving means can be synchronously switched on or switched-over by a simple apparatus without disturbing the reproduced video images.
The apparatus of the present invention further comprises a plurality of video signal generating means, such as television cameras, respectively connected to the plurality of transmitting means for feeding the video signal to the corresponding transmitting means. Each video signal generating means includes an internal synchronizing signal generation circuit for generating an internal synchronizing signal synchronized with the external synchronizing signal.
According to the present invention, the external synchronizing signal is a pulse signal having a voltage level higher than the maximum voltage level or lower than the minimum voltage level of the video signal. Each transmitting means includes a circuit for injecting the external synchronizing signal into a transmission line connected to the video signal generating means. Each video signal generating means further includes a level comparator circuit for extracting the external synchronizing signal by comparing the signal level of the external synchronizing pulse signal with a reference signal having a predetermined voltage and feeds the extracted external synchronizing signal to the internal synchronizing signal generation circuit. Since the external synchronizing pulse is generated during the vertical blanking period of the video signal, the external synchronizing signal can be transmitted commonly through the same transmission line used for transmitting the video signal without affecting the video signal.
In an embodiment, each transmitting means may preferably include a circuit for removing the external synchronizing signal from the output signal fed through the corresponding information transmission lines to the receiving means. Thereby, since the external synchronizing signal can be removed from the video signal transmitted through the information transmission lines, the external synchronizing signal does not influence the receiving means input circuits and the video signal can be flawlessly received.
In an embodiment, each video signal generating means may further include an identification code generation circuit for generating an identification code signal corresponding to an identification number, respectively allotted to each video signal generating means, for injecting the identification code signal into a video signal fed to the transmitting means. At least one receiving means further includes an identification code signal processing means for extracting the identification code signal from the output signal of the selection circuit and for feeding a signal corresponding to the extracted identification code signal to the video signal processing means.
The identification code signal processing means preferably includes a memory for storing identification data for each allotted code number, an extraction circuit for extracting the identification code signal from the output signal of the selection circuit and to generate a decoded signal by decoding the extracted identification code signal, and a controller for retrieving the identification data of the decoded signal from the memory and for superimposing the retrieved identification data onto the video signal. Thereby, the processed video signal can be identified by the identification code signal processing means for verification of the video generating means which is transmitting the video signal, thereby, providing the basis for error free controlling of the video generating means.
The apparatus of the present invention may further comprise a control means for generating and feeding a control signal combining a coded control command along with the identification code signal, decoded and fed by the extraction circuit, for controlling the video signal generating means. The coded control command is fed to the video signal generating means for operating the video signal generating means only when the identification code signal, combined into the control signal, corresponds to the identification number allotted to the video signal generating means being controlled. Thereby, only a specific video signal generating means, having its identification code extracted and decoded by the control means during the controlling process, can have its allotted identification number coincide with the identification code extracted from the control signal fed from the control means. Therefore, any specific video signal generating means can be verifiable and accurately controlled.
The control signal is injected into a video transmission line connecting the video signal generating means to the transmitting means during the vertical blanking period of the video signal, and the video signal generating means may further include a control signal processing means for extracting the control signal from the video transmission line and for feeding the extracted control signal only when the identification code signal, which is combined into the control signal, corresponds to the identification code allotted to it. Since the control signals are transmitted during the blanking period of the video signal they can be transmitted to the video signal generating means from the transmitting means through a common transmission line without disturbing the video signal.
Each transmitting means preferably further includes a signal mixing means for generating a mixed signal composed of a video signal and an audio signal by injecting the audio signal into the video signal and feeding the mixed signal to a plurality of corresponding information transmission lines. Thereby, both the mixed video signal and the audio signal can be transmitted between the transmitting means and the receiving means through a common information transmission line.
Each video signal generating means preferably further includes a signal mixing means for generating a mixed signal composed of a video signal and an audio signal by injecting the audio signal into the video signal and feeding the mixed signal to the corresponding transmitting means. Thereby, both the video signal and the audio signal can be transmitted between the video signal generating means and the transmitting means through a common transmission line.
Each receiving means may further include an audio signal retrieving means for outputting an audio signal by retrieving the audio from the mixed signal.
Each receiving means may further include a control signal driver for feeding the control signal to the plurality of information transmission lines in the reverse direction to the propagation direction of the video signal. Each transmitting means preferably further includes a control signal extractor for extracting the control signal from the information transmission line and for feeding the extracted control signal to the corresponding video signal generating means. Thereby, both the video signal and the control signal can be transmitted from the receiving means to the video signal generating means through the transmitting means and through a common transmission line.
Each transmitting means can feed the control signal to the video signal generating means by injecting the control signal into the video transmission line connecting the transmitting means to the video signal generating means or through a separate control transmission line.
The apparatus of the present invention may comprise an individual control means included in each receiving means for individually controlling the selection circuits, and a master controller for supervising or coordinating the controlling state of all control means in order to prevent any conflicting or prohibited selection.
The apparatus of the present invention may comprise an individual control means in each receiving means for individually controlling the video signal generating means through the information transmission line, and a master controller for supervising the controlling state of all control means in order to prevent any conflicting, prohibited or error control command.
In addition, the master controller can override and control each of the control circuits of the receiving means and each of the video signal generating means connected to the plurality of transmission lines.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing objects and features of the present invention will become apparent from the following description of preferred embodiments of the invention with reference to the accompanying drawings, in which:
FIG. 1 is a block diagram of an apparatus for selecting information signals of a preferred embodiment of the present invention;
FIG. 2 (A-C) shows waveforms of a signal transmitted by the apparatus of FIG. 1;
FIG. 3 is a block diagram of an electric circuit showing a transmitting apparatus of a preferred embodiment of the apparatus shown in FIG. 1;
FIG. 4 is a block diagram of an electric circuit showing a television camera of a preferred embodiment of the apparatus shown in FIG. 1;
FIG. 5 (A-C) shows waveforms of an identification code signal;
FIG. 6 and 6A is a block diagram of a code extraction circuit of a preferred embodiment of the television camera shown in FIG. 4;
FIG. 6A is a block diagram of a code extraction circuit of a modified embodiment;
FIG. 7 is a block diagram of an electric circuit showing a receiving apparatus of a preferred embodiment of the apparatus shown in FIG. 1;
FIG. 8 is a block diagram of an apparatus for selecting information signals of another preferred embodiment of the present invention;
FIG. 9 is a block diagram of an apparatus for selecting information signals of a further preferred embodiment of the present invention;
FIG. 10 is a block diagram of an electric circuit showing a receiving apparatus of a preferred embodiment of the apparatus shown in FIG. 9;
FIG. 11 is a block diagram of an apparatus for selecting information signals of still further preferred embodiment of the present invention; and
FIG. 12 is a block diagram of an apparatus for selecting information signals of yet further preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows an information signal selecting apparatus 10 for selecting information signals as a preferred embodiment when applying the present invention to a closed circuit television system such as a monitoring system. An information signal includes at least a video signal. In the following description, the video signal may be a multiplex video signal or a composite video signal.
Referring to FIG. 1, the information signal selecting apparatus 10 comprises a plurality of transmitting apparatuses 12 for transmitting information as an electrical information signal, a plurality of receiving apparatuses 14 for receiving the transmitted information signal, a plurality of information transmission lines 16 for carrying the information signal, a plurality of television cameras 18 respectively connected to the transmitting apparatuses 12 for outputting a video signal to the corresponding transmitting apparatuses 12, an external synchronizing signal generation circuit 20 for synchronizing the television cameras and the control circuits, and a control circuit 22 for outputting a control command to the transmitting apparatus 12 and the receiving apparatuses 14.
Each information transmission line 16 corresponds to a combination of the transmitting apparatus 12 and the receiving apparatus 14. Therefore, each transmitting apparatus 12 is connected to all the receiving apparatuses 14 through the plurality of information transmission lines 16 extending from the transmitting apparatus, while each receiving apparatus 14 is connected to all the transmitting apparatuses 12 through the plurality of information transmission lines 16 extending from the receiving apparatus. Thus, the number of arranged information transmission lines 16 corresponds to the product of the number of transmitting apparatus 12 and the number of receiving apparatuses 14.
The transmitting apparatuses 12, the receiving apparatuses 14, the information transmission lines 16, the external synchronizing signal generation circuit 20 and the control circuit 22 are mounted in a monitoring room. On the other hand, the television cameras 18 are mounted randomly anywhere for monitoring near or remote locations. Each of the transmitting apparatus 12 are connected through a video signal transmission line 24, such as a coaxial cable, to a television camera 18.
A transmission circuit 26 of each transmitting apparatus 12 receives a video signal from the corresponding television camera 18 through the video signal transmission lines 24 and feeds the received signal to a driver 28 for transmitting the received video signal as an information signal to all receiving apparatuses 14 through the information transmission lines 16. Thus, the driver 28 acts as a distribution circuit for distributing information signals to the plurality of information transmission lines 16. The driver 28 can be a circuit constructed from a readily available buffer I.C. or using wide band amplifier made of transistors and discrete components. An independent selection circuit 30, composed of a plurality of electronic switches corresponding to the information transmission lines 16 is incorporated in each receiving apparatus 14 for receiving information signals transmitted from the plurality of transmitting apparatuses 12 and switch on one or more of the electronic switches for connecting one or more information transmission lines 16 to the receiver circuit 32. Thereby, any one or more information signals transmitted through the information transmission lines can be selected and fed from the selection circuit 30 to the receiver circuit 32.
The frequency of an external synchronizing signal P1 is related to the vertical frequency of the video signal generated by the television camera 18, preferably having frame or field scanning frequency. For instance, in the case of an NTSC system, the frame frequency is 30 Hz, and the field frequency is 60 Hz. In such case, the frequency of the external synchronizing pulse P1 is either frame frequency of 30 Hz or a field frequency of 60 Hz.
As shown in FIG. 2(A), the time the external synchronizing signal P1 is generated adjoining the vertical synchronizing pulse, occurring during the vertical blanking period of the video signal transmitted from the television camera 18. Thereby, the external synchronizing signal P1 can be propagated to the television camera 18 through the common transmission line 24 transmitting the video signal without affecting the video signal. The voltage level of the external synchronizing signal P1 is preferably made higher than the white level Vw of the video signal. However, the voltage level of the external synchronizing signal P1 may be lower than the black level Vb, preferably the pedestal level Vp of the video signal.
In the following description, a frame external synchronizing pulse having a voltage level higher than the white level of the video signal, in particular, a frame external synchronizing pulse corresponding to the phase of a second field is used as the external synchronizing signal P1.
In the illustrated embodiment, each television camera 18 is a television camera operated in synchronization with the external synchronizing signal P1. For such a television camera, a well known television camera may be used synchronized with an external synchronizing signal having a voltage level higher than the white level (or lower than the black level) of the video signal, as disclosed in U.S. Pat. No. 4,603,352.
Each of the television cameras 18 or the transmitting means 12 is allotted an identification number for generating respectively an identification code made of numbers such as 1, 2, 3 . . . n, for injecting the identification code into the video signal during the vertical blanking period.
Each of the television cameras 18 or the transmitting means 12 includes a circuit for generating code signals corresponding to the identification code, and a circuit for generating a composite signal wherein the code signals are injected into the video signal. Such an apparatus is disclosed in U.S. Pat. No. 4,943,864, the content of which are incorporated herein by reference; therefore, each of the information signals received by each of the receiver circuit 32 incorporates identification code.
As shown in FIG. 3, each transmission circuit 26 includes a pulse shaping timing circuit 34 for outputting a pulse signal P2 shown in FIG. 2(B) synchronized with the external synchronizing signal P1 fed from the external synchronizing signal generation circuit 20 shown in FIG. 1. The pulse shaping timing circuit 34 outputs both the pulse signal P2 and the external synchronizing signal P1. An external synchronizing signal injection circuit 36 receives the pulse signal P1 fed from the pulse shaping timing circuit 34 and injects the pulse signal P1 into the video signal transmission line 24. A synchronizing pulse clipping circuit 38 is provided for clipping the synchronizing pulse P1 from a signal fed from the video signal transmission line 24 and passing through the synchronizing pulse clipping circuit 38, by using the timing signal P2 to clip the pulse P1 and feed a video signal containing no synchronizing pulse P1 to the driver 28.
The synchronizing pulse clipping circuit 38 is fed with the signal shown in FIG. 2(A) from the video signal transmission line 24 and the timing signal P2 shown in FIG. 2(B) from the pulse shaping timing circuit 34. The signal P2 activates the clipping circuit for the duration of P2, thereby the clipping circuit 38 clips the entire signal portion of the signal fed to its input terminal above the black level Vb of the video signal during the period of signal P2. Since the duration of P2 covers the period of the external synchronizing pulse P1 the external synchronizing signal P1 is removed by the clipping circuit 38 from the composite video signal transmitted to the receiving apparatus 14, as shown in FIG. 2(C).
Accordingly, even though the external synchronizing signal P1 is present in the video signal fed from the television camera 18 through the transmission line 24 it is removed by the clipping circuit 38; therefore, the external synchronizing signal P1 injected into the video signal transmission line 24 will synchronize the television camera 18 and will not cause any receiving error by the receiving apparatuses 14.
When the television camera 18 also generates an audio signal, the audio signal can be fed to the driver 28 through the transmitting circuit 26 and transmitted together with the video signal to the receiving apparatus 14.
When the audio signal is connected separately to the transmitting apparatus 12 it is fed through the transmission line 40 to a mixing circuit 42 for mixing or injecting the audio signal into the video signal for feeding it to the driver 28. When the audio signal is mixed with the video signal inside the television camera 18 the audio signal is fed to the transmitting apparatus 12 through the video signal transmission line 24. Since the video signal and the audio signal are already mixed together the mixing circuit 42 is not necessary. In this case, the output signal of the clipping circuit 38 may be fed to the driver 28 directly.
Each transmission circuit 26 includes a control generator 44 for generating a control signal for controlling the corresponding television camera 18. The control generator 44 includes a synchronizing separator circuit 46 for separating the horizontal and vertical synchronizing signals H and V from the video signal transmitted through the video signal transmission line 24. Also included is a control signal generator circuit 50 for outputting a control signal for operating the corresponding television camera 18 during predetermined timing suing the separated synchronizing signals H and V and the control command fed from the controller 22 shown in FIG. 1 through a control line 48. A counter 52 is provided for counting the number of horizontal scanning lines fed from the sync separator 46 during each frame or field. The control signal generator 44 also includes a gate circuit 54 for generating a gate signal when the counted value of the counter 52 is a predetermined value, and a buffer circuit 56 controlled by the gate signal for injecting the control signal fed from the control signal generator circuit 50 into the video signal transmission line 24.
In the preferred embodiment of the present invention, the injector circuit may include a mixer circuit wherein the code signals are mixed and injected into the composite video signal. Such a mixer circuit is disclosed in U.S. Pat. No. 4,989,085, the contents of which are incorporated herein by reference, or it can be an injection circuit disclosed in U.S. Pat. No. 5.335.014 the contents of which are incorporated herein by reference.
The control command fed to each transmitter circuit 26 through control line 48 from the controller 22 of FIG. 1 may include a control code for switching a power supply on-off, wiper on-off, tilting up-down, panning left-right and zooming tele-wide or the like, or a start or stop command of the transmission of a video signal. The control signal combines the control code corresponding to the control command and the identification code respectively allotted to each of the television cameras 18. In addition, the control signal is injected into the video signal transmission line 24 by the buffer circuit 56 of FIG. 3 at a predetermined time within the vertical blanking period. The injection timing of the control signal into the signal transmission line 24 is different from the injection timing of the external synchronizing signal into the video signal transmission line 24.
The control line 48 may be connected individually to each television camera 18 via each transmitting apparatus individually, or connected in common to the plurality of transmitting apparatuses. When the control line 48 is commonly connected to the plurality of transmitting apparatuses each of the transmitting apparatuses includes an identification code extractor for activating the control generator 50 only when the identification code incorporated in the control code is identical to the identification code of the corresponding television camera connected to the transmitting apparatus, using identical code extraction circuit shown in FIG. 6. Further, the control command can be directly transmitted from the controller 22 to each television camera 18.
It is apparent from the above description that both the external synchronizing signal and the control signal can be transmitted from each transmitting apparatus to the corresponding television camera through the respective video signal transmission line 24.
However, the control signal composed of the control code and the identification code can be transmitted to the television camera 18 through a separate control transmission line 58 instead of the video signal transmission line 24. A twisted pair transmission line or optical fiber transmission line can be used for transmitting the control signal directly to the television camera 18. Similarly, the external synchronizing signal P1 may be transmitted to the television camera through a separate transmission line, using coax cable, twisted pair or optical fiber transmission lines. For receiving separate audio signals a separate transmission line 40 using twisted pair or shielded cable can be used.
As shown in FIG. 4, each television camera 18 includes a reference voltage source 60 which feeds a reference voltage to the voltage comparator 62 for separating the external sync pulse by comparing the voltage level of the external synchronizing signal P1 transmitted from the transmitting apparatus through the video signal transmission line 24 with the reference voltage and generating a pulse signal P3 when P1 level is same or larger than the reference voltage. An internal synchronizing signal generation circuit 64 generates internal synchronizing signals Hi and Vi synchronized with the pulse signal P3 fed from the voltage comparator 62, a video signal generation circuit 66 generates video signal synchronized with the internal synchronizing signals Hi and Vi for feeding it to the video signal transmission line 24, an audio signal generation circuit 68 generates audio signal along with the video signal and an audio signal injection circuit 70 injects the audio signal into the transmission line 24.
When transmitting an audio signal through the separate transmission line 40 instead of injecting the audio signal into the video signal transmission line 24, the audio signal injection circuit 70 is not required.
As shown in FIG. 4, each television camera 18 further includes an identification code setting circuit 72 for generating an identification code respectively allotted to the television camera 18 at a predetermined time within the vertical blanking period of the composite video signal on the basis of the internal synchronizing signals Hi and Vi, and an identification code injection circuit 74 for injecting the identification code fed from the setting circuit 72 into the video signal transmission line 24.
The timing of the identification code injection into the video signal transmission line 24 by the injection circuit 74 is different from the timing the control signal is injected into the video signal transmission line 24 by the transmitting apparatus 12 shown in FIG. 3. The control signal is injected into the video signal transmission line 24 by the transmitting apparatus 12 during one or more predetermined horizontal scanning lines during the vertical blanking period of the composite video signal, while the identification code is injected into the video signal transmission line 24 by the television camera 18 during one or more predetermined different horizontal scanning lines during same or another vertical blanking period of the composite video signal.
Identification code signals are shown in FIG. 5 (A-C). The identification code signal is a binary code or a bar code signal having two or more levels composed of a high level or white, which is the maximum or highest level of the picture signal in the videos signals, a low level or black, which is the lowest level of the picture signal, and a median level or gray, which is the medium level of a picture signals in the video signal generated by the television cameras 18 as shown in FIG. 6A; the identification code may be a combination of pulse signal levels and varying pulse widths as shown in FIG. 6B.
Alternatively, the identification code signal may be either a sine-wave signal or a pulse signal having a frequency corresponding to the identification code, the sine-wave, or the pulse signal is generated during one or more horizontal scanning periods as shown in FIG. 6C, preferably, during the vertical blanking period.
The control signal generator circuit 50 shown in FIG. 3 generates the control code signals in electronic shaped signals similar to the identification code signal shown in FIG. 5 (A-C). However, different shaped electrical signals may be applied to the control code signal and the identification code signal, similarly, the identification code incorporated in the control signal does not have to be identical to the identification code generated by the identification setting circuit 72 of the television camera of FIG. 4. Any code commensurating with the allotted identification to each television camera can be used instead of an identical identification code.
In FIG. 4, each television camera 18 further includes a code extraction circuit 76 for extracting a control code and an identification code transmitted from the control signal generator circuit 50 shown in FIG. 3, an identification code comparing circuit 78 for comparing the extracted identification code with an identification code fed from the setting circuit 75 for feeding match signal to the decoder 80 when both codes correspond to each other, and a decoder 80 for decoding the control code fed from the code extraction circuit 76 and generating control commands corresponding to the decoded control code only when the decoder 80 is fed with match signal from the identification code comparator 78.
The code extraction circuit 76 of FIG. 6 incorporates a counter 84 for counting the number of horizontal synchronizing pulses during every field or frame of the video signal, a gate circuit 86 connected to the output of the counter 84 for outputting the video signal fed from transmission line 24 when the counted value of the counter 84 is a predetermined value, a level sensor 80 for sensing a signal level or for detecting the envelop of the signal fed from the gate circuit 88 to reproduce and output the code signal extracted from the video signal fed from transmission line 24.
The code comparing circuit 78 generates a match signal when the extracted code fed from the extraction circuit 76 corresponds or commensurate to the code set in the setting circuit 72, and generates a mismatch signal when the extracted code fed from the extraction circuit 76 does not correspond or commensurate to the code set in the setting circuit 72.
Referring to FIG. 6A, when using a control code and an identification code having the signal wave form shown in FIG. 5(A) or 5(B), the extraction circuit 76 can be also composed of a synchronizing signal separator circuit 82 for separating the horizontal and the vertical synchronizing signals from a composite signal transmitted from the television camera, a counter 84 for counting the number of horizontal scanning lines of the television camera for each field or frame, a gate circuit 6 for outputting the composite signal transmitted from the television camera only during a period of time when a counted value of the counter 84 is equal to a predetermined value, and a level sensor 88 for reproducing a code signal by sensing the level or the envelope of the output signal of the gate circuit 86.
When using a control code and an identification code having signal waveform shown in FIG. 5C the level sensor circuit may incorporate frequency or pulse counter for counting the frequency or the number of pulses fed from the gate circuit 86.
The decoder 80 of FIG. 4 feeds the different control commands to different drivers for operating the television camera by commanding the power supply on-off, wiper on-off, tilting up-down, panning left-right zooming tele-wide, focus near-far, iris open-close or the like, or commanding the start or the stop of the transmission of a video signal.
It has been apparent from the above description that a multiplex signal composed of the video signal consisting of the composite video signal, along with audio signal and the identification code respectively allotted to each television camera is transmitted from each television camera 18 to the corresponding transmitting apparatus 12 through the video signal transmission line 24.
As shown in FIG. 7, each receiver circuit 32 includes an interface 90 for receiving an information signal transmitted through the information transmission line 16 selected by the selection circuit 30. The interface 90 feeds the received information signal to a monitor 92 and a video recorder 94.
The monitor 92 is a television receiver for displaying an image corresponding to the video signal included in the information signal transmitted from the transmitting apparatus, and for reproducing sound in accordance with the corresponding audio signal included in the information signal. The video recorder 94 is a video tape recorder for recording and playing back the video signal and the audio signal transmitted from the transmitting apparatus.
Each receiving circuit 32 further includes a memory 96 for storing data for identifying the television camera connected to the monitor 92 and data identifying all other respective television cameras 18 connected to all the respective transmitting apparatuses 12, an identification code extraction circuit 98 for extracting an identification code from the information signal, a controller 100 for identifying the television camera connected to the monitor 92 by reading out data from the memory 96 on the basis of the code extracted from the information signal and for feeding the identifying data to the interface 90 for superimposing an identification text, numeric or graphic, for display on the monitor screen 92 along with the picture generated by the video signal. Similarly, the text, numeric or graphic display can be recorded by the video tape recorder 94 along with the video signal generated by the television camera 18.
The identifying data may be a graphic illustration data for displaying an installation location, an identification number data, a text description data related to the television camera or its location or the like.
The code extraction circuit 98 is similar to the extraction circuit shown in FIG. 6A which includes a synchronizing signal separator circuit 82 for separating the horizontal and vertical synchronizing signals from a composite signal transmitted from the television camera, a counter 84 for counting the number of horizontal scanning lines of the television camera for each field or frame, a gate circuit 86 for outputting the composite signal transmitted from the television camera only during a period of time when a counted value of the encounter 84 is equal to a predetermined value, and a level sensor 88 for reproducing a code signal by sensing the level or the envelope of the output signal of the gate circuit 86.
The extracted identification code fed from the extraction circuit 98 is applied by the controller 100 for reading out the stored data from the memory 96. The data fed from memory 96 via the controller 100 is superimposed onto the video signal in the interface circuit 90 for displaying a numeric, text or graphics onto the monitor screen 92, enabling an operator to recognize the location or position being observed or monitored by the television camera 18. The controller 100 also controls the superimposed display position and switching the display on and off. Such an apparatus for superimposing numeric text or graphics is disclosed in U.S. Pat. No. 4.943.864 the contents of which are incorporated herein by reference.
The controller 100 transmits and receives information between the controller 100 and the controller 22 shown in FIG. 1 through an internal control line 104. A signal fed from the control circuit 22 to the controller 100 also contains switching on or switching-over information for selecting an information transmission line 16 and an external synchronizing signal for controlling the timing of the switching of the information transmission line.
The controller 100 feeds a drive command to the driver 102 for driving the information transmission line selection synchronized with the external synchronizing signal. Therefore, the driver 102 drives the selector circuit 30 and switches on any of the information transmission line 16 or switches over from one information transmission line 16 to another in accordance to the drive command and in synchronization with the external synchronization signal.
As a result, the mixed video and the audio signals generated by the television camera selected through the controller 22 are fed to monitor 92 for reproducing a picture display and a sound, along with recording of the video and audio signals onto the video tape recorder 94. Therefore, the operator can select for monitoring and recording any of the television cameras through any of the controllers 22 of the respective receiving apparatuses 14. The operator can further superimpose any numeric, text or graphics for the displayed signal into the displayed picture reproduced from the video signal.
Further, when the superimposed numeric, text or graphics obstruct the observed picture, the operator can reposition the superimposed display or switch off the superimposed display from the monitor screen.
According to the information signal selecting apparatus 10 of FIG. 1, the transmitting apparatuses and the receiving apparatuses can be connected together by a simple apparatus in an arbitrary combination with each other, whereby, one, two or any arbitrary transmitting apparatuses can be connected to a plurality of arbitrary receiving apparatus.
Further, since the switching on or the switch-over timing of the information transmission line in the selection circuit 30 is synchronized by the external synchronizing signal fed from the controller 100 together with the transmission line selection information, the selection circuit 30 switches over the information transmission synchronously with the video signal. As a result, the reproduced picture images during and immediately after the switching on or the switching over from one information transmission line to another are not disturbed.
When the television camera is synchronized by the well known horizontal and vertical synchronizing signals, or by the well known composite synchronizing signal, or by the well known horizontal and vertical drive signals, a generation circuit for the horizontal and vertical synchronizing signals, the composite synchronizing signal or the horizontal and vertical drive signals can be arranged instead of the external synchronizing signal generator circuit 20 of FIG. 1. Accordingly, the external synchronizing signal injection circuit 36 and the clipping circuit 38 shown in FIG. 3 will not be required.
Instead of providing the external synchronizing signal injection circuit 36 and the clipping circuit 38 in the transmitting apparatus 12, the external synchronizing signal P1 can be directly fed through a separate transmission line to the level comparing circuit 62 in FIG. 4, of the television camera 18. When the television camera is not provided with any level comparing circuit, a signal corresponding to the pulse signal P3 can be fed directly as a vertical external synchronizing signal to the internal synchronizing signal generator circuit 64 of the television camera 18 through a separate transmission line. In the latter case, the transmitting apparatus 12 does not need the external synchronizing signal injection circuit 36 and the clipping circuit 38 shown in FIG. 3.
The mixing circuit 42 of the transmission circuit 26 can be a circuit for modulating a carrier wave by an audio signal, and for outputting a composite video signal mixed with the modulated audio. In this case, the receiving circuit 32 includes a circuit for demodulating the audio signal.
Further, the mixing circuit 42 can be provided with a circuit for compressing a time base of an audio signal at such a rate that a time corresponding to one vertical scanning period of a video signal becomes equal to a time corresponding to one or more horizontal scanning period of the video signal, and for injecting the compressed audio signal during the vertical blanking period of the video signal. In this case, the receiving circuit 32 includes a circuit for extracting the compressed audio signal from the video signal and for decompressing the time base of the extracted audio signal.
Other circuits can be used instead of the mixing circuit 42 described above. The audio signal injection circuit 70 of the television camera 18 shown in FIG. 4, can also be a circuit similar to the mixing circuit 42 of the transmission circuit 26 shown in FIG. 3.
The control signal for controlling the television camera 18 can be fed from a single controller to any arbitrary number of transmitting apparatuses, instead of to all the transmitting apparatuses. Otherwise, a controller may be respectively provided for each transmitting apparatus to feed the control signal from each controller individually to each of the transmitting apparatus 12. In addition, the control signal may be transmitted from each receiving apparatus to each transmitting apparatus through the information transmission lines 16.
Further, instead of having a single controller for each individual receiving apparatus, two or any arbitrary number of receiving apparatuses can be controlled by a single controller. Otherwise, a controller may be respectively provided for all the receiving apparatus to control individually each receiving apparatus.
An information signal selecting apparatus 110 shown in FIG. 8 comprises an individual controller 22 respectively provided for each receiving apparatus 14, wherein each receiving apparatus 14 along with each individual selection circuit 30 of the receiving apparatus 14 is controlled by the individual controller 22, a main controller 112 for controlling the state of selection of each individual controller 22 and coordinates the state of the receiving apparatuses 14, such as preventing conflicting selection and control, or prohibiting wrong selection or the like by any of the receiving apparatuses 14.
In addition, the main controller 112 may feed a control data to each controller 22, such control data may consist of data prohibiting the selection of one or more information transmission lines or the like.
When an operator of controller 22 selects a prohibited information transmission line the controller 22 feeds the selection data to the master controller 112 and the master controller overrides the controller 22 selection and cancel the selection through the internal control line 104 by feeding a prohibiting command to controller 100 of FIG. 7. When an operator selects a non prohibited information transmission line the controller 22 feeds both the received information transmission line selection data and the external synchronizing signal P1, fed from the external synchronizing signal generation circuit 20, to the receiver circuit 32 of the corresponding receiving apparatus 14. The information transmission line selection data fed to the controller 100 as shown in FIG. 7 is synchronized to the external synchronizing signal, thereby, the controller 100 feeds a drive command corresponding to the received data pertaining to the information transmission line selection information to the driver 102 synchronized with the external synchronizing signal, and the driver 102 drives synchronously the selection circuit 30 to select the information transmission line 16 corresponding to the drive command.
The controller 22 of the information signal selecting apparatus 110 shown in FIG. 8 can replace the controller 100 of the receiving circuit 32 shown in FIG. 7. Furthermore, the external synchronizing signal can be fed directly to the controller 22 through the main controller 112.
An information signal selecting apparatus 120 shown in FIG. 9 transmits a control signal from each receiving apparatus 14 to the transmitting apparatus 12 through the information transmission line 16. Therefore, each transmitting apparatus 12 includes an interface 122 for receiving the control signal, and each receiving apparatus 14 includes a drive circuit 124 for transmitting the control signal.
As shown in FIG. 9, the controller 100 of FIG. 10, of each receiving apparatus 14 extracts the control signal transmitted from the controller 22 and feeds the extracted control signal to the drive circuit 124. When the controller 100 of FIG. 10 receives a command to transmit the control signal from the controller 22, the drive circuit 124 injects the control signal fed from the controller 100 into the selected information transmission line 16.
Each interface 122 extracts the control signal transmitted through the information transmission line 16 and feeds the extracted control signal to the control signal generation circuit 50 shown in FIG. 3. The controller 22 prevents the same television camera 18 from being driven by the control signals fed from a plurality of different receiving apparatuses 14, thereby preventing contradictory control signals from being fed to the same television camera.
An information signal selecting apparatus 130 shown in FIG. 11 combines the information signal selecting apparatus 110 shown in FIG. 8 and the information signal selecting apparatus 120 shown in FIG. 9. Therefore, the information signal selecting apparatus 130 comprises the main controller 112, the controller 22 respectively provided for each receiving apparatus 14, the interface 122 provided for each transmitting apparatus 12 and the drive circuit 124 respectively provided for each receiving apparatus 14. Each of these circuits operates in a similar manner to the corresponding one of the circuits shown in FIGS. 8 and 9.
An information signal selecting apparatus 140 shown in FIG. 12 transmits a control signal only through the receiving apparatus 14 and the information transmission line 16 but not directly to the transmitting apparatus 12 as provided by the information signal selecting apparatus 130 shown in FIG. 11. In the information signal selecting apparatus 140, the main control circuit 112 receives current data of the selection in process from each controller 22, and feed the signal for controlling the video generating means to the controller 22 of the receiving apparatus, the controller 22 transfers the control signal through the selected information transmission line 16 connected to the transmitting apparatus 12 in a similar manner to the information selecting apparatus 130 of FIG. 11.
In the embodiment described above, there are as many transmitting apparatuses 12 as there are receiving apparatuses 14. However, the number of transmitting apparatuses 12 may be different from that of receiving apparatuses 14. Further for an information generating apparatus for generating information signals any reproduction signal generating apparatus or other apparatus, may be used instead of the video signal generating apparatus composed of the television camera 18.
The present invention can be applied not only to the information signal selecting apparatus used in a monitoring system but also to any other information transmitting apparatuses.
It should be understood, of course, that the foregoing disclosure relates to only a preferred embodiment of the invention and that it is intended to cover all changes and modifications of the example of the invention herein chosen for the purpose of the disclosure, which modifications do not constitute departures from the spirit and scope of the invention.
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An apparatus for selecting information signals includes a plurality of transmitters, each of which processes an electrical information signal preferably including a video signal. A plurality of receivers selectively receive that video signal. A plurality of information transmission lines connect each receiver to the plurality of transmitters. A generator for generating an external synchronizing signal generates and feeds an external synchronizing signal to the plurality of transmitters and the plurality of receivers.
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The present application claims the benefit of priority of provisional patent application Ser. No. 61/517,471, filed on Apr. 20, 2011, entitled “Toilet Paper Holder”.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a toilet paper holding device and, more particularly, the invention relates to a toilet paper holding device providing an artistically rendered housing for a spare roll of toilet tissue that also lends stylish flair to a bathroom.
2. Description of the Prior Art
Perhaps the most important and useful room in any home is the bathroom. The bathroom is the one room where people shower or bathe, brush their teeth, shave, apply makeup, and undergo other personal grooming tasks. Providing a quiet space in which a person can have a few moments to themselves, many people find that time spent in the bathroom is actually the only time during a hectic day when they are completely alone. Used by family members and guests alike, bathrooms are high traffic areas that are repeatedly accessed throughout the day and night. Because people spend so much time in their bathrooms, most people take care to decorate this room as they would any other room in their home. Whether by hanging crisp curtains and pretty wallpaper, matching hand and bath towels, or simply by placing a few scented candles on the countertop, creating a homey atmosphere can make time spent in the bathroom enjoyable and relaxing.
SUMMARY
The present invention is a toilet paper holding device for holding a spare roll of toilet paper or tissue. The toilet paper holding device comprises a base plate and a top plate. A plurality of panels and a plurality of rods are mounted between the base plate and the top plate. The spare roll of toilet paper is visible between the panels and the rods.
In addition, the present invention is a toilet paper holding device for holding a spare roll of toilet paper or tissue. The toilet paper holding device comprises a base plate and a top plate with the top plate having an opening sized and shaped for receiving the roll of toilet paper. A plurality of panels and a plurality of rods are mounted between the base plate and the top plate. A lid rests within the annular opening of the top plate and upon the toilet paper roll. The shape of the base plate and the top plate are selected from the group consisting of round, hexagon, and octagon. The toilet paper roll rests upon the base plate when positioned within the toilet paper holding device and is visible between the panels and the rods. Upon the toilet paper roll being removed, the lid is restable on the base plate.
The present invention further includes a method for holding a spare roll of toilet paper or tissue. The method comprises providing a base plate, providing a top plate having an opening sized and shaped for receiving the roll of toilet paper, positioning a plurality of panels between the base plate and the top plate, positioning a plurality of rods between the base plate and the top plate, resting a lid within the annular opening of the top plate and upon the toilet paper roll, selecting the shape of the base plate and the top plate from the group consisting of round, hexagon, and octagon, resting the toilet paper roll upon the base plate, visibly viewing the toilet paper between the panels and the rods, removing the toilet paper roll, and resting the lid on the base plate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view illustrating a toilet paper holding device, constructed in accordance with the present invention, with a toilet paper roll seated in the holding device;
FIG. 2 is a perspective view illustrating the toilet paper holding device of FIG. 1 , constructed in accordance with the present invention, with the toilet paper roll seated in the holding device, a lid positioned on top of the toilet paper roll, and the toilet paper roll visible through the toilet paper holding device;
FIG. 3 is a perspective view illustrating the toilet paper holding device of FIG. 1 , constructed in accordance with the present invention, with the holding device being empty and the lid completely positioned within the holding device;
FIG. 4 is a perspective view illustrating another embodiment of the toilet paper holding device, constructed in accordance with the present invention, with the toilet paper roll seated in the holding device;
FIG. 5 is a perspective view illustrating the toilet paper holding device of FIG. 4 , constructed in accordance with the present invention, with the toilet paper roll seated in the holding device, the lid positioned on top of the toilet paper roll, and the toilet paper roll visible through the toilet paper holding device;
FIG. 6 is a perspective view illustrating the toilet paper holding device of FIG. 4 , constructed in accordance with the present invention, with the holding device being empty and the lid completely positioned within the holding device;
FIG. 7 is a perspective view illustrating still another embodiment of the toilet paper holding device, constructed in accordance with the present invention, with the toilet paper roll seated in the holding device;
FIG. 8 is a perspective view illustrating the toilet paper holding device of FIG. 7 , constructed in accordance with the present invention, with the toilet paper roll seated in the holding device, the lid positioned on top of the toilet paper roll, and the toilet paper roll visible through the toilet paper holding device; and
FIG. 9 is a perspective view illustrating the toilet paper holding device of FIG. 7 , constructed in accordance with the present invention, with the holding device being empty and the lid completely positioned within the holding device;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As illustrated in FIGS. 1-9 , the present invention is a toilet paper holding device, indicated generally at 10 , providing an artistically rendered housing for a spare roll of toilet paper or tissue 12 that also lends stylish flair to a bathroom. The toilet paper holding device 10 of the present invention turns an ordinary toilet tissue housing unit into a functional, decorative showpiece.
The toilet paper holding device 10 of the present invention includes a planar base plate 14 and an annular top plate 16 spaced from the base plate 14 . Separating the base plate 14 from the top plate 16 is a plurality of panels 18 and rods 20 alternatingly positioned adjacent an outer edge of the base plate 14 and the top plate 16 . Preferably, a gap or other opening 22 is present between the panels 18 and rods 20 allowing a user to view whether a toilet paper roll 12 is within the toilet paper holding device 10 .
The shape of the base plate 14 and the top plate 16 of the toilet paper holding device 10 of the present invention can be selected from the group consisting of round, hexagon, and octagon. Preferably, the base plate 14 and the top plate 16 have the same shape with their outer edges aligned with each other. The shape of the base plate 14 and the top plate 16 are a user's choice and all configurations of the toilet paper holding device 10 allow a user to visually inspect the contents of the toilet paper holding device 10 to determine whether it is empty or not. It should be noted that while a particular shape of the base plate 14 and the top plate 16 have been designated and depicted herein, it is within the scope of the present invention for the bottom plate 14 and the top plate 16 to have other shapes.
The round configuration of the toilet paper holding device 10 of the present invention preferably has six panels 18 and six rods 20 . The rods 20 are preferably set into a hexagon frame 24 mounted on the base plate 14 and top plate 16 with the panels 18 mounted outside the frame 24 . In this embodiment, the panels 18 and rods 20 are substantially aligned adjacent an outer edge of the base plate 14 and the top plate 16 .
The hexagon configuration of the toilet paper holding device 10 of the present invention also preferably has six panels 18 and six rods 20 . The rods 20 are preferably set into a frame 26 mounted on the base plate 14 and attach to the top plate 16 with the panels 18 mounted within the frame 26 . In this embodiment, the rods 20 are mounted adjacent an outer edge of the base plate 14 and the top plate 16 with the panels 18 inset from the rods 20 and gaps between the panels 18 aligned with the rods 20 .
The octagon configuration of the toilet paper holding device 10 of the present invention preferably has eight panels 18 and eight rods 20 . Like the hexagon embodiment, the rods 20 are preferably set into a frame 28 mounted on the base plate 14 and attach to the top plate 16 with the panels 18 mounted within the frame 28 . In this embodiment, the rods 20 are mounted adjacent an outer edge of the base plate 14 and the top plate 16 with the panels 18 inset from the rods 20 and gaps between the panels 18 aligned with the rods 20 .
The top plate 16 of the toilet paper holding device 10 of the present invention has an opening sized and shaped for receiving the roll of toilet paper 12 such that the toilet paper roll 12 rests upon the base plate 14 when positioned within the toilet paper holding device. A lid 30 with a decorative knob 32 rests within the annular opening of the top plate 16 and upon the toilet paper roll 12 . When empty, the lid 30 rests upon the base plate 14 thereby providing an obvious visual determination that the toilet paper holding device 10 is empty.
The toilet paper holding device 10 of the present invention has dimensions of approximately five (5″) inches in height and four and three-quarters (4¾″) inches inside width. Preferably constructed of an attractive yet durable, 3-ply birch wood material, the framework of the toilet paper holding device 10 has an open-area adorned with a series of ornate rods surrounding the perimeter of the base plate 14 and the top plate 16 . The toilet paper holding device 10 can be made available in a wide variety of color combinations to appeal to individual tastes, or to match an existing decorative motif. Thus constructed, the toilet paper holding device 10 can be ready for use in a matter of seconds. Placing the toilet paper holding device 10 in an easily accessible area, such as on top of the toilet tank, a user simply inserts a full roll of toilet tissue 12 into the toilet paper holding device 10 and places the lid 30 on top of the toilet paper roll 12 . Should one find that he or she is out of toilet paper 12 , they need only access the toilet paper holding device 10 . When empty, the lid 30 of the toilet paper holding device 10 rests on the base plate 14 serving as a handy reminder that the toilet paper holding device 10 needs to be refilled.
The toilet paper holding device 10 of the present invention can be made available in a wide variety of color combinations to appeal to individual tastes, or to match an existing decorative motif. Additional design considerations may include, but are not limited to, an Adirondack country scene, oceanic scene, and even children's characters. Also, the toilet paper holding device 10 can be fabricated of plastic or chrome for a more contemporary look and feel. In addition to the shapes described and illustrated herein, other shaped toilet paper holding devices 10 can be produced to offer variety to the user.
There are many significant benefits and advantages associated with the toilet paper holding device 10 of the present invention. Foremost, the toilet paper holding device 10 offers users an attractive, decorative showpiece for use in any bathroom. Featuring a classical, ornate design, the toilet paper holding device 10 provides users a unique and stylish accent for the home. For the countless users who enjoy decorating their bathrooms, the toilet paper holding device 10 provides a dazzling focal point to their existing decor. Not only attractive, the toilet paper holding device 10 provides users quick and easy access to an extra roll of toilet tissue, eliminating embarrassing and ungraceful searches through cabinets and utility closets. When the toilet paper holding device 10 is empty, the lid 30 rests on the bottom of the device serving as a reminder that it needs to be refilled. Although designed with the home user in mind, the toilet paper holding device proves a charming addition to any public rest room, particularly those found in restaurants and hotel rooms.
The foregoing exemplary descriptions and the illustrative preferred embodiments of the present invention have been explained in the drawings and described in detail, with varying modifications and alternative embodiments being taught. While the invention has been so shown, described and illustrated, it should be understood by those skilled in the art that equivalent changes in form and detail may be made therein without departing from the true spirit and scope of the invention, and that the scope of the present invention is to be limited only to the claims except as precluded by the prior art. Moreover, the invention as disclosed herein may be suitably practiced in the absence of the specific elements which are disclosed herein.
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A toilet paper holding device for holding a spare roll of toilet paper or tissue is provided. The toilet paper holding device comprises a base plate and a top plate. A plurality of panels and a plurality of rods are mounted between the base plate and the top plate. The spare roll of toilet paper is visible between the panels and the rods. The lid sits on top of the toilet paper roll when inserted. When the holder is empty, the lid rests on the bottom of the device to serve as a reminder that the receptacle needs to be refilled.
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FIELD OF THE INVENTION
This invention relates to structural connectors, and more particularly, to a connector leaf for cooperating with a like leaf for detachably connecting panels or other structures together, either in fixed relation or for horizontal angular adjustment.
NEED FOR THE INVENTION
Panels or screens for dividing interior areas of buildings into a plurality of rooms, zones or cubicles are in relatively common use, particularly in office buildings. After the dividers have been initially positioned, it is often desired to modify the arrangement from time to time in order to better accommodate the changing needs of the building occupants. Such a modification cannot be readily accomplished by many of the panel mounting systems in use. Others require complicated or unsightly hardware, and most do not permit horizontal angular adjustment of the panels.
SUMMARY OF THE INVENTION
The present invention aims to provide a connector leaf for panels, screens, dividers, portable walls and the like, all of which will hereinafter be termed "panels," which can be easily fastened in place and does not require modification of the structure in which it is fastened.
Another object of the invention is to provide a connector leaf which, when used in multiple, allows quick and easy interconnection of multiple panels in a wide variety of arrangements and without the need for skilled manpower.
A further object is to provide a connector leaf assembly for joining panels which permits them to be easily disconnected and rearranged.
These and other objects are accomplished by providing a novel connector leaf which can be arranged in multiple and connected one to another by removable pins.
In the preferred embodiment, the connector leaf has a generally rectangular body with diagonally opposite knuckles. The leaves are nested with adjoining knuckles aligned and abutting to receive respective pins. Tapered holes are provided in the leaf body in symmetrical relation to receive mounting screws or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a connector leaf and suitable fastening screws, as seen from the rear, of the preferred embodiment of the invention;
FIG. 2 is a perspective view similar to FIG. 1 and showing a pair of the connector leaves nested together front face to front face, with one of the leaves partly broken away at one of the screw holes;
FIG. 3 is a top plan view illustrating two panels in phantom connected at right angles by a pair of the connector leaves nested in the manner shown in FIG. 2;
FIG. 4 is a top plan view showing three of the connector leaves of FIG. 1 connected together to join three panels shown in phantom; and
FIG. 5 is a perspective view of a modified connector leaf shown connected to a like leaf illustrated fragmentarily in phantom.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, in the preferred embodiment, denoted 10, the connector leaf has a planar, generally rectangular body portion 12 formed with a pair of diagonally opposite pairs of knuckles 14, 16 having axial through-bores 18, 20. The body portion 12 also is formed with a pair of tapered screw holes 22, 24 which are preferably located on the major axis and spaced apart equally from the minor axis of the body portion so that the holes, as well as the knuckles, perfectly exchange positions when the leaf is turned 180°. There is not any significance as to which diagonal of the body portion has the knuckles as long as the connector leaves which are to be used together are the same. It is also preferred that the inner ends of the knuckles 14, 16 be located on the major axis in alignment with the holes 22, 24.
It will be noted that the back surfaces of the knuckles 14, 16 are flush with the back face B, and that the front surfaces of the knuckles extend forwardly beyond the plane of the front face F of the body portion. Preferably, this forward extension of the knuckles does not exceed the thickness of the body portion 12. In the illustrated embodiment 10, the knuckle extension is equal to the body thickness, and the axis of each of the knuckle bores 18, 20 is coplanar with the plane of the front face F. The end portions of the body 12 adjoining the inner ends of the knuckles are preferably convexly curved as indicated at 32 to conform with the concave curvature 34 at the juncture of the knuckles and the front face F.
As shown in FIG. 2, a pair of the leaf connectors 10-10' will perfectly nest together, front face against front face, and the bores of the adjoining knuckles 14, 16' and 14', 16 will be aligned to receive respective connector L-pins 30. When one of these pins is used, the connector leaves become hinged together at the pin location and are free to swing relative to one another about the pin axis. The use of two pins completely locks the leaves together. It is important to note that the lower knuckle of each leaf gives vertical support for the adjoining upper knuckle of the other leaf.
Screws 26, 28 are provided, having the underside of their heads tapered to match the taper of the holes 22, 24 so that the outer faces of the screw heads will be flush with the front face F when the screws are used to mount the connector leaf in place on a panel or wall.
In FIG. 3, a panel 50 is shown rigidly connected at one end at right angles to a sidewall of a panel 52 by a pair of connector leaves 10-10' and two pins 30, the leaves being in the same face-to-face position as shown in FIG. 2. If one of the two pins 30 is removed, it is apparent that the panel 50 can then be swung to any desired position relative to the panel 52. Depending on the height and weight of the panels, normally two or more sets of the connector leaves are used at various elevations.
For purpose of example, in FIG. 4 a set of three of the afore-described connector leaves 10, denoted 66, 68 and 70 in this view, are shown mounted at the same level on the ends of three adjoining vertical panels 60, 62 and 64 which are spaced 120 degrees apart. The knuckles of the leaf connectors are coupled together in a triangular configuration with three of the L-pins 30. As a consequence, the three panels are locked against relative movement horizontally and vertically. It will be apparent that four panels can be held spaced apart by 90 degrees by the use of four connector leaves coupled together in a square configuration rather than in the equilateral triangular configuration shown in FIG. 4. Hence, the preferred embodiment makes it possible to couple together an odd or even number of panels with their joined end faces arranged as sides of a regular polygon.
In FIG. 5, there is illustrated a second embodiment 80 of the connector leaf in which a pair of knuckles 84, 86 are placed directly opposite one another rather than diagonally opposite. Tapered screw holes 92, 94 are provided along the major axis as before. As indicated in phantom by the leaf 80' in FIG. 5, when two leaves of the second embodiment are coupled together by a pin 30, one of the leaves must be reversed 180 degrees relative to the other. Hence, although having many of the same advantages and uses as the preferred embodiment, this second embodiment can only be coupled in multiples of two, and hence cannot be used to connect three panels together in the manner illustrated in FIG. 4. Furthermore, care must be shown in mounting the connector leaves so that panels to be joined together will have the knuckles of their respective connector leaves 80 arranged one at the top and the other at the bottom. Hence, it is seen that the second embodiment, although having considerable utility, is not as versatile and easy to use as the preferred embodiment.
The front face of the connector leaf of either embodiment can be made flush to an end face of the panel on which the leaf is mounted by recessing the panel face the thickness of the body portion of the leaf. Also, as indicated in FIG. 3 by the leaf 10' on panel 52, a leaf can be placed with its back face, including the knuckles, coplanar with a sidewall of panel. This is the advantage of not having the knuckles extend forwardly of the front face F more than the thickness of the body portion 12. However, since the connector leaf of this invention has other important advantages independent of such coplanar mounting advantage, it is not limited to the illustrated arrangement wherein the knuckles project the thickness of the body portion.
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A connector leaf for cooperating with a like leaf as an assembly for detachably connecting panels or other structures together comprises a generally rectangular planar body having a pair of knuckles at its opposite ends, each with an axial bore therethrough for receiving a connector pin. The knuckles are flush with one face of the body and project outwardly of the other face thereof. In the preferred embodiment, the knuckles are at diagonally opposite corners.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is the U.S. National Phase, under 35 USC 371 of PCT/DE 03/00268, filed Jan. 31, 2003; published as WO 03/072476 A1 on Sep. 4, 2003, and claiming priority to DE 102 08 017.8 filed Feb. 26, 2002 and to DE 102 08 292.8 also filed Feb. 26, 2002, the disclosures of which are expressly incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention is directed to folding drums of a folder. The folding drum has at least one folding element arranged on a support and a gear unit.
BACKGROUND OF THE INVENTION
[0003] It is the general purpose of a folding drum to temporarily convey a product, which is to be folded in a folder, and to push the product into a folding jaw of a folding jaw cylinder in an orientation suitable for folding, or, depending on the type of the folder, to transfer the product to two folding rollers, which two folding rollers draw the product, with the desired fold line at the front, into a gap formed between them and to thus fold the product in this way. The folding drum has a plurality of movable folding blades for accomplishing this purpose, which movable folding blades can be extended through openings in a shell of the folding drum in order to insert the product to be folded into a folding jaw or into a gap between two folding rollers.
[0004] The extending and retracting movement of the folding blade is coupled to the rotation of the folding drum by the use of a gear. Folders are known, wherein the coupling can be cancelled for one of the two folding blades in the folding drum, and the folding blade can be stopped. This stoppage of one of the folding blades allows for so-called collection production. A product can be transferred to the folding drum at a transfer point and can make a complete revolution on the folding drum without being pushed off by a folding blade. When the product again passes the transfer point, a second product is placed on top of the first one, and both products are moved on together by the folding drum. If now both products are pushed off together by the folding blade, they are folded together.
[0005] DE 195 11 054 C2 discloses a drive mechanism for a folding blade of a folding drum. Driving of the folding blade is provided via a central gear wheel.
[0006] DE 12 22 082 B1 describes a wheel folder, whose folding blades can be adjusted by an adjusting gear via an axially displaceable gear wheel.
[0007] A folding drum of a folder with a folding blade arranged on a support is known from GB 1 059 158 A. A gear wheel, which is arranged coaxially with respect to the axis of rotation of the support is provided, which gear wheel, in one mode of operation, has a number of revolutions which is different from that of the folding drum.
SUMMARY OF THE INVENTION
[0008] The object of the present invention is directed to providing folding drums for a folder.
[0009] In accordance with the present invention, this object is attained by the provision of a folding drum of a folder having at least one folding element arranged on a support. A gear unit, which has at least one central gear wheel can be arranged coaxially with respect to a rotating shaft of the support. This gear wheel can be shifted axially between two positions. This gear wheel can also have a number of revolutions that is different from the number of revolutions of the folding drum. The folding element may also rotate at one of first and second different numbers of revolutions, or can be stopped. The rotating shaft of the folding element may be located eccentrically with respect to the rotating shaft of the folding drum.
[0010] One of the two gear wheel disks is fixed, while the other gear wheel disk rotates as a function of the production mode which is selected.
[0011] For engagement, the folding drum is stopped in a defined position, because the gear coupling is unequivocal. Alternatively, the tooth coupling can catch slippingly while the folding drum rotates.
[0012] With this folding drum structure, in accordance with the present invention, switching from single to collection production is possible more rapidly and is simpler than with constructions which were previously used.
[0013] For the coupling of the first and second gear wheel disk to each other, which is necessary for accomplishing single production, these gear wheel disks are usefully equipped with complementary tooth arrangements, which tooth arrangements can be brought into engagement or out of engagement by axially displacing the first wheel disk.
[0014] By the provision of irregular distances or widths of the teeth, these tooth arrangements have been configured in such a way that they can be be brought into engagement by the use of only a small number “m” of evenly distributed rotary positions of the two wheel disks with respect to each other. The number “m” is a function of the gear ratio of the groups of gears. If, with the frame of the gear unit assumed to be fixed, the gear groups convert one revolution of the center wheel to a whole number “n” of revolutions of the folding blades, “m” can be any arbitrary whole number divisor of “n”, including 1 or “n”. Because of this, it is assured that switching back to single production takes place only when the folding blade, which had previously been deactivated during collection production, is in a correct phase position.
[0015] It is possible, in particular, to fix a single defined position.
[0016] The first wheel disk preferably has a further, or an additional tooth arrangement, which further tooth arrangement is complementary to a tooth arrangement at the frame of the gear unit, and which can be brought into engagement with the first gear wheel disk by displacing the latter. This further tooth arrangement is used for stopping the folding blade coupled to the first wheel disk during collection production. These tooth arrangements can be brought into engagement with each other in a multitude of rotary positions, so that switching from single to collection production can take place in any arbitrary orientation of the folding drum.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Preferred embodiments of the present invention are represented in the drawings and will be described in greater detail in what follows.
[0018] Shown are in:
[0019] FIG. 1 , a schematic perspective view of a folding drum, with which the present invention can be used, in
[0020] FIG. 2 , a view, in the same perspective as in FIG. 1 , of the internal structure of the folding drum depicted in FIG. 1 , in
[0021] FIG. 3 , a schematic representation of a gear unit for the folding drum represented in FIG. 1 , and in
[0022] FIG. 4 , an end view of a wheel disk in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Referring initially to FIG. 1 , there may be seen a preferred embodiment of a folding drum of a folding device in accordance with the present invention. Three groups of slits 02 , each group of slits 02 being spaced at an angular distance of 120° in a circumferential direction from each other, have been formed in a drum shell 01 of the folding drum which is represented in FIG. 1 . A plurality of protruding projections 03 are shown extending radially through the group of slits 02 which are located at the top of the drum shell 01 , as seen in FIG. 1 , which protruding projections 03 are a part of a folding element 04 , such as for example, a folding blade 04 . The folding blade 04 is arranged on a support, which structure will be explained in greater detail subsequently, in connection with FIG. 2 .
[0024] Various function groups, such as, for example, grippers or spur needle strips, for use in holding a product taken along by the folding drum, can be arranged on or at the drum shell 01 , which function groups are not shown in FIG. 1 for simplifying the representation in FIG. 1 and which function groups will also not be described, since they are generally known to one skilled in the art and are not further developed or modified by the present invention.
[0025] Two end flanges 06 , each with an enlarged central opening 07 , which central opening 07 is concentric with respect to a longitudinal axis of the drum shell 01 , are located at the end faces of the drum shell 01 , as seen in FIG. 1 . A shaft 08 has been formed at the openings 07 and is used for the rotatable support of the folding drum in a frame, which is not specifically represented, of a folder.
[0026] A shaft 09 which supports the internal structure of the folding drum, extends eccentrically through the central opening 07 of the end flange 06 .
[0027] As is shown in FIG. 2 , the eccentrically located shaft 09 has, in the interior of the folding drum, two arms 11 , which project in opposite radial directions from shaft 09 , and a gear unit 12 , which areas 11 and gear unit 12 support two folding blade shafts 13 , 28 , which two folding blade shafts 13 and 28 are rotatable around axes of rotation which are parallel to the shaft 09 . The housing of the gear unit 12 is rigidly connected with the section of the shaft 09 facing the viewer, as depicted in FIG. 2 , and is rotatable in the interior of the folding drum together with this section of the shaft 09 . On the far side of the gear unit 12 , in the perspective view shown in FIG. 2 , the shaft 09 is extended by a second shaft section 14 , which is here called a second gear wheel disk shaft 14 for reasons which will become clear in connection with the subsequent discussion of FIG. 3 . This second gear disk shaft 14 is structured for being mounted non-rotatably in a lateral plate of the folder. A first shaft section 16 , which is a so-called first gear wheel disk shaft 16 , extends through an axially extending, centralhollow space or bone in the second gear wheel disk shaft 14 ;
[0028] FIG. 3 shows the internal structure of the gear unit 12 . The first and second gear wheel disks shafts 16 , 14 , respectively have been rotatably passed through an opening of the housing 17 or of the frame of the gear unit 12 , and respectively support a first gear wheel disk 18 or a second gear wheel disk 19 . Since the second gear wheel disk 19 is rigidly connected with the second gear wheel disk shaft 14 , it does not follow a rotation of the gear unit 12 around the axis of the shaft 09 . In this way, when the gear unit 12 rotates, it drives a gear group constituted by an intermediate gear wheel 21 , which intermediate gear wheel 21 is rotatable around a shaft that is connected with the housing 17 , and also drives a gear wheel 22 that is fastened on the folding blade shaft 13 . While the gear unit 12 rotates around the axis of the eccentrically positioned shaft 09 , the folding blade shaft 13 moves on a circular path around the shaft 09 , and at the same time, rotates around its own axis. In the process, the tip or tips 03 of the folding blade 04 mounted on the folding blade shaft 13 describes a cycloid. Due to the eccentric arrangement of the shaft 09 with respect to the drum shell 01 , the folding blade 04 is extended through the slits 02 of the drum shell 01 at only one location of its cycloidal track. The gear ratio of the gear group 19 , 21 , 22 must be selected in such a way, that the folding blade shaft 13 performs one entire revolution around itself with every revolution of the gear unit 12 . In the situation under discussion, the gear ratio of the gear group 19 , 21 , 22 has been selected to be such that, with the housing 17 assumed to be fixed, one revolution of the second gear wheel disk 19 drives “n”=3 revolutions of the folding blade 04 .
[0029] The first gear wheel disk 18 can be displaced axially between first and second positions by axially displacing the first gear wheel disk shaft 16 . In the first position, the first gear wheel disk shaft 16 is coupled with the second gear wheel disk shaft 14 via first tooth arrangements 23 , 24 arranged on the facing front ends of the two gear wheel disks 18 , 19 , and in this way is kept immovable with regard to the frame of the folder. In this position, the first gear wheel disk 18 drives another gear wheel group 26 , 27 , which consists of an intermediate gear wheel 26 and a gear wheel 27 of the second folding blade shaft 28 . In this state, the folding blade 04 of the second folding blade shaft 28 moves on the same cycloidal track as that of the first folding blade shaft 13 . This state corresponds to single production.
[0030] In the second axial position of the first gear wheel disk 18 , it is coupled by the use of a second tooth arrangement 29 on its second end face with a tooth arrangement 31 , which is fixedly connected with the housing 17 . In this position, the first gear wheel disk 18 follows the rotation of the housing 17 , and the folding blade 04 of the second folding blade shaft 28 moves on a circular track, on which it does not extend out of the folding drum, i.e. it does not move with respect to the cylinder. This state corresponds to collection production.
[0031] The second tooth arrangements 29 , 31 consist of a large number of evenly arranged teeth, which permit their engagement with each other in a plurality of orientations, which plurality of orientations are respectively separated from each other by small angles of rotation. Thus, even when tooth tips of the two second tooth arrangements 29 , 31 meet each other in the course of the axial displacement of the first gear wheel disk 18 , in relation to the tooth arrangement 31 , a slight turning of the housing 17 is sufficient to make an engagement possible. In contrast thereto, as can be seen in FIG. 4 , the first tooth arrangements 23 , 24 each have a small number of teeth 32 , which are of irregular length and which are arranged at irregular distances in order to permit an engagement with each other only in three orientations of the two gear wheel disks 18 , 19 . It is assured by this structural feature that, when restoring the coupling between the gear wheel disks 18 , 19 , the folding blade 04 of the temporarily stopped second folding blade shaft 28 is in the same position as prior to the release of the coupling. This could require that, in the course of switching from collection to single production, the folding drum must initially be rotated some distance until the tooth arrangements 23 , 24 can be brought into engagement.
[0032] The teeth 32 of the first tooth arrangements 23 , 24 can also be arranged in such a way that an engagement is only possible in a single position of rotation.
[0033] If the gear ratio of the gear groups 19 , 21 , 22 , and 18 , 26 , 27 would correspond, for example, to “n”=4 revolutions of the folding blade shafts 13 , 28 per revolution of the gear wheel disks 18 , 19 , the teeth 32 could also be arranged in such a way that they would permit “m”=1, 2 or 4 engagement positions.
[0034] The change of the number of revolutions of the folding elements 04 is provided by the use of an actuating device, which is arranged coaxially with respect to the rotating shaft 09 , 14 , 16 of the support, i.e. the shaft 09 or the shaft sections 14 or 16 , particularly in the shaft journal.
[0035] The rotating shaft of the folding drum, which is not specifically shown, and the rotating shaft 09 , 14 , 16 of the support are arranged eccentrically with respect to each other. Each folding element 04 is rotatingly arranged on its further rotating shaft 13 , 28 , as discussed above, each of which rotating folding blade shaft 13 , 28 is arranged eccentrically with respect to the rotating shaft 09 , 14 , 16 of the support.
[0036] The described gear structure can also be used for a folding drum which has folding jaws 04 in place of folding blades 04 , i.e. for a folding jaw cylinder.
[0037] While preferred embodiments of a folding drum of a folding device, in accordance with the present invention, have been set forth fully and completely hereinabove, it will be obvious to one of skill in the art that various changes in, for example, the supports for the folding drum, the type of web being folded, and the like could be made without departing from the true spirit and scope of the present invention which is accordingly to be limited only by the appended claims.
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A folding drum of a folding device is comprised of at least one folding element and a transmission unit. The transmission unit has at least one toothed wheel which is coaxially arranged with respect to the rotational axis of the folding drum. The toothed wheel can be moved in the axial direction of the folding drum between at least two positions.
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CROSS REFERENCE TO RELATED DOCUMENT
[0001] Priority is herewith claimed under 35 U.S.C. §119(e) from copending U.S. Provisional Patent Application No. 60/356,387, filed Feb. 12, 2002, entitled “A COMPOSITION AND METHOD FOR PROTECTING LABILE ACTIVE COMPONENTS DURING HIGH TEMPERATURE DRYING,” by James V. Gruber et al. The disclosure of this U.S. Provisional Patent Application is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a composition and method for protecting personal care components, advantageously labile active personal care components, from decomposition during high temperature drying, employing water-soluble hydrolyzed polysaccharide encapsulants.
BACKGROUND OF THE INVENTION
[0003] The use of active components in personal care compositions continues to expand as the knowledge of human skin, its functionality and its biochemistry continues to grow. As used herein, the term “personal care compositions” is used to designate soaps, shampoos and skin care medicaments, as well as cosmetic, therapeutic, and homeopathic compositions. It is now generally accepted that the skin is not a non-living entity that simply covers the human body. Rather, it is a major organ that responds to forces from both internal biochemical signals and external physical and chemical markers. For example, even momentary contact of living skin with ultraviolet radiation, such as sunlight, causes an immediate cascade of biochemical processes designed to prevent damage from free radicals created instantly in the skin because of the radiation.
[0004] Many different eukaryotic organisms respond to external stresses in much the same way that human skin does. One example of such an organism is live yeast that is one of the simplest single-celled organisms for which the entire genome is well established. Under normal fermentation conditions yeast will grow, live and die a typical lifetime determined by their genetic make-up and environmental surroundings. Sperti recognized in U.S. Pat. No. 2,320,478 that extracts from live yeast cells comprise a cosmetic composition that will actually improve cellular respiration in cells onto which the extract is topically applied. It was further recognized in U.S. Pat. No. 2,239,345 that these yeast extracts could be further modified by applying sub-lethal stresses, such as chemicals or radiation, to the growing yeast so that the yeast responds by forming agents that are resistant to the external stress. For example, yeast exposed to ultraviolet radiation responds by forming increased amounts of cellular antioxidants and free radical inhibitors. The active ingredients are suitably used to provide protection to human skin when applied topically to the surface of the skin.
[0005] It is now possible to grow and maintain living human skin cultures. These cultures require very specific conditions to maintain the active growing fibroblasts, corneocytes, keratinocytes and melanocytes that comprise normal human skin. The growth medium in these cultures is typically comprised of a mixture of nutrients, vitamins and other components that the growing skin thrives on. Such “growth media” are sold commercially through, for example, PromoCell [see (http://www.promocell.com/Default.htm)] and Biowhittaker [see (http://www.medprobe.com/is/biowhittaker.htm1)].
[0006] Once these growth media are employed for the growth of human fibroblasts or skin substitutes, the culture media becomes “enriched” in human growth factors, polypeptides, cytokines, and other cellular components that provide the media with unique opportunities in topical applications, thus providing “enriched growth media”. Enriched growth media are also referred to herein as “conditioned media”. Disclosure regarding the use of conditioned media in topical applications is provided in PCT patent publications WO 0069449 and WO 0114527. These publications are incorporated herein by reference in their entirety.
[0007] Fermentation technology has also progressed significantly in the last decade, and it is now routinely possible for companies to bioengineer microorganisms that can produce any number of active, biologically interesting, molecules. For instance, E. coli is a commonly occurring microorganism that has been harvested to grow a number of pharmaceutically and topically active ingredients. Typically, fermentation requires the use of specialized fermentation reactors, such as those that are sold by New Brunswick Scientific [see (http://www.nbsc.con/index2.htm]. New Brunswick, N.J.). Generally, the microorganisms are grown on a nutrient broth that provides the bacteria with the essential nutrients, vitamins and other components for cell growth. Once the bacteria have grown to viability, they are typically lysed, a process that kills the bacteria, and the cellular contents are isolated as an aqueous mixture. If necessary, valuable components can be further purified if, for example, isolation of a particular pharmaceutically-active material is desired.
[0008] Active products resulting from fermentation processes have also found application in topically-applied products, as disclosed in U.S. Pat. No. 5,334,518 issued to Yakurigaku Chuo Kenkyusho. The '518 patent discloses the use of bacterial fermentation processes to manufacture gamma-pyrone derivatives for cosmetic applications.
[0009] Active products made using the above-described production methods are typically provided as aqueous or water-miscible organic solvent mixtures, such as aqueous alcohol mixtures. For example, live yeast cell derivative is typically provided as an aqueous solution that contains insoluble materials that include cell wall components. Likewise, fibroblast conditioned growth media are also typically provided as water-based compositions that contain all of the components of the fibroblast growth media plus the skin cellular components that leach from the growing fibroblasts or skin samples. Additionally, bacterial fermentation growth media typically comprise water-soluble growth factors and nutrients that are then enhanced by the presence of the bacterial lysate components.
[0010] These aqueous and aqueous alcohol active compositions (so-called “conditioned media”) have potential application as components of topical pharmaceutical, cosmetic, and personal care products. The compositions are suitable for use “as is” in water based product applications. However, in applications requiring anhydrous or substantially anhydrous components, the water-containing active compositions must be further processed to remove essentially all of the water. Drying to remove water can be effected in the presence of heat (i.e., high temperature drying) or in the absence of heat (i.e., low temperature drying).
[0011] Low temperature drying, such as freeze drying, poses certain disadvantages. For example, freeze drying is expensive because it requires freezing the components of the active composition in the presence of a vacuum to cause sublimation of the water in the composition. Another disadvantage is that many materials cannot be properly freeze dried due to the presence of salts and other low molecular weight hydroscopic materials that prevent the components from freezing correctly. More specifically, the presence of even a small amount of salt will lower the freezing point of water significantly, and can cause problems in efforts to freeze-dry a salt-containing material. Therefore, other kinds of drying need to be considered.
[0012] High-temperature drying techniques have been employed for many years in the food industry for the drying of products such as starches, vitamins and proteins for human consumption. Typical high temperature drying methods include spray drying, drum drying and flash drying. These methods typically expend significantly less energy and time, as compared to low temperature processes like freeze-drying. When using these methods of drying, the surface area of aqueous solutions or aqueous/organic solvent mixtures exposed to the drying is increased either by atomizing the solutions (as is done in spray and flash drying) or by forming films of the solutions (as is done in drum drying). The resulting increased surface area allows the products to be dried very rapidly by causing the moisture present to be exposed to the heated air. The dried products are typically collected as powders. Since the drying time is short, there is minimal contact between the active component and the hot drying surface, thus minimizing the risk of product decomposition. Nonetheless, any exposure to high temperature poses a risk of an unwanted result attributable to the drying process in view of the “labile” nature of the active component.
[0013] Labile components are unstable at elevated temperatures, and tend to undergo physical changes and/or chemical degradation at elevated temperatures. The “unwanted result” can manifest itself in various ways, such as by a color change in the product, development of an undesirable odor, or, in an extreme case, decomposition of the labile component of the composition. The latter result is particularly unacceptable since the labile components are typically the active, and hence most desirable, components of the composition, and decomposition causes loss of activity of the labile component.
[0014] Accordingly, what is needed is a new method and composition for protecting labile active compositions against heat-related physical degradation and decomposition during high temperature drying to effect water removal. The present invention provides one answer to that need.
BRIEF SUMMARY OF THE INVENTION
[0015] It is an object of the present invention to provide a method for protecting labile active compositions against heat-related physical degradation and decomposition during high temperature drying utilized in order to effect water removal. It is another object of the present invention to provide a personal care component that is at least partially encapsulated within a hydrolyzed polysaccharide encapsulant in order to reduce or eliminate the risk of damage to the personal care component during drying at an elevated temperature. It is a further object of the present invention that the active labile components are protected from the intense heat of drying by encapsulation of the active, labile component into a hydrolyzed polysaccharide matrix. It is a further object to provide an additive suitable for use in anhydrous or essentially anhydrous personal care products. It is a further object of the present invention to provide personal care components exhibiting a “slow release” or a “timed release” characteristic due to encapsulation by means of a hydrolyzed polysaccharide matrix.
[0016] In one aspect, the present invention relates to a composition comprising an additive for a personal care composition comprising a personal care component that is at least partially encapsulated within a hydrolyzed polysaccharide encapsulant.
[0017] In another aspect, the present invention relates to a composition comprising a biologically active component encapsulated within a hydrolyzed polysaccharide matrix.
[0018] In yet another aspect, the present invention relates to a method for protecting a labile personal care component which comprises dispersing, or dissolving, the component in an aqueous or aqueous alcoholic solvent in order to provide a dispersion or solution, and drying the dispersion or solution at an elevated temperature in the presence of a hydrolyzed polysaccharide, thereby causing particles of said personal care component to become encapsulated within particles of said hydrolyzed polysaccharide.
[0019] In still another aspect, the present invention relates to a method for protecting a composition containing labile biologically active particles which comprises encapsulating at least a portion of said biologically active particles within hydrolyzed polysaccharide particles, thereby protecting said portion of said biologically active particles.
[0020] These and other aspects will become apparent upon reading the following detailed description of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] It has now been surprisingly found by the present inventor that hydrolyzed polysaccharides are suitably employed in order to protect labile, active components such as live yeast cell derivatives, conditioned media or bacterial fermentation broths from the heat associated with high temperature drying of these components. Without wishing to be bound by any particular theory, it is thought that the hydrolyzed polysaccharide acts to partially dissipate the instantaneous transfer of heat into the drying particle (or “droplet”), during the drying process, by transferring the heat into the molecular structure of the hydrolyzed polysaccharide. The hydrolyzed polysaccharide thus acts as a heat sink for at least a portion of the transferred heat. This minimizes the amount of heat that the active component experiences in the drying chamber, and thus prevents undesirable decomposition reactions from occurring.
[0022] After drying, the resulting dried particle is comprised of the personal care component entrapped inside a matrix of the dry hydrolyzed polysaccharide. Because the hydrolyzed polysaccharide is essentially water soluble, it can be easily redissolved into moist environments as might be desired. Dissolution of the hydrolyzed polysaccharide will slowly release the entrained active, providing a timed-release of the active. Under certain circumstances, for example if the hydrolyzed polysaccharide is a product of starch hydrolysis, certain enzymes may also help to accelerate the dissolution of the hydrolyzed polysaccharide matrix. For instance, it is well known that the human mouth contains a variety of amylases that are known to break down the anhydroglucose bonds in starchy molecules. If the hydrolyzed polysaccharide is a starch-based material, and the composition of the present invention finds its way into a product intended for topical application to the mouth, such as, for example, lipstick, the release of the active components will be further enhanced. The use of live yeast cell derivatives in lipsticks has been suggested, for example, in U.S. Pat. No. 5,776,441, and the disclosure of this patent is incorporated herein by reference in its entirety.
[0023] As used herein, the term “hydrolyzed polysaccharide” is defined as a low molecular sugar macromonomer having a molecular weight of less that about 25,000 grams/mole, more preferably less than 10,000 grams/mole, most preferably less than 8,000 grams/mole range but greater than 1000 grams/mole. A commercially available hydrolyzed polysaccharide POLYSORB C (available from Roquette America) has a molecular weight of about 3,500 grams/mole. The hydrolyzed polysaccharides of the present invention are essentially water-soluble. “Essentially water-soluble” means that the hydrolyzed polysaccharides are soluble in water at any pH at concentrations greater than 0.5 grams per 100 grams of water at 25° C. and ambient pressure. The hydrolyzed polysaccharides useful in this invention can come from hydrolysis of a variety of polysaccharide sources including, but not limited to, hydrolyzed polyglucoses, polygalactomannans, polyglucomannans, polyarabinoses, polymannoses and the like. Especially preferred for the purposes of this invention are hydrolyzed polysaccharides derived from hydrolyzed polyglucoses such as hydrolyzed starches. Such hydrolyzed polysaccharides are available commercially from, for example, Roquette America (Koekuk, IA).
[0024] In the compositions of the present invention, the weight ratio of the concentration of the labile active component to the concentration of the hydrolyzed polysaccharide encapsulant suitably ranges from about 5:1 to about 1:20, preferably from about 1:1 to about 1:10, most preferably from about 1:1 to about 1:5, based upon the total weight of these two components.
[0025] As used herein, the term “anhydrous” means free of water, and the term “essentially anhydrous” means essentially free (i.e., contains less than 5 wt % ) of water. “Live yeast cell derivatives” as used herein includes both aqueous and aqueous alcoholic extracts from growing yeast cultures. Such extracts may comprise, among other ingredients, vitamins, proteins, growth factors and other cellular components as disclosed, for example, in U.S. Pat. No. 2,320,478, incorporated herein by reference in its entirety. Such live yeast cell derivatives are available commercially from, for example, Arch Personal Care (South Plainfield, N.J.).
[0026] “Conditioned media” as used herein designates growth media that supports the development of human fibroblast, ketatinocytes, comeocytes or melanocytes. This media contains the nutrients, vitamins and other nutritional supplements necessary to support the growth of the skin cells along with various human growth factors, cytokines and ancillary active components excreted by the fibroblast, ketainocytes, corneocytes or melanocytes during growth. Such conditioned media are described in more detail in PCT patent publication WO PCT 01/14527 assigned to Organogenesis (Canton, Mass.) and incorporated hereinby reference in its entirety.
[0027] “Bacterial fermentation media” as used herein denotes the broth that is used to support the growth of active eukaryotic or prokaryotic bacterial cultures grown aerobically or anaerobically using standard fermentation technology known to those skilled in the art. The fermentation media may comprise agar, fetal bovine serum, vitamins, minerals, and other nutritional supplements required to sustain the growth of the bacteria. In addition, nutritional supplements such as corn steep liquor, the by-product of corn wet milling, can be added to increase the nutritional content of the fermentation broth. Bacterial growth media may also include the cellular (i.e., cytoplasmic, periplasmic and nuclear) components of the bacteria, retrieved along with the growth media by lysing of the living bacteria. Such “cellular components” may include various growth factors, cytokines and polypeptides, as well as other minor components of the living cells. Cellular components are described in more detail, for example, in U.S. Pat. No. 5,334,518 and U.S. Pat. No. 6,180,367 B1, the disclosures of which are incorporated herein by reference in their entirety.
[0028] Commercial spray drying equipment useful in the present invention is available, for example, through Spray Drying Systems, Inc. (Randallstown, Md.) [see (http://www.spraydrysys.com/)]. A number of factors, principally the method of atomization, the pressure of the atomization and the temperature of the drying chamber, control particle size of the spray-dried material. Spray drying is suitably effected at a temperature from about 30° C. to about 600° C., preferably from about 400° C. to about 500° C. Typical particle sizes for spray-dried products can measure between 200 microns and 10 microns, more typically between 100 microns and 20 microns. Under these conditions, the drying process typically adversely affects each of the active components if an attempt is made to dry them without the presence of the protective hydrolyzed polysaccharide. Often this adverse effect is manifested by a color change in the product and/or development of undesirable odors attributable to the drying process.
[0029] The composition of the present invention can be used with any number of additional inert or active ingredients, as might be required to manufacture the desired therapeutic, cosmetic or personal care products. Such materials include, but are not limited to, “functional ingredients” such as, for example, conditioners, emollients, waxes, oils, polymers, fixatives, colorants, humectants, moisturizers, stabilizers, diluents, solvents, fragrances and the like, as well as “active ingredients” such as, for example, botanicals, neutraceuticals, cosmeceuticals, therapeutics, pharmaceutics, antifungals, antimicrobials, steroidal hormones, antidandruff agents, anti-acne components, sunscreens, preservatives and the like. Such additional ingredients are suitably present in an amount of from about 0.5% to about 99.9% by weight, based upon the total weight of the personal care composition.
[0030] The compositions of the present invention, being anhydrous or essentially anhydrous in nature, are suitably employed in a number of topical products and formulations. In the therapeutic, cosmetic or personal care products the composition of the present invention might be used in the range of 0.1 to 95 wt %, more preferably in the range of 0.5 to 50 wt %, most preferably in the range of 0.5 to 10 wt %. Examples of topical products into which the composition of the present invention may find use include, but are not limited to, powdered compositions such as pressed powder cosmetics, bath salts, foot powders, athletes foot treatments, anti-itch products, anti-lice products, talc and eyeshadows, shaped solid products such as lipsticks, soaps, deodorant sticks, antiperspirants, sunscreen sticks or eye pencils, solvent-based products such as nail enamels or lacquers, alcohol-based products such as sprays, body sprays, spritzes, and hair sprays, alcohol-based antimicrobial products such as lotions, sprays and towelettes, anti-comedometic products such as anti-acne products and nose strips and facial masks, oral personal care products such as toothpastes, mouthwashes, mouth deodorizers and soap compositions such as bar soaps and synthetic detergent (often called syndet) bars.
[0031] The following examples are intended to illustrate, but in no way limit, the scope of the present invention.
EXAMPLE 1
[0032] A mixture of 500 grams of a 25 wt % aqueous solution of live yeast cell derivative available from Arch Personal Care and 1000 grams of POLYSORB C available from Roquette America, which is a 68 wt % solution of hydrogenated starch hydrolyzed polysaccharides, was prepared by adding the live yeast cell derivative to the hydrolyzed polysaccharide with vigorous mixing. Upon complete mixing of the two components the products were spray dried using a pilot scale spray dryer supplied by Niro (Soeborg, Denmark) at a temperature of about 450° C. The resulting spray dried composition was a white anhydrous powder composed of approximately 15 wt % live yeast cell derivative and 85 wt % hydrolyzed polysaccharide.
EXAMPLES 2 AND 3
[0033] In a similar fashion to Example 1 mixtures of live yeast cell derivative at 480 and 600 grams with 520 and 400 grams of POLYSORB C hydrolyzed polysaccharide, respectively, were prepared and spray dried in a similar fashion as described above. This provided powdered compositions that comprised 20 and 35 wt % live yeast cell derivative encapsulated into 80 and 65 wt % of hydrolyzed polysaccharide, respectively.
Comparative Example 4
[0034] An unadulterated sample of 25 wt % live yeast cell derivative (but containing no hydrolyzed polysaccharide) was spray dried using similar conditions as described above in Example 1. The resulting dry powdered product was discolored to a deep brown and had an offensive, burnt odor.
EXAMPLE 5
[0035] A sample of 200 grams conditioned growth medium was blended with 200 grams of POLYSORB C hydrolyzed polysaceharide. The mixture was spray dried using conditions similar to those described in Example 1. The resulting white powder comprised approximately 30 wt % of conditioned growth media encapsulated in approximately 70 wt % hydrolyzed polysaccharide.
[0036] While the invention has been described above with reference to specific embodiments thereof, it is apparent that many changes, modifications, and variations can be made without departing from the inventive concept disclosed herein. Accordingly, it is intended to embrace all such changes, modifications and variations that fall within the spirit and broad scope of the appended claims. All patent applications, patents and other publications cited herein are incorporated by reference in their entirety.
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A composition and method for protecting personal care components, advantageously labile active personal care components, from decomposition during high temperature drying, employing water-soluble hydrolyzed polysaccharide encapsulants. Also disclosed is an additive for a personal care composition comprising a personal care component that is at least partially encapsulated within a hydrolyzed polysaccharide encapsulant. Also disclosed is a method for protecting a composition containing labile biologically active particles which comprises encapsulating at least a portion of the biologically active particles within hydrolyzed polysaccharide particles, thereby protecting said portion of said biologically active particles.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and is a continuation of U.S. patent application Ser. No. 14/317,343, filed Jun. 27, 2014. This application is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present subject matter relates generally to tower structures, and more specifically to methods and apparatus for assembling tower structures.
BACKGROUND OF THE INVENTION
[0003] Construction of towers for support of various items has been practiced for many years. Various towers of various materials, including wooden, steel, and, more recently, concrete, have been provided to support, for example, electrical transmission lines. In a like manner, wind driven apparatus including windmills and wind-driven power generators in various forms and designed for many purposes (including for example pumping of water from wells as well as, more recently, generation of electrical power) have also been developed.
[0004] Such towers are generally constructed of multiple pieces that are assembled at the location of the tower. The pieces are usually hoisted in place by a crane. Cranes can be very expensive to maintain and operate, and a substantial hourly cost is incurred for every hour the crane is on site.
[0005] For example, a large construction crane may require 16 truckloads to transport all of the component parts, substantial labor to assemble and inspect, and then substantial labor to disassemble. Accordingly, a method and apparatus for constructing a tower that minimizes or eliminates the need for a crane is desired.
SUMMARY OF THE INVENTION
[0006] The present invention broadly comprises a method and apparatus for constructing a tower. In one embodiment, the apparatus may include a structure including a foundation including a plurality of hydraulic cylinders; a truss tower located on the foundation and configured to support a tower built on the foundation; and a controller configured to control extension and retraction of the hydraulic cylinders.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] A full and enabling disclosure of the present subject matter, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
[0008] FIG. 1 illustrates a perspective view of an embodiment of the present invention;
[0009] FIG. 2 is a top view of the foundation of the embodiment shown in FIG. 1 ;
[0010] FIG. 3 illustrates a top view of the tower and a schematic of the cylinder control system;
[0011] FIG. 4 is a side view of all of the cylinders extended before the insertion of a new level;
[0012] FIG. 5 is a side view showing half of the cylinders retracted and half extended;
[0013] FIG. 6 is a side view of the first block that is fully inserted and the hydraulic cylinders below are extended to contact the block;
[0014] FIG. 7 is a side view of the insertion of the second block;
[0015] FIG. 8 is a side view of the completion of a level; and
[0016] FIG. 9 is a top view of an embodiment of the restraining truss shown in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Reference is presently made in detail to exemplary embodiments of the present subject matter, one or more examples of which are illustrated in or represented by the drawings. Each example is provided by way of explanation of the present subject matter, not limitation of the present subject matter. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present subject matter without departing from the scope or spirit of the present subject matter. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present subject matter covers such modifications and variations as come within the scope of the disclosure and equivalents thereof.
[0018] FIG. 1 shows a perspective view of an exemplary embodiment of an apparatus 10 for constructing a tower 80 in accordance with the present invention. Tower 80 supports wind turbine 82 , but towers made according to the present invention may support other equipment, power lines, or other objects. Any such towers may be constructed according to the present invention.
[0019] Apparatus 10 includes a foundation 20 and a truss tower 40 located on the foundation 20 . Foundation 20 includes a plurality of hydraulic cylinders 22 , shown in FIGS. 3-8 . Truss tower includes vertical legs 42 , upper restraining truss 44 , and lower restraining truss 46 . As shown in FIG. 2 , the base 42 A of each vertical leg 42 of the truss tower 40 rests on foundation 20 .
[0020] FIG. 1 shows a truss tower including two restraining trusses, but more than two can be included and are within the scope of the present invention. The restraining trusses 44 and 46 provide horizontal force to support the tower 80 during construction of the tower. In particular, the restraining trusses 44 and 46 counteract uneven forces on the tower 80 during the method of construction described hereafter.
[0021] FIG. 9 shows a close up top view of a restraining truss, such as upper restraining truss 44 . Each restraining truss includes force bearing devices 48 to transfer force from the truss tower 40 to the tower 80 . Further, the force bearing devices 48 allow tower 80 to move past vertically as additional levels are added to tower 80 from below. In the embodiment shown in FIG. 9 , the force bearing device includes rollers 49 to exert horizontal force on tower 80 while still allowing tower 80 to move vertically. However, other devices known in the art may be used in this manner. Further, the force bearing devices may include hydraulic cylinders 50 to tighten the force bearing device up to the wall of tower 80 . The embodiment shown in FIG. 9 includes a hydraulic cylinder 50 for each force bearing device 48 . However, fewer may be used as long as the restraining truss can be sufficiently tightened around tower 80 .
[0022] In the embodiment shown in FIGS. 1-9 , tower 80 has an octagonal cross-section. However, other cross-section shapes are possible, such as square or circular cross-sections. All of these modifications are within the scope of the invention.
[0023] Tower 80 as shown in FIG. 1 includes a wind turbine 82 located on top of levels 84 . In one embodiment, levels 84 are first constructed with a crane, the truss tower 40 is constructed around the levels 84 , and then the crane lifts the wind turbine 82 to the top of levels 84 . The following procedure is then used to add additional levels to the tower using hydraulic cylinders 22 . However, if a heavy object like a wind turbine is not going to be located at the top of the tower, then the truss tower 40 can be constructed over foundation 20 and all levels can be constructed using the hydraulic cylinders 22 . This would allow the elimination of the need for a crane, as the addition of levels using the hydraulic cylinders 22 only needs a forklift, as discussed hereafter.
[0024] In an embodiment for a tower 80 with a wind turbine 82 , 10 2 m levels 82 may be constructed using a crane, and a height of wind turbine 82 may be 50 m. Thus, each leg 42 would be 20 m tall, upper restraining truss 44 would be at 20 m in height while lower restraining truss 46 may be at approximately 8 m from the bottom of truss legs 42 . Truss legs 42 may be square of 12 inches on a side, and may be 22 feet apart from each other.
[0025] In the embodiment shown in FIG. 1 , foundation 20 is constructed, and hydraulic cylinders 22 and block supports 24 are installed in the foundation 20 . Hydraulic cylinders 22 are arranged in pairs, with a block support 24 extending between each pair of cylinders. A plurality of levels 84 are constructed using a crane, the truss tower 40 is constructed around levels 82 and on foundation 20 , and the wind turbine 82 is added to the top of levels 84 . Additional levels are then added using hydraulic cylinders 22 and block supports 24 as shown in FIGS. 4-8 . In the embodiment shown in FIGS. 1-9 , hydraulic cylinders 22 and block supports 24 are then removed from foundation 20 after the desired number of additional levels are added.
[0026] In the embodiment shown in FIGS. 1-9 , there are 24 hydraulic cylinders 22 . In one embodiment, cylinders 22 are sized to lift a concrete tower with a final weight of 1800 tons. However, towers of any dimensions and material may be constructed using this method and apparatus. The size and number of cylinders may vary depending on the dimensions of the tower and the building material. All of these modifications are within the scope of the present invention.
[0027] In this regard, in the embodiment shown in FIGS. 1-9 , each level 84 and 86 is slightly wider than the level above, as shown in FIG. 3 . When the final level is added, the bottom of this final level will line up with the top of foundation 20 .
[0028] The first step of the process is shown in FIG. 4 , in which all of hydraulic cylinders 22 are extended to push up tower 80 by the height of one level. In the embodiment shown in FIGS. 1-9 , all of the levels 84 and 86 have approximately a same height. However, different heights could be used as long as the extension height of hydraulic cylinders 22 is greater than the tallest level. At this step, the tower must slide past the force bearing devices 48 on the restraining trusses, as noted above.
[0029] As shown in FIG. 5 , one half of hydraulic cylinders 22 are then retracted to allow block 86 A of new level 86 to be inserted. As noted above, in the embodiment shown in FIGS. 1-9 , new level 86 is made of two equal sized blocks 86 A and 86 B. However, embodiments where three or more blocks are used and/or each block is more or less than half of each level are possible and are within the scope of the present invention.
[0030] Block 86 A is inserted by the use of a forklift. Block 86 A is then connected to the level above. Block 86 A may be adhered to the block above, or may have grooves or projections that mate with the block above, or both. During this time, uneven forces are placed on the existing tower 80 . Accordingly, restraining trusses 44 and 46 exert horizontal forces on the tower 80 to prevent tower 80 from tipping over due to these uneven forces.
[0031] At this point, the other half of the hydraulic cylinders 22 are retracted, as shown in FIG. 6 . This allows block 86 B to be inserted using a forklift, as shown in FIG. 7 . Block 86 B is then connected to the level above in a similar manner as block 86 A, as shown in FIG. 8 . This should end the uneven forces on the tower, and reduce the load on the truss tower 40 .
[0032] Finally, the new level 86 is pushed up the height of a level by extending all of the hydraulic cylinders 22 , as shown in FIG. 4 . Half of the hydraulic cylinders are then retracted to allow the next level to be added, as described above. However, in the embodiment shown in FIGS. 1-9 , the seams between the two blocks are alternated from level to level. That is, the seam between two blocks is only located on a particular face for every other level, as shown in FIG. 1 . Thus, for example, a first level 86 is constructed by lowering a front half of hydraulic cylinders 22 , adding block 86 A to the front opening, lowering the back half of hydraulic cylinders 22 , and then adding back block 86 B. The following level would be constructed by lowering either the right (or left) half of hydraulic cylinders 22 , adding block 86 A to the right (or left) opening, lowering the left (or right) half of hydraulic cylinders 22 , adding block 86 B to the left (or right) opening. This is accomplished using the control computer 60 shown in FIG. 3 .
[0033] Control computer 60 receives position and pressure readings from each of the cylinders 22 through lines 60 A ( FIG. 3 does not show all of lines 60 A). Control computer 60 then sends signals to control pressurized fluid to each cylinder 22 through line 60 C to pressure manifold 62 . Based on the signals from the control computer 60 , pressure manifold 62 supplies pressurized fluid to each cylinder 22 through a respective valve 62 A. (Not all of valves 62 A are shown in FIG. 3 .) Control computer 60 also controls a return valve on each cylinder 22 through line 60 B. (Not all of lines 60 B are shown in FIG. 3 .) When the return valve is opened by control computer 60 , fluid runs through a respective return line 66 A to fluid reservoir 66 . (Only one of the 24 return lines 66 A is shown in FIG. 3 ). Fluid from fluid reservoir 66 is pressurized by electrical or diesel pump 64 before it is supplied to the pressure manifold 62 .
[0034] Control computer 60 has several programs to control multiple sets of the cylinders 22 . As discussed above, in the embodiment shown in FIGS. 4-8 , half of cylinders 22 are controlled to extend and retract together, and the halves are alternated for each level between (1) right and left half and (2) front and back half. Thus, control computer 60 at has programs to extend and retract (1) the right half of cylinders 22 , (2) the left half of cylinders 22 , (3) the front half of cylinders 22 , and (4) the back half of cylinders 22 . Additional commands such as all extend and all retract can also be programmed into control computer 60 . Further, if each level includes more than 2 blocks, additional commands will be needed to control smaller subsets of cylinders 22 .
[0035] Accordingly, a tower 80 may be constructed with less use of a crane, or without the use of a crane at all. As a forklift is much cheaper to operate than a crane, a substantial cost savings may be gained by using the present method and apparatus for constructing a tower.
[0036] The present written description uses examples to disclose the present subject matter, including the best mode, and also to enable any person skilled in the art to practice the present subject matter, including making and using any devices or systems and performing any incorporated and/or associated methods. While the present subject matter has been described in detail with respect to specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art.
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A method and apparatus for constructing a tower, where the apparatus may include a structure including a foundation including a plurality of hydraulic cylinders; a truss tower located on the foundation and configured to support a tower built on the foundation; and a controller configured to control extension and retraction of the hydraulic cylinders.
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BACKGROUND OF THE INVENTION
The invention relates to a method and a device for detecting a degree of pollution of an operational converter.
When converters, for example frequency converters, are operated in an environment which is polluted but for which they do not have a corresponding protection grade, deposits are formed inside the converter. Since the ambient air of the converter is used as a coolant, the dust particles contained in the ambient air can deposit on surfaces of the converter's components, especially elements to be cooled. For surfaces to be cooled, for example of a heat sink or surfaces of lossy components, these deposits lead to overheating with subsequent failure. Deposits on insulating surfaces can bridge the electrical insulation and therefore endanger the function and safety of the converter.
Whether a converter put on the market is used according to its protection grade can no longer be checked by the manufacturer of this converter. Only when a converter has shut down owing to the occurrence of a fault and technicians open this converter in order to remedy the fault, can it be established whether this converter has been used according to its protection grade. If not, the components of the converter must be covered with deposits. Only then is it established that the cause of the shutdown of the converter is not due to design but due to use. When such a converter is incorporated in a production process, the entire production sometimes has to be interrupted because of the converter which has shut down, which entails significant consequential costs.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a method and a device for detecting a degree of contamination of an operational converter, so that the risk of a protective shutdown of the converter due to pollution can be detected even before an operational interruption.
According to one aspect of the invention, this object is achieved by a method for detecting a degree of pollution of an operational converter, wherein an operating state of at least one of the converter's components which is exposed to the ambient air of the converter is determined, wherein a corresponding operating state of this component in the unpolluted state is determined, and wherein these two operating states are compared with each other and a comparison value thus determined represents a measure of the degree of pollution of the converter.
According to another aspect of the invention, this object is achieved by a method for detecting a degree of pollution of an operational converter, wherein a surface conductance of one of the converter's parts which is exposed to the ambient air of the converter is determined and compared with a predetermined limit value, the comparison value of which represents a measure of the degree of pollution of the converter.
According to yet another aspect of the invention, this object is achieved by a device for detecting a degree of pollution of an operational converter, having a thermal model for estimating a temperature of a heat sink of the converter and having a temperature sensor for determining a heat sink temperature and having an evaluation circuit, which is linked on the input side to the thermal model and the temperature sensor.
According to still another aspect of the invention, this object is achieved by a device for detecting a degree of pollution of an operational converter, having a resistor bridge circuit which is linked on the input side to a voltage supply of the converter and whose resistors are dimensioned so that two diagonally opposite resistors change their resistance by heating as a result of operation, whereas the other two maintain their resistance, and the output of which is linked to an evaluation circuit.
According to still another aspect of the invention, this object is achieved by a device for detecting a degree of pollution of an operational converter, having two conductor tracks extending close to each other, wherein one is provided with a discharge resistor, wherein the other conductor track is linked to a voltage supply of the converter, and wherein a voltage follower is electrically connected in parallel with the discharge resistor.
Since on the one hand an operating state of at least one of the converters components which is exposed to the ambient air of the converter and on the other hand an operating state of this component in the unpolluted state are determined, the degree of pollution of the converter can be deduced by means of a comparison of these two operating states. The comparison value thus determined is a measure of the degree of pollution of the converter.
By means of the second method according to the invention, the degree of pollution of a converter is detected by means of determining a surface conductance of one of the converter's parts which is exposed to the ambient air of the converter and a predetermined limit value. With increasing pollution inside the converter, the surface conductance of one of the converter's parts which is exposed to the ambient air of the converter increases, and therefore the value of a leakage current increases.
In an advantageous embodiment of the method for detecting the degree of pollution, the recorded comparison values are stored. The progress of the pollution of a converter is therefore available for further evaluations. From this progress of the pollution of the converter, for example, a prognosis can be determined for the time of the protective shutdown of the converter. This means that the remaining operating hours of the converter can be displayed, so that a production process can be run down in a controlled way.
In a further advantageous method, a warning signal is generated when a predetermined comparison value is exceeded. In this way, the fact that unperturbed operation is at risk is displayed visually and/or acoustically.
In a further advantageous method a warning message, which reports an imminent protective shutdown of the converter, is generated when a second predetermined comparison value, which is greater than the first comparison value, is exceeded. This second comparison value is predetermined so that it is still possible to suspend the production process.
Components of the converter, whose power loss and/or temperature can be determined, are advantageously employed for diagnosing the pollution of the converter. The heat sink of the converter, on which the power semiconductors of the converter are fitted in a thermally conductive way, is particularly suitable for diagnosing the pollution of the converter. The temperature of the heat sink is recorded in order to monitor the power part of the converter. When a limit value is exceeded, the converter is shut down.
A first device according to the invention for detecting a degree of pollution of an operational converter has a thermal model for estimating a temperature of a heat sink of the converter, a temperature sensor for determining a heat sink temperature and an evaluation circuit, which is linked on the input side to the thermal model and the temperature sensor. In this way a degree of pollution of an operational converter can be diagnosed with few components, some of which are already present in the commercially available converter.
In a second device according to the invention for detecting a degree of pollution of an operational converter, a resistor bridge circuit is used which is linked on the input side to a voltage supply of the converter and whose resistors are dimensioned so that two diagonally opposite resistors change their resistance by heating as a result of operation, whereas the other two maintain their resistance, and the output of which is linked to an evaluation circuit.
Advantageously, at least one resistor of the two resistors which change their resistance as a result of operation consists of a plurality of electrical resistors connected in series, which are arranged distributed in the converter. In this way, the pollution of the converter is detected not only at one predetermined position but inside the entire converter.
A third device according to the invention consists of the measurement of surface conductance. To this end this device comprises two conductor tracks extending close to each other, one of which is connected to a discharge resistor, in parallel with which a voltage follower is connected. The second conductor track is linked to a voltage supply of the converter. A measurement voltage is provided at the output of the voltage follower, the amplitude of which is proportional to a diagnosed degree of pollution of the converter.
With these methods and devices according to the invention, it is possible to reduce the number of failures due to a mode of operation of the converter which is not compliant with the protection grade, and the concomitant disadvantages such as costs and image loss.
BRIEF DESCRIPTION OF THE DRAWINGS
To explain the invention further, reference will be made to the drawing in which several embodiments of the device according to the invention are illustrated schematically.
FIG. 1 shows an advantageous embodiment of a first device according to the invention,
FIG. 2 illustrates a further advantageous embodiment of the first device according to FIG. 1 ,
FIG. 3 shows a second device according to the invention,
FIG. 4 illustrates a third device according to the invention,
FIG. 5 shows an embodiment of the measuring sensor of the device according to FIG. 4 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
An advantageous embodiment of a first device according to the invention is schematically represented in FIG. 1 . This device comprises a temperature model 2 , a temperature sensor 4 and an evaluation circuit 6 . The temperature sensor 4 is placed on the converters component whose temperature is intended to be measured. This component is the heat sink of the converter, which comes directly in contact with the ambient air of the converter. The temperature model 2 is a temperature model which is known per se for the heat sink. With this temperature model, an expected heat sink temperature T KK is determined as a function of an actual power loss P V and an actual coolant temperature T umg . The integration time constant corresponds to the thermal inertia, and the feedback coefficient corresponds to the inverse of the thermal resistance R th of the heat sink. The power loss P V is determined as in a conventional thermal model, for example for estimating a depletion layer temperature of a power semiconductor, from a load current value, an intermediate circuit voltage value, the phase control factor and a switching frequency. The coolant temperature T umg is determined by means of a further temperature sensor which, for example, is arranged in the coolant flow. As a result, this temperature model 2 of the heat sink delivers an estimated heat sink temperature T KK which the heat sink assumes by dissipating the power loss P V , when it is not polluted.
The evaluation circuit 6 comprises a comparator 8 on the input side, downstream of which a memory 10 is connected. This memory 10 is connected on the output side to a comparison instrument 12 , at the output of which a warning signal S W is provided. Two limit values T KKeG1 and T KKeG2 for a comparison value T KKe thus determined are furthermore fed to this comparison instrument 12 . The memory 10 is needed only so that the time variation of the pollution can also be evaluated. Otherwise, the comparison value T KKe thus determined may also be fed directly to the comparison instrument 12 .
When the heat sink of the converter is polluted, the measured heat sink temperature T KKmes is higher than the estimated heat sink temperature T KK Of the temperature model 2 . A negative value is obtained as the comparison value T KKe . The minus sign signifies that the heat sink of the power part of the converter is operating worse than intended. The value of this comparison value T KKe indicates how much worse this heat sink is operating. Only when the value of this comparison value T KKe thus determined is negative and its magnitude is equal to or greater than the first limit value T KKeG1 is a warning signal S W generated, for example by driving a display. If the magnitude of the comparison value T KKe increases owing to continuous pollution of the heat sink of the power part of the converter, so that it is equal to or greater than a second limit value T KKeG2 which is greater than the first limit value T KKeG1 , then a second warning signal S W is generated. This warning signal S W can be used in order to display that a degree of pollution is reached which makes it likely that a protective shutdown will be triggered within the foreseeable future, or an equipment malfunction will occur. By recording these individual comparison values as a function of time, for example, a residual operating time can be calculated. The residual operating time indicates that, under the prevailing operational conditions, the converter will shut down after the indicated time period has elapsed. An acoustic signal may be used in addition to the visual representation.
FIG. 2 shows a further advantageous embodiment of the first device according to the invention. This embodiment differs from the embodiment according to FIG. 1 in that the temperature model 2 is supplemented with an estimator for the thermal resistance R th of the heat sink. This means that the value of the temperature difference T KKa determined between the heat sink and the coolant is no longer fed directly to the inverse of the thermal resistance R th , but instead to a multiplier 14 at the second input of which the inverse of the thermal resistance R th is applied. An integrator 16 , which is fed on the output side to the inverse of the thermal resistance R th , is furthermore connected downstream of the comparator 8 of the evaluation circuit 6 . The value which is obtained at the output of the integrator 16 is the efficiency η KK of the heat sink, which is a direct measure of the effectiveness of the cooling system. An efficiency η KK less than one means that there is pollution of the heat sink. The difference from η KK =1 indicates the degree of pollution of the heat sink of the converter. This value for the efficiency η KK may be evaluated just like the temperature deviation T KKe which is determined for the heat sink.
A second device according to the invention for detecting a degree of pollution of an operational converter is represented in more detail in FIG. 3 . This second device according to the invention consists of a resistor bridge circuit 18 , which is linked on the input side to a voltage supply U of the converter. This resistor bridge circuit 18 comprises two resistors R 2 and R 3 , which heat up as a result of operation and therefore increase their resistance, and two resistors R 1 and R 4 which do not change their resistance during operation of the converter. These resistors R 1 and R 4 either remain at ambient temperature or are made of a material having a temperature-independent resistance. If the resistances of these resistors R 1 to R 4 are selected so that a bridge diagonal voltage U diag is exactly zero for unpolluted resistors R 1 to R 4 in the steady state, then this bridge diagonal voltage U diag can be used directly as a measure of any pollution occurring in the operational converter.
In an advantageous embodiment of this device, the resistors R 2 and/or R 3 consist of a plurality of electrical resistors, which are arranged distributed inside the converter and are electrically connected in series. In this way, the pollution of the operational converter is determined not only at one predetermined position but in the entire converter.
A third device for determining a degree of pollution of an operational converter is illustrated in FIG. 4 . This device comprises a measuring instrument 20 for the surface conductance and a voltage follower 22 . The measuring instrument 20 comprises a discharge resistor 24 and a measuring sensor 26 . The measuring sensor 26 used consists of two conductor tracks 28 , 30 extending close to each other, for example, which are routed over those circuit board regions of the converter in which the greatest pollution is expected during operation of the converter. This design of this measuring sensor 26 is represented in more detail in FIG. 5 . A supply voltage U of the converter is applied to the input terminals 32 and 34 of the measuring instrument 20 . The input terminal 32 is connected electrically conductively to the conductor track 28 of the measuring sensor 26 , whereas the conductor track 30 is connected to one pole of the discharge resistor 24 . The second input terminal 34 of the measuring instrument 20 is linked to the free pole of the discharge resistor 24 . So that a leakage current proportional to the pollution of the converter can flow, these two conductor tracks 28 and 30 are free of solder stop resist. A voltage proportional to this is then set up across the discharge resistor 24 . This voltage is smoothed by means of a capacitor 36 . The voltage follower 22 , which is used as an impedance converter, generates from this smoothed voltage a measurement voltage U mes which is proportional to the pollution of the operational converter. Instead of the two conductor tracks 28 and 30 extending close to each other, it is alternatively possible to use solder eyelets which are provided at regular intervals.
With these devices, whose components may be integrated in a converter or sometimes already belong to the converter, the pollution of the converter can be diagnosed straightforwardly during its operation. The risk of equipment malfunctions or failures due to progressive pollution can therefore be detected already before an operational interruption takes place. This reduces the number of failures and the concomitant disadvantages such as costs and image loss.
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A method and a device for detecting the degree of pollution in an operational converter are disclosed. An operating state of at least one of the converter components that is exposed to the ambient air is determined and a corresponding operating state of said component in an unpolluted state is determined. The two operating states are then compared and the calculated comparison value is used as a measurement for the degree of pollution of the converter. Detecting the degree of pollution of an operational converter permits a reduction in the number of breakdowns caused by unprotected operation of a converter, and associated disadvantages such as costs and damage to a company's image.
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FIELD OF THE INVENTION
This invention relates to headwall structures and in particular to improved lightweight headwall structures used with standard culvert or drainage pipes in infrastructure water management system. Because they are lightweight while having adequate strength, headwall structures according to the invention are easily transported and installed. They may be largely prefabricated. They are intended to be used in substitution for standard heavy concrete headwalls.
BACKGROUND OF THE INVENTION
Headwalls are structures that attach to the end of a culvert or drainage pipe and support the surrounding earth or fill, thus preventing or impeding local erosion and undercutting of the bank around the culvert, thereby minimising the risk of serious washout. These structures also facilitate the attachment of auxiliary components, e.g., trash gates for debris and animal control, security grids for prevention of entry into culvert or pipe, weir boards for use in control of water flow and levels in agricultural installations, etc. Such structures include a back wall having an orifice to receive a culvert or pipe, and often include a tray joined to the lower edge of the back wall and extending outwards therefrom and may have two outwardly flared (diverging) wings or sidewalls joined to the back wall and to the tray to retain and stabilize the surrounding earth or fill side wings for earth bank stabilization. The wings and tray when present as part of a headwall structure used as an outflow (exit) structure downstream of the culvert or pipe, direct the outflow received from the pipe or culvert away from the headwall. If used as entrance structures upstream of the pipe, such headwall structures receive water from a source such as an open ditch or drain and direct the water into the orifice and thence into a connected pipe if such is present.
Conventionally such headwall structures are made of relatively heavy concrete either formed in place or precast. It is well known that structures formed in place are labour-intensive and may also require prolonged traffic diversion if they have to be erected in association with a road in use. Because of their heavy weight, precast concrete structures require heavy-duty equipment to transport, handle and install. Additionally, concrete has several disadvantages. It is rigid and prone to cracking in the event of earth movement due to seismic events or subsidence or due to permafrost conditions in northern areas. Concrete is not environmentally friendly due to leaching of material into the ground water. It is also highly porous and subject to spalling and salt absorption.
A representative conventional culvert with associated concrete headwall can be found in U.S. Pat. No. 4,993,872 to Lockwood; this patent discloses a prefabricated headwall but without a pipe. A concrete headwall for use with a connected pipe is disclosed in U.S. Patent No. 3,779,021 to Green. An alternative concrete structure for connection to a pipe is disclosed in U.S. Pat. No. 5,551,798 to Goodreau. On occasion the use of plastics materials for coupling pipe to another structure has been proposed; see for example U.S. Pat. No. 5,971,663 to Brothers.
The Green patent discloses headwalls manufactured by pouring concrete into a light plastic prefabricated form. This method substantially reduces the amount of labour required to build the headwall, but still requires considerable time and effort, because the concrete has to be transported to the site. Poured-in-place concrete is increasingly unacceptable because of potential negative environmental and ecological impact on wildlife habitats and drinking water quality. Note that the Green design, because of the complexity of surface detail, would not readily accommodate after-market add-on auxiliary devices such as trash gates, security grids and weir boards.
Goodreau's disclosed structure embodies two prefabricated end walls of the culvert with a specific retainer system; his structure suffers from the inherent disadvantages of using concrete slabs. Goodreau does not disclose the use of sidewalls or wings that retain the adjacent earth bank, so there could be a tendency for the earth bank to spill over the flat bottom portion of the headwall outlet area. Goodreau's design does not retain side bank slope material nor minimize ingress into pipe opening, nor does it provide complete retention of the integrity of the side slope. His headwall may not be suitable for permafrost or boggy areas without some modification, because his footings appear to be inadequate for the weight of the precast concrete unit. The structural stability of the Goodreau design is reliant on the stability of the backfill material, as no other means of supporting the headwalls to remain vertical is apparent other than the pipe connection itself.
Other patents disclosing prefabricated concrete headwall structures, mostly for use with box culvert systems or other channel constructions, include U.S. Pat. Nos. 2,041,267 to Schroeder, and 5,836,717 to Bernini.
An inexpensive headwall constructed from material other than concrete was proposed in U.S. Pat. No. 4,723,871 by Roscoe. This headwall for culverts consists of a substantially monolithic plastics shell structure, filled with a granular material or a flowable material capable of solidifying. This specific headwall is simpler and lighter than many known before it; however, it does not provide reliable performance in use. Roscoe's design does not offer full bank retention nor prevent undermining of the structure from water flow, as it does not provide wing walls nor an extended base. Further, Roscoe's design does not permit rapid installation under adverse weather conditions; yet once installed, it cannot be readily removed if need be. The manufacture in place of the Roscoe structure may not be economically viable in remote areas nor environmentally acceptable in maintaining non-contamination of water systems from poured-in-place materials during installation.
In short, while various previously known designs have utility, they all suffer from disadvantages. A strong, reliable, lightweight, easily transported and easily installed structure is needed that will provide adequate bank stabilization and adequate downstream water diversion away from the surrounding earth or fill. Such structure should be readily connectable to associated pipe and should be readily capable of receiving auxiliary devices such as trash gates, security grids and weir boards for attachment thereto. A problem to overcome is that while reinforced concrete structures are sufficiently heavy to tend to stay in place and sufficiently strong and rigid to maintain structural stability under load, a lightweight unit designed to serve the same purpose as a given concrete headwall may lack inherent structural stability and may not readily withstand the forces imparted to it in use.
SUMMARY OF THE INVENTION
A principal object of the present invention is to provide a headwall structure that meets the foregoing need and overcomes the disadvantages of conventional headwalls. Such structure should facilitate the control of water flow, erosion, flooding, silt and debris and should be readily attachable to any culvert pipe of any type, size or style, used in an infrastructure water management system.
Another object of the present invention is to provide a headwall that is economical, efficient, easy to install, and also easy to remove to accommodate the possibility of future reclamation of areas to their natural state.
Another object of the present invention is to provide a headwall structure with earth-stabilizing sidewalls and a bottom plate or tray providing in combination with the sidewall configuration (including associated reinforcing elements preferably integrally formed therewith) a suitable water flow channel that serves either as an outlet chute defining a satisfactory exit channel configuration for water outflow, or when used in reverse (entrance) orientation, a satisfactory inlet flow channel configuration.
Yet another object of the present invention is to provide a headwall of relatively light weight and therefore relatively well suited for use in areas subject to permafrost or high-water-table areas as compared with conventional concrete structures.
Such headwall should be suitable for use in many different types of terrain, possibly even in some areas of unstable ground. Such structure should provide good earth or fill anchorage in fast-flow situations.
In accordance with the foregoing objectives, one preferred embodiment of a headwall according to the invention is formed as an integral prefabricated structure preferably using a composite of plastics material and glass fibers, and preferably incorporating selected cores of selected core material in selected portions of the structure, especially where additional mass, rigidity or strength is required—typically in those portions of the structure that may be expected to be under load. Instead of steel bar reinforcement that is conventional in the manufacture of precast reinforced concrete, different cores of different materials can be used, depending upon the situation. One option is to use a polymer concrete core material that is reinforced by incorporating a composite laminate fully encapsulating the polymer concrete and that can be incorporated selectively to form a relatively rigid skeleton or framework that supports the composite laminate material overlying the polymer concrete.
While a preferred headwall structure according to the invention is preferably formed as an integral unit, such structure may be thought of as comprising a number of interconnected members including a generally vertical back wall optionally incorporating a pipe-receiving orifice, a tray joined to the lower edge of the back wall and extending generally horizontally outwardly therefrom, and a pair of sidewalls on either side of and joining both the back wall and the outlet tray. The tray may be a generally planar continuum or may be stepped downwardly outwardly or otherwise shaped to meet the inflow or outflow requirements to be met for any particular installation. The top edge of the back wall, the top and outer edges of the sidewalls, and the outer edge of the tray are each preferably provided with margins that provide a degree of rigidity to the integral structure and additionally serve to stabilize earth or fill in the immediate vicinity of the headwall. The aforementioned elements are preferably prefabricated as a single integral structural unit.
The sidewalls may be generally planar or may be curved, in the manner described below. Equally, the upper edges and associated margins of the sidewalls may be generally rectilinear, but may instead be generally convex. The use of curved surfaces tends to strengthen the resulting structure.
In headwalls according to the invention, the thickness of the laminate can be varied and the type or quantity of composite reinforcement can be varied so as to vary the overall physical properties of the structure. Suitable adjustment of mass and quantity and type of reinforcement can accommodate the varying structural requirements of headwalls of varying sizes. In contrast with conventional precast concrete designs, the required structural rigidity of headwalls according to the invention is provided primarily by form and bracing rather than by thickness and weight.
To provide walls of a given strength, composite laminates can be formed as relatively thin, lightweight panel sections whose outermost edges may continue as flanged margins for both rigidity and earth retention. A problem with such relatively thin-walled material, however, is that the walls can easily flex under load, and a headwall made of such material will lack inherent mass and thus be susceptible to shifting once installed in an earth bank or the like. According to an aspect of the invention, at least the lower outer portions of the sidewalls are sculpted to provide both structural reinforcement and stabilizing cavities or recesses into which earth or fill enters upon installation to help stabilize the structure. In one embodiment of the invention, the sidewalls comprise wing panels diverging from one another, the rear vertical edges of the wings being common with the vertical side edges of the backwall, and reinforcing panels interconnecting the wings to outer side portions of the tray and to the lower side margins of the sidewalls. The reinforcing panels are at an oblique angle to both the wings and to the tray so as to provide a buttressing reinforcement for the wings. The back wall, tray, sidewalls (including both wings and reinforcing panels) and margins form a single continuous surface defining the flow channel for constraining the water flow.
Reinforcing panels designed as aforesaid perforce provide cavities or recesses at the outsides of the lower outer portions of the sidewalls, permitting earth or fill to enter into and bear against the outer surfaces of the reinforcing panels defining these recesses, thereby helping to stabilize the structure in the earth bank or the like in which it is installed. Such stabilization function is enhanced if the recesses are partially closed off in the outer portion thereof by front reinforcing panels lying in a plane that will be close to parallel to the slope of the earth or fill in the vicinity and also close to perpendicular to the water flow. These front reinforcing panels tend to prevent or impede earth or fill from moving outwards in the vicinity of the lower side edges of the sidewalls, as well as providing stiffness and buttressing reinforcement for the adjoining portions of the sidewalls. If desired, backfill may partly cover the outer front surfaces of the front reinforcing panels to help anchor the structure. For use in entrance mode, the front reinforcing panels are preferably inwardly inclined so as to direct water into the entrance channel of the headwall structure.
Alternatively, as much of the foregoing structure as wished may be formed as a curved continuum. Instead of discrete planar panels, albeit integrally formed together as a single unit, the wings, top brace above the back wall, reinforcing panels, and even at least the side portions of the back wall itself, may be integrally formed as a curved continuum. In such curved continuum embodiment, the lower outer edges of the sidewalls should be reverse-curved to provide convex surfaces relative to the interior flow channel space defined by the sidewalls and the tray, for preferred flow channel definition and so as to stiffen and buttress the upper portion of the sidewalls. These convex surfaces are of course concave on the outside surfaces of the sidewalls and form recesses or cavities engaged by the adjacent soil bank. As in the case of the planar panel embodiment earlier described, the lower outer portions of the reverse-curved surfaces should include a substantial front surface area that lies generally parallel to the slope of the adjacent earth bank so as to define with the remaining concave surfaces of the reverse-curved portions of the sidewalls a substantial recess or cavity that receives a substantial amount of earth or fill and thus helps to stabilize the headwall structure in place, and which front surface area can be partially covered by backfill if desired.
Hybrids of the foregoing designs are possible; for example the back wall and tray may be generally planar, the sidewall wings curved, the reinforcing panels either planar or curved but not following the curvature of the wings.
In this description, terms such as “vertical” and “outward” are relative and apply to the installed headwall. Further, as the overall orientation of any given headwall as installed will be variable, and as the demands of any particular culvert outlet (say) will be variable, some latitude is to be given such terms. For example, if the headwall is located at the top of a sloped land area, it may be desired that the tray, serving as an outlet tray, also be designed to be downwardly outwardly sloped so as to merge with the land, rather than having a strictly horizontal orientation, or its margin extended as an apron to impede erosion of the earth bank thereunder. Note also that as a given headwall may be installed either upstream or downstream of a culvert (say) for use either as an exit structure or an entrance structure, the terms “upstream” and “downstream”, “outflow”, and the like, are inherently relative. For convenience of description, an exit mode of use of the headwall is frequently presumed in this specification unless otherwise specified; a term such as “outlet tray” used to describe an element of the headwall is used in such relative sense. Clearly if the headwall were reversed in orientation for use in entrance mode immediately upstream of a culvert inlet, the tray of the headwall structure would in fact serve as an inlet tray. The term “longitudinal” herein refers to the general direction of water flow and is coincident with the axis of the pipe stub or spigot to be described below.
The sidewall structure preferably comprises a pair of side brace panels, one for each said sidewall. Each side brace panel may conveniently extend obliquely between (and relative to) both the associated sidewall wing and a respective side portion of the tray. Each side brace panel is fixed along an upper edge to the associated sidewall wing and along a lower edge to the tray. The side brace panel may be formed integrally with and as an angled continuum of the associated sidewall wing, and likewise may form a continuum with the tray. For surface continuity, earth bank stabilization and further reinforcement of the sidewall structure, a pair of generally triangular front brace panels join the outer edges of the side brace panels to the outward portion of the tray and to the front side margins. The outer bottom edge of each front brace panel may stop short of the outer edge of the tray and may be angled inwardly so that if the headwall is installed for entrance use (so that the tray becomes an inlet tray), water will be directed inwardly for channeling into the entrance channel. The combined exposed surfaces of the brace elements and the tray serve to define chute (flow channel) surfaces for either incoming or effluent water, depending upon the installation, in either case providing a preferred flow channel shape for the water flow. The brace elements further provide buttressing of the wings. The brace elements further define the cavity or recess earlier described at the outer lower side edges of the sidewalls for receiving earth or fill to help stabilize the structure.
Where the curved continuum embodiment of the invention or a hybrid embodiment is designed and used, the front brace panels may be planar and the side brace panels curved, or both sets of panels may be curved, or there may be no discrete side or brace panels, but simply a continuous curved surface, the outer lower portion of which is reverse-curved as previously described to provide a convex inside surface for preferred chute configuration and a concave outside surface for stabilizing the structure in the earth bank or the like.
All of the constituent walls of this structure may conveniently be of substantially uniform cross-section whereby the front and rear surfaces of the headwall structure are substantially identical. The flanged margins optionally but preferably provided along the back wall and sidewalls of the structure and formed at a substantial angle to the adjoining walls further reinforce the structure and facilitate stabilization of the adjacent earth bank.
Note that headwall structural units as described may be configured to nest and stack, and therefore can be economically shipped in large quantities.
Advantageously, for connection to a pipe, the headwall is provided with a spigot mating with the pipe or with a range of possible pipe connections. It is advantageous that the spigot be designed for maximum adaptability. To this end, the spigot may be formed to be substantially dimensionally identical to a section of a standard pipe so that a connector for such pipe will fit the spigot without the requirement of any special adapter. Thus a given manufacturer's pipe section can be connected to the headwall structure as desired. The prefabrication permits the spigot to be designed to mate with the pipe connection system of any given pipe manufacturer.
To build a spigot that conforms to a given pipe connection system, the headwall manufacturer may advantageously use an actual pipe section having a terminal end portion structured in conformity with a given manufacturer's specifications, and may, using an appropriate mold, replicate this end portion exactly on the spigot, thereby to generate a spigot of a particular size and form that can be interconnected with a mating pipe section by using the manufacturer's double female coupling element. To this end, a section of the terminating portion of the actual pipe is inserted into a hollow container from which a female mold is prepared. The spigot mold can then be integrated with other mold portions to form part of the overall mold for the headwall, and is used to generate a spigot inherently configured in exactly the same pipe-end configuration as the mating pipe to which the spigot is designed to be coupled. Such spigot design facilitates a bond generally free of leaks, a smooth confluence of interior surfaces, and without loss of cross-sectional area within the headwall. Such design also facilitates and expedites installation.
Some but not all of the advantages of the above-described embodiments of the invention can be obtained by manufacturing the headwall structure as a set of discrete substructures that are finally assembled together on site. For example, the tray and associated margin could be one substructure, each of the sidewalls with margins another substructure, and the back wall, top cross-piece margin and spigot a further substructure. These substructures could be provided with fasteners for mechanical interconnection, or could be bonded together by laminating or adhesive bonding or the like. This manufacturing approach may be desirable where the fully assembled headwall structure is very large or very heavy.
Further, since the manufacturer of headwalls according to the invention will probably wish to provide headwalls having differently configured spigots that match terminating ends of various pipe connection systems, it is advantageous to manufacture the spigot units as discrete components, each having a standard interface for mating with another component of the complete headwall structure. The manufacture and sale of headwalls as such two-component structures can help reduce the size and weight of the manufacturer's inventory. In such two-component headwall structures, one component is the spigot that is molded integrally with an immediately adjoining flanged wall structure (open, of course, with the same interior opening as the spigot itself). The other component, comprising the main body portion of the headwall, is provided with a mating aperture in its back wall for receiving the flanged wall of the spigot portion in a mating engagement. The interface between the spigot component and the body component is accordingly standard, so that a number of different spigot components for connection to a number of different standard pipes could be available in manufacturer's inventory, each mating with the body portion of the headwall by reason of the mating of the outer periphery of the spigot flange with the aperture of the body portion of the headwall. A square interface is preferred for ease of manufacture and because one need not be concerned about the orientation of the spigot component when fitting it to the aperture in the body portion of the headwall.
The spigot component can be both chemically bonded and mechanically fastened within the aperture of the body component using any glues and fasteners desired (e.g., plastics bonding glue, screws or various nut-and-bolt arrangements, or attachment brackets) once the outer surfaces of both components are flush.
This two-component design permits the manufacturer to have available in inventory a relatively small number of precast body portion components and few if any spigot components; the manufacturer may cast spigot components on demand as orders come in. The total volume and weight of the manufacturer's inventory can thus be appreciably reduced. Further, the shipping weight of each component and the size of each component is lower than if the two were combined into an integral unit, and handling each individual component is facilitated. A disadvantage of these two-component headwall structures is that fasteners and an assembly operation are required, presumably on site, to couple the two components of the headwall together. This disadvantage, however, is expected for most installations to be more than offset by the aforementioned advantages.
Headwall structures made according to the invention are relatively environmentally safe, because the structures can be made of materials not subjected to serious erosion or leaching, and may be suitably coated to this end. All materials used to fabricate these structures can be selected to be chemically resistant to acids and alkalis, including road salts and wood preservatives. Such inert materials are not conducive to bacterial growth.
The gross weight of a headwall structure according to the invention can be as little as 10 to 15 percent of the weight of a conventional precast concrete structure suitable for use in the same location. It can be readily seen that the use of headwall structures according to the invention can substantially reduce the cost of labour, handling, shipping, and lifting equipment for installation of such structures as compared with the cost of conventional structures.
SUMMARY OF THE DRAWINGS
FIG. 1 is a schematic isometric view of a first embodiment of a headwall according to the invention, in which the inside wall surfaces of the sidewalls are generally planar and all edges generally rectilinear.
FIG. 2 is a schematic front elevation view of the embodiment shown in FIG. 1 .
FIG. 3 is a schematic plan view of the headwall shown in FIG. 1 .
FIG. 4 is a schematic side elevation section view of the headwall shown in FIG. 1 taken along section line 1 B— 1 B of FIG. 2 .
FIG. 5 is a schematic plan section view of the headwall shown in FIG. 1 taken along section line 1 A— 1 A of FIG. 2 .
FIG. 6 is a schematic side elevation section view of the headwall shown in FIG. 1 taken along section line 1 C— 1 C of FIG. 2 .
FIG. 7 is a schematic side elevation view of the headwall shown in FIG. 1 .
FIG. 8 is a schematic isometric view of a second embodiment of a headwall according to the invention, in which the inside wall surfaces of the sidewalls are generally concave and the top edges of the sidewalls are generally arcuate.
FIG. 9 is a schematic front elevation view of the headwall shown in FIG. 8 .
FIG. 10 is a schematic plan view of the headwall shown in FIG. 8 .
FIG. 11 is a schematic side elevation view of the headwall shown in FIG. 8 .
FIG. 12 is a schematic side elevation section view of the headwall shown in FIG. 8 taken along the section line 2 B— 2 B of FIG. 9 .
FIG. 13 is a schematic plan section view of the headwall shown in FIG. 8 taken along section line 2 A— 2 A of FIG. 9 .
FIG. 14 is a schematic side elevation section view of the headwall shown in FIG. 8 along section line 2 C— 2 C of FIG. 9 .
FIG. 15A is a schematic isometric view of a body component of a headwall structure in another embodiment of the present invention, in which the headwall consists of a body component and a spigot component to be coupled together.
FIG. 15B is a schematic isometric view of a spigot component of a headwall structure in another embodiment of the present invention, in which the headwall consist of a body component and a spigot component to be coupled together.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-7, it will be seen that the headwall structure generally indicated as 10 consists of a number of component elements all of which are molded from a lightweight reinforced composite. For manufacturing convenience, aesthetics, and design balance, the overall design of this embodiment of the invention is symmetrical about a vertical center plane (the plane defined by section line 1 B— 1 B of FIG. 3 ). The structure 10 is designed to be prefabricated as an integral unit, so constituent surfaces and angles are chosen accordingly to permit ready release from the mold, and also to facilitate nesting and stacking for transport and storage. When manufactured as an integral unit, the headwall 10 is only conceptually made of component elements; these component elements merge together and their surfaces form a single uninterrupted surface. However, it is useful to think of the integral structure 10 as formed of component elements, for convenience of description.
Suitable composites of which the headwall may be manufactured are previously known and consist of various resins loaded with suitable fibers, especially glass fibers, and other solids. The resins of choice are not limited to thermosetting resins, but may be thermoplastic. Where additional mass is desired for stabilizing the headwall structure or the adjacent earth mass when the headwall is installed, some of the constituent wall portions of the headwall may be provided with cores made of suitable polymer concrete core material, also previously known per se. While the structure herein described is preferably prefabricated as an integral unit, selected portions of the structure may instead be mechanically fixed or adhesively bonded to previously formed substructure; in some circumstances, depending upon site requirements, some portions may be left to be bonded or otherwise attached to a partially installed substructure at the work site. Manufacture of the structure 10 as a number of discrete substructures and subsequent assembly of these substructures on site may be desirable where the overall structure 10 is very large or very heavy as compared with integral headwall structures according to the invention.
After fabrication, the headwall 10 may be post-cured to facilitate as much cross-linking as possible of the resin, thereby tending to minimize future leaching, and optimizing physical properties. In accordance with industry-accepted practice, the entire surface of the headwall 10 prior to installation may be covered with a gel coat that may optionally be granite-impregnated to improve resistance to erosion, moisture damage, and wear. Preferably the gel coat should be selected to conform to water potability standards. Both the outer surface of the composite laminate of the exposed headwall surfaces and the gelcoat should have a rough or non-reflective finish to reduce glare if such surfaces will reflect vehicle headlights.
The headwall 10 has a back wall 15 provided with an integrally formed pipe connection stub or spigot 16 surrounding a generally central orifice comprising the outlet end of a water conduit. The spigot dimensions and configuration may be of several different standard selections each corresponding to the terminal end of a standard drainpipe supplied by any one of several different manufacturers. This design feature permits ready coupling of the spigot 16 to a selected drainpipe, using couplings or connectors of a design typically provided by the pipe manufacturer to couple together abutting pipe sections.
Extending outwards from the base of the back wall 15 is a tray 17 that may be planar but is preferably stepped as illustrated in FIG. 1 both for strength and rigidity of the integral headwall structure, and also to provide a shallow waterfall immediately downstream of the spigot 15 , thereby facilitating outflow of small-size debris, when the tray is used in exit mode. Where there are fish in a stream served by the headwall 10 , the step also may serve to define in part a turbulation pond that facilitates fish migration. As will be seen in FIG. 4, the tray is manufactured to include a core 18 that may be incorporated into the tray during the fabrication process and is preferably made of polymer concrete.
A pair of outwardly diverging or flared sidewall wings 20 and 21 join the back wall 15 and the upstream step of the tray 17 . In this embodiment the wings 20 , 21 are planar and together with the back wall 15 and the tray 17 define and partially enclose a space approximating that occupied by a truncated right rectangular prism of generally corresponding dimensions. Configurations of this general sort are per se known in the design of concrete headwalls. Along the lower inclined edges of the wings, side brace panels 22 , 23 are formed that extend downwards and inwards to join the side edges of the tray 17 . These brace panels 22 , 23 partly define side recesses generally indicated by the reference numeral 54 on each side of the structure 10 , the right-hand one of which (as seen in FIG. 1) is visible in the illustrations. The recesses are further defined by generally triangular planar front brace panels 42 , 44 that extend between the forward edges of the side brace panels 22 , 23 and the tray 17 .
For improved structural rigidity and especially to provide soil or fill stabilization in the immediate vicinity of the headwall 10 when installed, the top, bottom and side edges of the structure are continued as marginal flanges. These marginal flanges include a top flanged crosspiece 26 , sloped side flanges 11 and 12 , front flanges 41 and 43 , and bottom flange 13 , each formed integrally with the adjoining structure to be described in detail below.
In many installations, the top flange or cross-piece 26 may be expected to have to withstand fairly heavy stresses and impact, since it may have to absorb traffic loads; further, stones and debris from above may strike it, so for such reasons the top flange 26 may be formed with a relatively thick wall if desired. Further, the top flange 26 is preferably provided with end corner reinforcements in the form of stepped corner extensions 46 , 48 that interconnect the top flange 26 with the top portions respectively of sloped side flanges 11 and 12 and also serve to maintain the structural integrity and rigidity of the rear (inward) upper portions of the associated sidewall wings 20 , 21 . Because the flanged crosspiece 26 also should resist overshoot of material from above the headwall 10 , it may be designed as an oversize element.
All of the flanged elements may, if desired, be formed with incorporated polymer concrete cores, as will be described further below. Any of the flanges may be extended or attached to aprons or the like (preferably formed integrally therewith); such extension or apron may be especially desirable for the bottom flange 13 , depending upon soil slope and conditions immediately downstream of the tray 17 used in outflow mode, for the purpose of impeding soil erosion underneath the tray 17 . Further, the outer edge of the tray 17 and associated bottom flange 13 may be centrally inwardly recessed if desired for improved rigidity and to further define the water flow exit channel (when tray 17 is used in exit mode).
It is intended that the headwall 10 be lightweight for ease of transportation and handling during installation. Accordingly, the wall thicknesses of component walls of the headwall 10 should be as thin as possible consistent with adequate strength and rigidity to meet the earth stabilization demands of the installation site. Especially, the outer portions of sidewall wings 20 , 21 would in the absence of reinforcement be prone to excessive flexure and deformation in response to soil pressure from the adjacent earth or fill bank. To provide such reinforcement, the essentially identical side brace panels 22 and 23 are present, side brace panel 23 being the mirror image of side brace panel 22 and its joinder with the associated structure also mirroring that of panel 22 . Side brace panel 22 extends from an oblique upper edge 19 constituting the lower edge of the associated sidewall wing 20 to a lower edge 14 lying along the tray 15 . The corresponding mirror-image side brace panel 23 is similarly joined to its associated sidewall wing 21 and to the tray 15 . The side brace panels 22 , 23 perform a multiple function in providing reinforcement to the sides of the structure, in defining a portion of the stabilizing recess 54 , and in defining in part the water outflow channel.
The side brace panels 22 , 23 merge respectively into the generally triangular front (outer) brace panels 42 , 44 that are also mirror images of one another. The combination of a given side brace panel, say 22 , with its associated front brace panel 42 , constitutes a strong buttressing reinforcement of the associated sidewall wing 20 of the headwall 10 and adds desirable rigidity to the overall structure so that the adjacent earth or fill is more reliably stabilized than would be the case if the sidewall wing 20 were readily able to flex relative to the rest of the structure of headwall 10 . It can be seen that each front brace panel 42 , 44 joins the outer edges of the respectively associated side brace panel 22 , 23 to an associated outward portion of the tray 17 and to the associated front marginal flange 41 , 43 respectively. The lower edges 51 , 53 of the front brace panels 42 , 44 are inwardly angled so that they are inset from the bottom flange 13 . The inward inclination of the front brace panels 42 , 44 facilitates flow of water inwardly into the flow channel when the headwall 10 is used in entrance mode, thereby impeding erosion of the underlying earth or fill.
The recesses 54 are filled with adjoining earth or fill when the headwall 10 is installed, thereby facilitating stabilization of the structure 10 . When backfill is applied to the headwall 10 once it is installed in place, some of the backfill can overlap the front brace panels 42 , 44 to further stabilize the headwall structure 10 in place. The particular angles and dimensions chosen for the bracing elements 42 , 44 , 22 and 23 may be selected to meet particular side slope and ditch contour conditions at the work site at which the headwall structure is to be installed. Further, since the bracing elements 42 , 44 , 22 and 23 define the water flow channel, their configuration and angulation should be selected with optimal flow characteristics in mind.
While the structure illustrated, to reinforce the sidewalls, comprises at each side a side brace panel and a front brace panel, thereby comprising an interjoined two-panel bracing structure, it will be readily apparent that instead of only two such interjoined panels, three or more bracing panels could be used instead. Such panels should meet at outside obtuse angles to one another for effective water flow channeling, effective bracing, and effective definition of the stabilizing recesses 54 . Of course, on the inside surfaces of the interconnected panels, the angles at which the panels meet would typically exceed 180°.
As will be seen in FIGS. 4, 5 and 6 , the tray 17 , the sidewall wings 20 , 21 , the brace panels 22 , 23 , 42 , 43 , the associated marginal flanges 11 , 12 , 13 , 41 , 43 , and the top flange 26 with its associated corner reinforcement portions 46 , 48 , all may incorporate polymer concrete cores. Cores 24 and 25 are illustrated for the sidewalls 20 , 21 ; core 27 for the top flange 26 with its associated corner reinforcement portions 46 , 48 , and core 18 for the tray 17 . The cores 27 and 18 are shown as extending all the way to the outer limit of the spigot 16 (FIG. 4) to provide collar reinforcement for the spigot 16 where it joins the back wall 15 . Cores may be provided to add mass and rigidity; they may be selectively provided where a higher modulus of elasticity of the structure is required. Polymer concretes are known; they typically include binders comprising selected resins carrying aggregates, sand, microspheres, glass fibers or organic fillers, and the resin used should preferably be matched to the resin used for the composite overlay for optimum bond between cores and composite laminate layers. It can be readily perceived that the cores may constitute a skeleton or framework to the extent required to provide or supplement support and rigidity to the overlying composite laminate.
It can be seen from the foregoing description that all of the parts of the headwall structure can be fabricated as a single unitary integral piece that incorporates cores as and where required. When installed at a work site, such integral structure is able to withstand the forces from the adjacent soil bank and yet is sufficiently flexible to accommodate settling of the bank and backfill. The polymer concrete cores add mass, strength and rigidity with minimal additional weight; even with the cores included, the headwall structure according to the invention can weigh a small fraction—perhaps as little as ⅙—of the weight of a concrete structure designed to meet the same requirements.
The angles chosen for the surface slopes and common edges of the sidewalls including associated brace panels are preselected to retain side banks and slopes of various properties in various types of terrain. The headwall structures 10 can accordingly be manufactured in various standard sizes and configurations to meet a range of expected conditions and requirements, or may be individually designed as required. Note that the choice of frontal area of the front brace panels 42 , 44 is particularly important as these panels 42 , 44 lend stability to the installed unit, because once the headwall 10 is in place, bank slope backfill overlaps the front brace panels 42 , 44 , thereby anchoring the headwall 10 in place. In addition, the shaping especially of the side brace panels 22 , 23 can be selected to assist in funnelling the water flow, minimizing turbulence by cooperating with the sidewall wings 20 and 21 to provide a gradual tapering of flow cross-section.
As will be seen in FIG. 8, a second preferred embodiment of a headwall according to the invention, generally indicated as 50 , differs from the first embodiment previously described in that interior wall surfaces of sidewall wings 32 , 33 are generally concave and the top edges of the sidewall wings 32 , 33 are generally arcuate. The back wall 30 of the headwall 50 containing the spigot 31 continues to be planar, but the sidewall wings 32 and 33 are generally cylindrically shaped or otherwise suitably curved. The sidewall wings 32 , 33 with the headwall 50 may instead together form a single curved continuum if desired. Side brace panels 34 and 35 similarly may optionally be formed with a generally cylindrical or other curvature. Such curvature assists in funnelling the flowing water over the tray 37 . The top flanged crosspiece 36 desirably continues the curve of sidewall wings 32 and 33 and as before adds to the rigidity of the structure in the vicinity of the top of back wall 30 .
As in the case of the first embodiment, the headwall 50 is fabricated from a lightweight reinforced composite with cores of polymer concrete introduced where desirable, and coated with a gel coat to provide protection against environmental damage.
It can be seen from viewing the illustrations of this second embodiment of the headwall that the overall relative dimensions, configuration and juxtaposition of front and side brace elements and the tray are very similar to those of the first embodiment, so the various physical characteristics and interrelationships of these elements need not be re-described. Note that while the wings and bracing elements are shown as discrete surfaces, they could form a curved continuum. Note also that relative dimensions and preferred angles will be expected to vary considerably from one installation site to another, whether the first or second embodiment or any other embodiment of the invention is employed.
As illustrated in FIGS. 15A and 15B, the headwall may be formed as a two-component structure, namely a body part (component) 7 and a spigot part (component) 8 . The spigot component 8 consists of a spigot 16 and an immediately adjoining flanged wall 81 having a central circular aperture of the same internal diameter as that of the spigot 16 and a square periphery. The flanged wall 81 forms a mating part of the back wall 72 of the headwall after the spigot portion 8 is inserted and affixed into a square aperture 71 in the body component 7 (FIG. 15A) whose dimensions are very slightly oversize relative to those of the periphery of the flanged wall 81 to permit ready insertion of the spigot component 8 into the aperture 71 for a mating fit. At or before installation, the spigot component 8 after insertion into the aperture 71 is bonded and fastened in place by any known convenient means. The choice of bonding agents and fasteners is not per se a part of the present invention. By thus designing the two-component embodiment of FIGS. 15A and 15B, any selected spigot component 8 having a spigot 16 of desired size and configuration may be coupled with the body component 7 to form a headwall structure that can be matingly interconnected with a pipe of a particular terminal style by means of a standard double-female coupling that mates with both the spigot 16 and the pin end of a pipe section manufactured to the same specifications. All other parts of the body portion 7 of the headwall structure (i.e., sidewall wings 21 and 20 , the tray 17 , the top flange 26 ) may be similar to the parts of the headwall 10 illustrated in FIGS. 1-7 and described above.
Not illustrated in the drawings of either of the preferred embodiments illustrated but conveniently provided are attachment lugs, brackets, slots, apertures, eyes, etc. to enable auxiliary devices such as trash gates, security grids and weir boards to be attached to the headwall structure.
Other variants and modifications will readily occur to those skilled in headwall design and plastics composites structural design.
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A headwall structure constructed of lightweight reinforced composite and incorporating a rigid polymer concrete core in selected portions, for use with standard culvert or drainage pipes in infrastructure water management systems in substitution for conventional concrete headwalls. The headwall structure has a vertical back wall with an integral spigot or pipe stub surrounding a central orifice. The pipe stub is preferably cross-sectionally dimensioned and configured to be identical to a selected standard pipe section end so that such pipe section can be connected to the pipe stub without an adapter. A tray is joined to the lower edge of the back wall. A pair of outwardly flared sidewalls are joined to the back wall and to the tray. Angled brace panels extending from the sidewalls to the tray reinforce the sidewalls. The tray, sidewalls and brace panels define the water channels. Front and side brace panels define a recess into which earth enters and against which earth bears to provide stabilization. The sidewalls and all or selected ones of the brace panels may be curved to form a curved continuum. The structure may be a one-piece structure or a two-component structure, the latter preferably including as one of the two components the spigot with a surrounding flanged wall receivable by a mating aperture in the back wall of the other component that includes the remaining elements of the headwall structure.
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FIELD OF THE INVENTION
[0001] The present invention relates to a candle trimmer and more particularly, relates to a device for trimming the wax ends of candles.
BACKGROUND OF THE INVENTION
[0002] The number of candles sold over the past few years has increased greatly as they have gained status as a decorative item. As such, there is a far greater variety of candles now available than what previously existed. In particular, candles having a relatively large diameter are very popular. However, a problem which exists with such candles is that the burning is uneven with an outer unburned rim portion surrounding an inner portion which has been used as a fuel. As a result, the appearance is frequently deemed to be unattractive.
[0003] To date, the only method known to Applicant of attempting to rectify the appearance of the candle has been to use a sharp device such as a knife or a razor blade to remove the outer rim. This is extremely difficult to accomplish by hand and often a ragged uneven appearance results.
[0004] A further disadvantage of attempting to trim the upstanding unburned rim portion surrounding the central portion is the safety factor. The wax forming the upstanding rim can be relatively hard and a sharp knife is required. Naturally, slippage is possible and severe injury can result.
SUMMARY OF THE INVENTION
[0005] It is an object of the present invention to provide a device for trimming candles and in particular, for trimming candles having an unburned rim portion.
[0006] It is a further object of the present invention to provide a candle trimmer which is both easy to use and relatively inexpensive to manufacture.
[0007] According to one aspect of the present invention, there is provided a device for trimming candles wherein the candles have an upwardly extending rim portion, the device comprising a housing, a blade assembly mounted to the housing, and the blade assembly including at least one blade, the at least one blade being movable between first and second positions, the arrangement being such that when the device is placed in position on a candle having an upwardly extending rim, and when the blade is moved from the first position to the second position, the at least one blade is operative to remove wax from the upwardly extending rim.
[0008] In a further aspect of the present invention, there is provided a device for trimming a candle, the device having a relatively thin filament, the ends of the filament being connected such that the filament can form a loop about a candle. Actuating means are provided to tighten the filament such that it will be drawn to the candle. Preferably, clamp members are provided for supporting the candle.
[0009] Preferably, according to the first embodiment of the present invention, the housing has a generally dome shaped configuration with a generally frustraconical side wall terminating in an annular generally cylindrical skirt. The skirt does not extend through 360° for reasons which will be discussed hereinbelow.
[0010] Conveniently, the housing may be molded of a plastic material and may have ridges or other like gripping surfaces formed on an exterior surface thereof.
[0011] The blade assembly is designed to be retained by the housing. To this end, there may be provided different means such as a groove within the annular skirt. In a preferred embodiment, there are provided a plurality of tab members which are designed to retain the blade assembly in a desired position during operation but which will also permit the ready removal of the blade assembly for purposes of accessing wax material which has been removed from the candle.
[0012] As aforementioned, the blade assembly is preferably retained by the housing in a desired position whereby at least one blade extends substantially horizontally. The blade assembly is movable from a first position to a second position by rotation within the housing such that a blade on the blade assembly will trim the upstanding unburned rim on the candle. In this respect, a number of different blades may be provided and they may be positioned according to the size of the candle to be trimmed.
[0013] Separate blade members such as metallic knives may be integrated into the blade assembly which is preferably in the form of a generally circular disk. Alternatively, by utilizing sufficiently hard plastic material, the blade may be formed intrically as a portion of the disk.
[0014] Preferably, there is provided an actuating means for turning the blade assembly to thereby remove the upstanding wax rim. Such actuating means may comprise a portion of the disk which extends exteriorly of the housing. To this end, the rim of the housing may include either a gap or an aperture formed therein to permit the actuating member to extend outwardly of the housing.
[0015] The device also preferably includes positioning means which are designed to hold the device in a fixed position with respect to the candle while the blade assembly is moved from the first position to the second position. To this end, the positioning member may include a shaft mounted centrally of the housing and about which the blade assembly rotates. The positioning member may have teeth at one end thereof to dig into the wax of the candle and prevent rotation of the housing to which the positioning member is secured.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Having thus generally described the invention, reference will be made to the accompanying drawings illustrating embodiments thereof, in which:
[0017] [0017]FIG. 1 is a top plan view of a candle trimmer according to one embodiment of the present invention;
[0018] [0018]FIG. 2 is a side elevational view thereof;
[0019] [0019]FIG. 3 is a bottom plan view thereof;
[0020] [0020]FIG. 4 is a side elevational view showing views of the device with a smaller candle compared to the embodiment of FIG. 2;
[0021] [0021]FIG. 5 is a top plan view of a candle trimming device according to a further embodiment of the present invention;
[0022] [0022]FIG. 6 is a side elevational view thereof;
[0023] [0023]FIG. 7 is a cross sectional view thereof;
[0024] [0024]FIG. 8 is a side elevational view, partially in section, of the cover portion of the candle trimming device;
[0025] [0025]FIG. 9 is a top plan view of the blade assembly of the candle trimming device;
[0026] [0026]FIG. 9A is a cross sectional view taken along the lines X-X of FIG. 9;
[0027] [0027]FIG. 10 is a bottom view of the cover portion;
[0028] [0028]FIG. 11 is a detailed sectional view illustrating the retaining tabs of the cover portion; and
[0029] [0029]FIGS. 12 and 12A illustrate the use of the device.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0030] Referring to the drawings in greater detail and by reference characters thereto, there is illustrated in FIG. 2 a first embodiment of a candle trimmer which is generally designated by reference numeral 10 .
[0031] Candle trimmer 10 has a body portion 14 and a handle portion 12 . Mounted at a distal end of body portion 14 are a first clamp 16 and a second clamp 18 . Each of clamps 16 and 18 are arcuate in nature to conform, in a general manner, to the surface configuration of a circular candle.
[0032] Preferably, although not shown, both first clamp 16 and second clamp 18 are pivotally connected, proximate their center point, to body portion 12 . Thus, the clamps would be able to move about their pivot point and securely grasp different size candles. As seen in FIG. 3, clamp 18 has an upper section 21 and a lower section 23 with a recess 25 therebetween. Clamp 16 is of a similar construction.
[0033] Formed in the upper wall of body portion 14 are a plurality of notches generally designated by reference numeral 22 .
[0034] Candle trimmer 10 also includes a cutting filament generally designated by reference numeral 24 and which may be of any suitable material—preferably of a metallic wire material. At either end, cutting filament 24 is provided with enlarged portions 26 and 28 .
[0035] Depending from body portion 14 and mounted so as to be movable therealong is a trigger 30 .
[0036] In operation, a first enlarged portion 26 is placed in one of the notches 22 . The cutting filament 24 is then looped about a candle C, shown in FIG. 2, and the second enlarged portion 28 placed in a receiving area of trigger 30 with filament 24 passing around guide wheel 31 . Trigger 30 is then pulled as shown by the arrow in FIG. 2 and pressure is then exerted on cutting filament 24 such that it will pass through candle C to remove excess wax. Thus, as may be seen, there is provided an inexpensive candle trimmer which is adapted for different sizes of candles. The groove in the clamps 16 and 18 permits the passing of the filament therethrough.
[0037] In a further variation of this embodiment of the invention, there may be provided means for heating filament 24 . This would be particularly useful when the candle is cold and would ensure a smooth passage of the filament therethrough. Various different types of heating means including electrical resistance heating may be utilized.
[0038] Turning to the embodiment illustrated in FIGS. 5 to 11 , there is provided a candle trimming device which is generally designated by reference numeral 110 .
[0039] Candle trimming device 110 includes a housing generally designated by reference numeral 112 , a blade assembly generally designated by reference numeral 114 , and a positioning means generally designated by reference numeral 116 .
[0040] Housing 112 , as may be seen in FIGS. 6, 7 and 8 , has a frustraconical side wall 120 having a plurality of ridges 122 formed thereon for purposes of gripping. At its lower end, side wall 120 is provided with an annular skirt 124 . At the opposite end, side wall 120 terminates to provide an open top 126 . Also, as may be seen in FIG. 10, there are a plurality of retainer tabs 128 formed in annular skirt 124 , there being three such retainer tabs in the illustrated embodiment.
[0041] Blade assembly 114 has the form of an annular disk 132 with a plurality of reinforcing ribs 134 extending radially thereof. A plurality of blades 136 are formed in disk 132 and extends slightly downwardly therefrom to provide a cutting edge 140 as may be seen in FIG. 9A. An actuator 138 extends outwardly from disk 132 and as may be seen in FIG. 10, there is provided an approximately 90° portion of housing 112 wherein there is not provided an annular skirt to thereby permit movement of actuator 138 .
[0042] A positioning means 116 comprises a shaft 142 , one end of which fits within a cap 148 while at the opposite end, there is provided a seating edge 144 designed to seat in the wax of the candle. As may be best seen in FIG. 11, each retaining tab 128 has an inner recess 150 which is designed to receive the outer edge of disk 132 and retain the same therein while permitting rotational movement thereof.
[0043] As may be seen in FIGS. 12 and 12A, the housing 112 may be placed on the candle and actuator 138 operated to rotatably move disc 122 and thereby trim the outer rim of the candle.
[0044] It will be understood that the above described embodiments are for purposes of illustration only and that changes or modifications may be made thereto without departing from the spirit and scope of the invention.
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A device for trimming candles which have burnt and left an upwardly extending rim portion, the device comprising, in one embodiment, a housing, a blade assembly mounted thereon and at least one blade member in the blade assembly, the blade being movable between first and second positions so as to trim wax from the upwardly extending rim portion.
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BACKGROUND OF THE INVENTION
This invention relates to devices for the paving of roads and, more particularly, to a device for applying asphaltic material to a road surface or to the shoulder thereof.
Spreader boxes have long been used to resurface roads with asphaltic material or to spread crushed stone or other aggregrate. Such spreader boxes, as for example, those described in U.S. Pat. No. 2,186,081, and U.S. Pat. No. 2,403,820, are generally towed behind a dump truck so that the material to be spread can fall from the dump body into the spreader box and then be spread in a layer that is substantially as wide or wider than the dump body and whose thickness is defined by the height of the bottom of the rear wall of the spreader box above the pre-existing surface. Such spreader boxes provide an efficient means for resurfacing wide stretches of deteriorated road. However, small areas of a roadway, and particularly the edges thereof, often require repair before general resurfacing is called for. Spreader boxes of the type described above are not well suited for the repair of such limited areas of deterioration.
Side delivery conveyors have also been in general use for some time. Such conveyors use endless belts or augers to move material from a dump truck laterally for deposit to one side of the truck's direction of travel. A side delivery conveyor may be used by itself to spread crushed stone or other loose material along the shoulder of a road. However, such a conveyor simply allows the material to fall to the ground and thus cannot, by itself, deposit material in a smooth strip of uniform width, as is required to pave or repair the shoulder of a road with "cold mix" or other asphaltic material. As a result, the paving or repair of a road shoulder normally requires a crew of men with shovels and rakes to lay asphaltic material.
SUMMARY OF THE INVENTION
The present invention provides a three sided spreader box that is adapted for mounting alongside the discharge opening of a side delivery conveyor that is mounted at the rear of a dump truck. The spreader box is mounted in such a way that it can freely move vertically in relation to the conveyor and truck. A road wheel is provided that supports the weight of the box and facilitates its being pulled along with the truck. The road wheel is adjustably attached to one side of the box so that the height of the box, and so the average thickness of the strip of material being laid, can be adjusted. Chutework is provided to direct material from the discharge opening of the conveyor into the spreader box. Means are also provided to lubricate the chutework to prevent the asphaltic material from sticking to it. A removable baffle is provided that can reduce the effective width of the spreader box and thus reduce the width of the strip of material being laid. The rear wall of the spreader box may be hinged so that the bottom edge of the rear wall, and thus the surface of the strip of material being laid, can be inclined from the horizontal.
It is an object of this invention to provide a lightweight spreading device for spreading asphaltic material from a dump truck along the shoulder of a road or in other restricted areas.
It is a further object of this invention to provide a device that can lay a strip of material completely outside the path of travel of the vehicle from which the material is being spread. This will permit the laying of material in areas in which the vehicle cannot conveniently be driven. It has the further advantage of allowing the drive of the vehicle to fully visualize the laying of the strip.
Another object of this invention is to provide a device that can lay strips of asphaltic material of differing thickness and widths and having top surfaces inclined from the horizontal to differing degrees.
Still another object of this invention is to provide an asphalt spreading device that can be quickly and easily be taken out of service and be transported on the truck and side delivery conveyor with which it is used without unduly interfering with other uses of either.
Other objects and purposes of the invention will be clear from the description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of one embodiment of the asphalt spreader
FIG. 2 is a plan view of the removable baffle that may be used in conjunction with the asphalt spreader.
FIG. 3 is an isometric view of one of the brackets used to couple the spreader box to a dump truck.
FIG. 4 is an elevation view of the asphalt spreader illustrating its attachment to a dump truck when in use.
FIG. 5 is an elevation view of the asphalt spreader from the direction opposite that of FIG. 4.
FIG. 6 is an isometric view of the asphalt spreader illustrating its attachment to a dump truck when not in use.
FIG. 7 is an elevation view of a second embodiment of the asphalt spreader as seen from the rear.
FIG. 8 is an isometric view of a part of the asphalt spreader of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, FIG. 1 shows an sphalt spreader generally designated 10. The spreader 10 includes a spreader box 12 which is comprised of a first side wall 14, a second side wall 16, and a back wall 18. The side walls 14 and 16 are connected at their rear edges (20 and 24 respectively) by the rear wall 18. The side walls 14 and 16 are connected near the front by a bar 26. Sections of angle iron 28 and 30 are welded to back wall 18 and bar 26 respectively at a slope so as to support a removable baffle, which is shown in FIG. 2.
FIG. 2 shows the removable baffle, generally designated 34, comprising a rectangular plate 36 having a first stop 38 projecting from the first side edge 40 and a second side stop 42 projecting from the second edge 44. The width of the plate 36 (i.e. the distance between the first side edge 40 and the second side edge 44) is such that it can be supported by the angle irons 28 and 30 shown in FIG. 1. The stop 38 (which is a section of small diameter bar welded to the plate 36) is located near the top edge 46 of plate 36 and is intended to engage the top 48 of back wall 18 (shown in FIG. 1). The stop 42 is similar to stop 38 but is attached to edge 44 at a height such that it will engage the top of bar 26 when the plate 34 is supported by the angle irons 28 and 30 and stop 38 is engaging the top edge 48 of back wall 18. The length of plate 36 (i.e. the distance between the top edge 46 and the bottom edge 50) is such that, when the baffle is supported by the angle irons 28 and 30 with the stops 38 and 42 engaged as described above, the bottom edge 50 will be level with the bottom edge 54 of the back wall 18 and top edge 46 of the baffle 34 will be substantially level with the top 48 of the back wall 18. As will be made more clear from the later description of the operation of the invention, when the baffle 34 is in place the width of the strip of material laid will be equal to the distance from the bottom edge 50 of the baffle 34 to the bottom edge 56 of the first side wall 14.
In the embodiment shown in FIG. 1, the first side wall 14 is comprised of a plate 58 having a strip 60 welded to the bottom thereof. The plate 58 and strip 60 form a flat vertical surface inside the spreader box 12. On the outside however, the strip 60 provides a ledge 62 on which are mounted a first pipe (or similar columnar member) 64 and second pipe 66. The pipes 64 and 66 are welded to the ledge 62 and the plate 58 and, in conjunction with the brackets 68 and 70 are used to couple the spreader box 12 to a side delivery conveyor (not shown in FIG. 1). Bracket 68 is comprised of a sleeve 72 which slidingly engages pipe 64, a mounting plate 74 and a web 76 connecting sleeve 72 to mounting plate 74. As is shown in more detail in FIG. 3, bracket 70 is comprised of a sleeve 78 (which slidingly engages pipe 66) to which is attached a first web 80, and mounting plate 82 to which is attached a second web 84. The webs 80 and 84 have corresponding holes 86 and 88 so that they can be fastened together by bolt 90 and nut 92. When the webs 80 and 84 are so fastened the spreader 10 can be mounted for use in the manner shown in FIG. 4.
FIG. 4 shows a side delivery conveyor 94 having a discharge opening 96 from which material is discharged by means of, for example, an endless belt 98. The conveyor 94 is attached to a dump truck body 100 by means of a hinge 102 so that the conveyor will remain upright when the truck body is inclined to deposit material into the conveyor. Mounting plate 74 is attached to conveyor 94 to the rear of discharge opening 96 and mounting plate 82 is attached to conveyor 94 in front of discharge opening 96. The spreader box 12 is supported by road wheel 104 and is held upright by the pipes 64 and 66, which are slidably engaged by sleeves 72 and 78 respectively. The spreader box 12 is thus coupled to the conveyor 94 in such a manner that it will be drawn along by the dump truck, but is free to move vertically independently.
In operation, asphaltic material 106 falls from the discharge opening 96 of the side delivery conveyor 94 and is directed into the spreader box 12 by chute 108. As the spreader box 12 is drawn forward (to the left in FIG. 4) a strip of asphaltic material 106 is left behind it. The bottom edge 54 of the back wall 18 of the spreader box 12 smooths the surface of the strip of material 106 and establishes its elevation. When the removable baffle 34 is not in place the material 106 is free to fill the entire width of the spreader box 12 (i.e. from the first side wall 14 to the second side wall 16) and the strip of material 106 that is laid will thus have that width. However, when the removable baffle 34 is in place the material 106 is confined to the space between the baffle 34 and the first side wall 14 and the width of the strip laid will be equal to the distance from the bottom edge 50 of baffle 34 to the bottom edge 56 of first side wall 14.
The elevation of the top surface of the strip of material 106 that is spread can be changed by adjusting the elevation of the bottom edge 54 of back wall 18. As is illustrated in FIG. 1 and FIG. 5, the hub 110 of road wheel 104 is rotatably mounted on bar 112. Bar 112 is, in turn, rotatably mounted on pin 114 which is attached to the outside of first side wall 14. A slot 116 comprising a part of the circumference of a circle about pin 114 is cut in side wall 14 and a bolt 118 attached to bar 112 projects through slot 116 into the inside of spreader box 12. When the nut 120 on bolt 118 inside spreader box 12 is tightened against side wall 14, bar 112 is held fixed in relation to the spreader box 12 and the elevation of the bottom edge 54 of back wall 18 above the point at which road wheel 104 will engage the ground is thus held constant. The elevation of bottom edge 54 can be adjusted by loosening nut 120, adjusting the position of bar 112, and then retightening nut 120.
Asphaltic material has a tendency to stick to the chute 108 and the walls 14, 16 and 18. This can be avoided by applying approximately 2 ounces of motor oil, diesel fuel, kerosene or similar lubricant to these surfaces approximately every 4 minutes. An oiler is, therefore, provided. FIG. 6 shows a manual oiler, generally designated 122, comprised of a reservoir 124, a hose 126, a spray nozzle 128, and a pump 130, mounted on the conveyor 94 near the spreader box 12. If manual application of oil is considered to be inconvenient, a pair of oiler nozzles 127 and 129 may be clamped to the spreader box 12 as shown in FIG. 1 so as to provide coverage of the chute 108 and substantially all of the interior of the spreader box 12. It will be understood that it will be necessary to reposition the nozzles 127 and 129 when the baffle 34 is in place.
The asphalt spreader 10 can be taken out of service by removing bolt 90 from holes 86 and 88 in the webs 80 and 84 and removing the pin 132 from the holes 134 and 136 in pipe 64 and then lifting the spreader box 12 by the handle 138 until hole 134 and 136 are above the level of sleeve 72, at which time pin 132 is reinserted in holes 134 and 136 and the handle 138 is lowered until pin 132 rests on sleeve 72. With the spreader box 12 and ground wheel 104 thus suspended, they can be rotated on pipe 64 to the position shown in FIG. 6. A ring 138 attached to side delivery conveyor 94 by a chain 140 is provided to engage pipe 66, thereby holding the spreader box 12 and ground wheel 104 in the position shown in FIG. 6. In this position the asphalt spreader can easily be transported to and from job sites. With the asphalt spreader in this position the truck can also travel on the roadway in a normal manner while using the conveyor 94 in operations requiring the discharge to the right side of the truck (i.e. the side opposite discharge opening 96). In addition, discharge opening 96 can also be used for some other operations while the spreader box 12 is in the position shown in FIG. 6. Also, it is most convenient to have the spreader box 12 in the position shown in FIG. 6 when adjusting the position of the bar 112 and road wheel 104 as described above to change the elevation of the top surface of the material.
The shoulder of a road often is sloped away from the main surface of the road in order to facilitate drainage. The embodiment of my invention shown in FIG. 7 and FIG. 8 is particularly well suited to the resurfacing of such shoulders. In this embodiment the back wall 18 is comprised of a short section 142 rigidly attached to first side wall 14 and a long section 144. Back wall sections 142 and 144 are rotatably connected near the bottom by a hinge 146 comprised of a pin 147 through corresponding holes in the two back wall sections. A slot 148 comprising part of the diameter of a circle about hinge 146 is cut in back wall section 144 near the top thereof. A pin 150 is rigidly attached to back wall section 142 and projects through slot 148 to provide support for back wall section 144.
A short bar section 152 having a transverse threaded hole 154 therethrough is rotatably attached to the outside of back wall section 144 by means of bracket 155. Bar 152 is located on the side of slot 148 away from side wall 14. A smaller diameter bar 156 has a threaded end 158 engaged in the threaded hole 154 in bar 152. Bar 156 is supported near its other end by bracket 160, which is attached to pipe 64. Bracket 160 allows bar 156 to rotate about its axis, but does not allow it to move in a direction parallel to its axis. Therefore, rotation of bar 156 by means of handle 162 will cause back wall section 144 to rotate about hinge 146, thereby altering the inclination from the horizontal of the bottom edge 164 of back wall section 144.
In the embodiment shown in FIG. 7 and FIG. 8 the bar 26 connecting side walls 14 and 16 is attached to side wall 14 by means of clevis 166 so as to allow the inclination from the horizontal of bar 26 to vary along with the inclination of bottom edge 164 of back wall section 144. Clevis 166 is located such that the axis of rotation of bar 26 about clevis 166 coincides with the axis of rotation of rear wall section 144 about hinge 146. This permits bar 26 and rear wall section 144, which are rigedly connected by side wall 16, to turn on a common axis. Because bar 26 is positioned substantially lower than in the embodiment shown in FIG. 1, the top of angle iron 30 is braced by support 168, which is comprised of a section of angle iron welded to angle iron 30 and to side wall 16. Except for these and the other differences that have been pointed out, the two embodiments of my invention described above are identical to each other.
For the resurfacing of road shoulders I have found it desirable to use a spreader of the type described above having a bottom edge 54 of the rear wall 18 approximately 55.88 cm. (22 inches) long and sides 14, 16 and 18 all approximately 31.75 cm. (12 inches) high. I have also found it useful to locate the angle irons 28 and 30 such that use of the removable baffle will reduce the width of the strip of material being laid to approximately 31.75 cm (12 inches.) These dimension can, of course, be varied to accommodate the anticipated use of the device. Many other changes and modifications in the above-described embodiments of the invention can also be carried out without departing from the scope thereof.
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A three sided spreader box has a pair of columnar members attached to one of its sides. A pair of sleeves slidingly engage the columnar members and allow the spreader box to be coupled to a dump truck having a side delivery conveyor in such a way that the spreader box is held in fixed horizontal relation to the discharge opening of the conveyor but is free to independently move vertically. A road wheel supports the spreader box and provides means for changing the elevation of the bottom edge of the rear wall of the spreader box. Chutework directs asphaltic material from the conveyor into the spreader box. An oiler periodically oils the chute to prevent sticking of the asphaltic material. The rear wall of the spreader may be hinged to allow the inclination from the horizontal of the bottom edge of the rear wall of the spreader box to be varied.
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BACKGROUND OF INVENTION
In zone climate control systems for residential forced air HVAC systems, airflow control valves are installed in air ducts. The airflow control valves can be pneumatically operated through small air tubes or powered and controlled by electrical signals through wires in a cable. When zone systems are installed in existing systems, it is often difficult to find a path for the air tubes or cable from an airflow control valve to the central controller because the ducts are behind walls and ceilings or in the attic or crawlspace.
For retrofit installations, the inside of the existing ducts can provide a path for the tube or cable. The tube or cable needs to be pulled from the airflow control valve through the air duct to a central location such as the discharge plenum of the HVAC blower. This is accomplished by connecting a strong installation blower to the duct system at the central blower plenum and blocking all airflow paths except one so the only airflow path is through the one unblocked air duct to the installation blower. The blower is connected so that air flows from the air duct toward the blower. A parachute about twice the diameter of the air duct is connected to a strong and flexible string and placed in the airflow. The airflow inflates the parachute and quickly pulls the parachute and string through the duct path to the installation blower. The string is then used to pull the tube or cable from the air vent to the central plenum.
The airflow control valves can be installed at the air vents where the air ducts terminate in a room. FIG. 1 illustrates three typical paths from air vents 102 , 103 , 104 through air ducts to the blower plenum 100 . Air ducts 101 can have a round or rectangular cross section and all cross section dimensions are greater than 3″. Duct paths can be over 100 feet long and have several sharp bends such as 114 and 113 where the ducts transition from horizontal to vertical and/or connect to main trunks.
The tubes or cables 110 , 111 , 112 are typically no more than ¼″ in diameter and sufficiently flexible and strong to be pulled through the duct path using the pull string. However, air ducts are often poorly installed and have sharp edges where ducts make turns and connect to trunks.
FIG. 2A illustrates the problem caused by the sharp edge 204 formed by duct 202 making an off-center connection with trunk 203 . The pull string 201 has a small diameter and is very flexible, so when pull string 201 pulls tube or cable 200 , the pull string makes tight contact with the edge 204 . Referring to FIG. 2B, when tube or cable 200 reaches position 211 , the tube or cable is obstructed by the edge. Applying additional tension on the pull string can not generate a force that can lift the tube or cable over the edge. Using a rigid device or flexible material to transition from the pull string to the tube or cable does not prevent obstruction because the obstructing edge is sharp. The edge deforms the pull string as the pull string is pulled over the edge. The obstructing edge catches any discontinuity in diameter or change in flexibility.
Using residential HVAC air duct as conduits for tubes or cables is unusual and there is little prior art to teach solutions to passing an obstructing edge. The electrical and communication industry has the most applicable prior art, but the ducts and conduits are designed for cables to be pulled, so obstructing edges are uncommon. Access ports at bends and corners are often provided to limit the length of the pull. Therefore the prior art for cable pulling does not teach how to pass by an obstructing edge. For example, U.S. Pat. No. 5,654,526 issued Aug. 5, 1997 to Sharp describes connectors for conduit sections that provide access for lubrication to reduce the friction when pulling. Patent U.S. Pat. No. 5,029,817 issued Jul. 9, 1991 to Tamm describes a device that includes a roller for installation at a bend in the conduit so the cable can pass by the corner when pulled, but this does not provide a method to pass an obstruction edge. U.S. Pat. No. 5,310,294 issued May 10, 1994 to Perkins describes a connector for connecting a boring devise to a cable for pulling the cable through the hole made by the boring device, but this connector is not adaptable to connecting a pull string to a cable. U.S. Pat. No. 4,078,767 issued Mar. 14, 1978 issued to Battaglia describes a connector for connecting a multi-wire cable to a pull wire. The connector provides a strong, quick, and non-damaging connection, but does not provide a way of passing by an obstructing edge. U.S. Pat. No. 4,552,338 issued Nov. 12, 1985 to Lindgren describes a devise for pushing or pulling a cable through a conduit comprised of many beads with axial holes and helical springs and a connector that connects sections of beads together. This devise is not adaptable for use in a HVAC air duct and provides no method for passing by an obstruction.
SUMMARY OF THE INVENTION
The invention is a connector to connect a pull string to a tube or cable. The connector converts the tension force in the pull string to a rotation force about a pivot point between the connector and an obstructing edge so that increasing the tension on the pull string causes rotation about the pivot point until the pivot point becomes unstable and the connector slips by the obstructing edge so that a tube or cable can be pulled by the obstructing edge.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a diagram of typical air duct paths in a residential forced air HVAC system.
FIG. 2 is a diagram showing how a sharp edge obstructs pulling a tube.
FIG. 3 is a cross section drawing of the invention.
FIG. 4 is a diagram showing how the invention enables a tube to pass an obstruction.
FIG. 5 is a diagram showing two alternative embodiments of the invention.
FIG. 6 is a diagram showing the invention adapted for pulling a cable.
DETAILED DESCRIPTION
FIG. 3A is a cross section drawing of the connector. The pull string 300 passes through an axial hole in the header 302 . The pull string is typically a high quality fishing line 0.015″ to 0.030″ in diameter with a tensile strength of at least 100 lbs. The header 302 is cylindrically symmetric, approximately 0.25″ in diameter to match the diameter of the tube 305 . The header presents a spherical surface in the direction of pulling. The header is made of a rigid and hard material such a steel, and is polished smooth so there are no sharp edges that might abrade the pull string and so it is easy to thread the pull string through the hole.
A compressible elastic cylinder 303 connects to the header 302 . The compressible cylinder 303 is approximately 0.25″ in diameter to match the diameter of the tube 305 and approximately 1″·2″ long. The cylinder material and length is selected so that the cylinder is axially unstable as it is compressed. As the cylinder is compressed, the cylinder axis deforms into a “c ” or “s” shape while the cross section remains substantially circular. Surgical tubing made of silicon rubber is an example of suitable material.
A joiner 304 mates the compressible cylinder 303 to the tube 305 . The joiner is a plastic or metal tube approximately ½″ to ¾″ long and selected to press fit to the inside of the compressible cylinder and the inside of the tube.
To make the connection between the pull string and tube, the pull string 300 is threaded through the header 302 and compressible cylinder 303 and joiner 304 . A loop 306 is tied at the end of the pull string and the loop is inserted into the tube 305 . A pin or nail 307 with a sharp point is pushed through a side of tube 305 approximately ½″ from the end of the tube so that the pin passes through the loop 306 in the pull string and the pin then passes through the opposite side of the tube. FIG. 3C is a cross section end view showing the pin passing through the loop in the pull string the pin is perpendicular to the axis of the tube and passes through the axis of the tube. The pin end 308 is cut off so that the pin end is flush with the outside of the tube. The pin is held in place by friction between the pin and the sides of the tube. The tube is pushed onto the joiner and the pull string is pulled while holding the header. This completes the connection.
FIG. 3B is a cross section diagram of the connector and completed connection with the pull string 300 under tension and the header 302 obstructed by an edge 301 . The pull string passes freely through the hole in the header so the tension is transferred to the tube by the pin 307 . As pull string tension is increased, the compressible cylinder deforms and the walls take a “c” or “s” shape as illustrated by 311 and 312 . The contact point 310 between the header and the obstructing edge is a pivot point. Since the pivot point is below the axis where the tension is applied, the compressible cylinder will preferentially deform upward. The upward deformation of the compressible cylinder causes the header to rotate about the pivot point. An increase in tension in pull string 313 causes an increase in deformation and additional rotation.
FIG. 4 illustrates the behavior of the connector 400 as the tube 404 is pulled by pull string 401 to the obstructing edge 403 . Referring to FIG. 4A, a the tube is pulled, the header 402 is obstructed. Referring to FIG. 4B, a tension in pull string 411 increases, the connector 410 begins to deform. Additional tension 421 causes more deformation and more rotation of the header of the connector 420 . Referring to FIG. 4C, a the header rotates and tension increases, the pivot point between the obstruction edge and the spherical surface of the header becomes unstable and slips. Referring to FIG. 4D, te header passes the obstructing edge and the connector 430 returns to a substantially cylindrical shape and the pull string 431 can pull the tube 432 past the obstructing edge 433 .
FIG. 5A illustrates using a coil spring 502 as part of the compressible cylinder 500 . One end of the spring presses against the header 502 and the other end presses against the Joiner 501 . The spring can provide a wider range of compression and instability characteristics than possible with rubber or plastic alone.
FIG. 5B illustrates an alternate embodiment where the compressible cylinder 510 has an integrated joiner 511 that mates with the tube 512 . This shape is practical if the compression cylinder is made by injection molding or by chemically joining together two separate plastic or rubber cylinders of the appropriate size.
FIG. 6A illustrates the connector 600 adapted for pulling a thin cable 602 . A short section of tube 601 approximately 2″ -4″ long is connected to the pull string as described above. The cable is fastened to the tube in a similar way the pull string is fastened to the tube. A loop is made in the end of the cable by twisting or other known process. A pin 603 is pushed through the side of tube 601 , through the loop in the cable, and into the opposite side of the tube.
FIG. 6B illustrates an alternate embodiment of the connector 610 where the joiner is adapted to receive the cable 612 . A thicker, multi-wire cable is illustrated where the cable sheath has sufficient strength so that the loop in the cable can be omitted. Pin 613 is pushed through the cable and cut flush with the other side of the joiner.
The forgoing describes illustrative examples of how to construct and use the invention, and should not be interpreted to limit or restrict the generality of the invention. Other methods of converting pull string tension into a rotational force can be devised by those with ordinary skills in the art of mechanical design.
From the description and the figures described above, the function and benefit of the connector can be understood and practiced by those ordinarily skill in the art of pulling tubes and cables through ducts.
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A connector for connecting a pull string to a tube or cable for pulling the tube or cable through a duct. When an obstructing edge stops progress, the connector converts additional pull string tension into a rotation force that enables the connector header to pivot on the obstructing edge until it slips and passes by the obstructing edge.
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This invention relates to clutch mechanisms; and more particularly relates to a novel and improved clutch assembly for automatically engaging and disengaging the ground-engaging wheels of a motor vehicle.
BACKGROUND AND FIELD OF THE INVENTION
There is set forth and described in my prior U.S. Pat. No. 4,694,943, a novel and improved means for converting a drive system of a vehicle between two-wheel and four-wheel drive and in such a way as to establish dynamic engagement or disengagement of a clutch assembly by remote activation. That system was designed to overcome problems associated with the prior art systems which are capable of maintaining four-wheel drive only when the engine is running.
It is recognized that a clutch engaging or disengaging under applied torque must provide high linear or axial forces to assure sufficient penetration of the teeth on a clutch or high interface forces on friction drive clutches. In the case of gear-type clutches, insufficient or only gear tip penetration under torque will tend to destroy the gears. Moreover, when a vehicle is loaded or has variable tire sizes or pressures, or is used off-highway, the engaged components of the power train are subjected to wind-up torque lock. Thus, the force necessary to separate the clutch gears is often greater than the original force required for engagement.
In addition, it has been proposed to employ vacuum systems as a means of engagement and disengagement of the clutch gears. However, such systems have not been entirely satisfactory from the standpoint of meeting the force and loading requirements in effecting engagement and disengagement. Among other problems, the applied vacuum within the wheel envelope must be maintained continuously during four-wheel drive operation and can impose external atmospheric pressures on the wheel seals beyond the capability of the seals.
It has also been proposed to employ an electrical heating unit to expand a chambered gas for driving a piston which then drives a fork against a clutch gear. However, among other things, systems of this type do not always function quickly and can be affected by wide swings in temperatures.
In U.S. Pat. Nos. 4,293,061 to Brown and 4,627,512 to Clohessy, power shift mechanisms are provided and which are mounted coaxially with respect to the clutch members but are powered in one direction only and must overcome a spring force acting in the opposite direction. In the '061 patent to Brown, it is necessary to compress the air in an envelope in order to shift in the one direction and the reverse spring pressure must then create a vacuum in order to return the envelope to its original state; and in both it is necessary to apply a continuous pressure or vacuum to maintain the clutch members in the engaged mode. U.S. Pat. Nos. 2,913,929 to Anderson and 4,271,722 to Campbell generally rely upon a power shift mechanism to effect engagement and disengagement of a clutch member but are not mounted coaxially with respect to the clutch member. Other representative patents in this field are U.S. Pat. Nos. 3,123,169 to Young et al. and 3,050,321 to Howe et al.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide for a novel and improved clutch assembly which can be positively engaged and disengaged by remote activation in a highly efficient and reliable manner; and specifically wherein a clutch assembly is adaptable for use in effecting dynamic engagement and disengagement of one or both of the front or rear ground-engaging wheels of a four-wheel drive vehicle.
It is another object of the present invention to provide for positive, dynamic engagement and disengagement of an axle disconnect or wheel clutch mechanism either while the vehicle is static, in motion, or in response to remote operated control and during either forward or reverse direction of movement of the vehicle, and wherein engagement and disengagement can be effected independently of the application of torque between the driving and driven elements.
A further object of the present invention is to provide for a novel and improved method and means for effecting positive engagement and disengagement of a clutch mechanism employed in a four-wheel drive vehicle which is under the complete control of the operator at all times, will not accidentally shift as a result of engine shut-off or stall, sudden temperature or atmospheric changes or other exterior influences; and further wherein the clutch mechanism places the main driving force member on the same axis as the drive and driven clutching members or gears so as to establish circumferentially uniform axial clutching forces to avoid cocking, transverse wedging and high torque application to the gear sections.
A still further object of the present invention is to establish dynamic engagement or disengagement of a clutch assembly by remote activation and through the utilization of coaxially located, expandable and contractable power shift pressurizable compartments whereby under the pressurized expansion of one compartment the alternate compartment will contract proportionately to the expanding compartment enabling the total cubic displacement of the combined compartments to remain a constant in selectively driving clutch members to and from engagement.
It is an additional object of the present invention to provide for positive but remote activation of a clutch mechanism for selectively converting a motor vehicle between two-wheel and four-wheel drive modes in such a way as to avoid damage to the wheel seals or axle envelopes, is readily conformable to existing vehicle designs and can employ existing pressure sources on the vehicle as a means or remote activation of the clutch mechanism.
In accordance with the present invention, a remote-activated clutch assembly for effecting positive engagement and disengagement between a first rotatable drive member and second member to be driven in which an axially displaceable clutch member is keyed for rotation to the first drive member and a second clutch member is drivingly connected to the second member to be driven; the first clutch member is movable into and out of intermeshing engagement with the second clutch member, pressure-responsive shift means being associated with the first clutch member and which includes a pressure chamber(s) expandable and contractable in axial directions toward and away from the second clutch member, and fluid pressure-operated means for applying positive pressure to the shifting means and positively advancing the first clutch member into and out of engagement with the second clutch member.
A preferred form of the present invention resides in a remote activated, positive fluid pressure-operated system for converting a vehicle between two-wheel drive and four-wheel drive wherein drive means are provided for selectively and positively rotating a drive shaft for a ground-engaging wheel to be driven, the clutch assembly comprising a receiver gear drivingly connected to the ground-engaging wheel to be driven, a drive gear mounted for rotation with the drive shaft and axially movable with respect to the drive shaft into and out of engagement with the receiver gear, fluid pressure-responsive shift means engageable with the drive gear, and fluid pressure operated activating means for applying positive pressure to the shift means for positively advancing the drive gear into and out of engagement with the receiver gear in converting between two-wheel and four-wheel drive. The preferred form of invention is capable of utilizing the energy and force available from existing pressure pumps on the vehicle, such as, power steering pumps or vacuum brake assist motors as well as existing shift actuators on the vehicle to control the power shift means. Either one or two assemblies per vehicle may be utilized depending on whether it is incorporated as a part of the axle disconnect at an axle location or a hub lock at a wheel hub location or at other locations along the vehicle power train; and, regardless of location, is compatible with other components within the power train so that shifting may be sequenced preceding, simultaneously with, or subsequent to torque application to the train or utilize a different sequence for engagement than for disengagement to relieve functions of other power train components.
In the preferred form, the shift means comprises coaxially located, expandable and contractable compartments separated by a fixed wall, and the compartments cooperatively expand and contract so that with the pressurized expansion of one compartment the coaxially located alternate compartment contracts in proportion to the expansion of the one compartment thereby enabling the total cubic displacement of the combined compartments to remain constant during the shift operation; and in shifting an integrated linear shift drive means is coaxially located with respect to the clutch members and driven axially in reverse or opposite directions depending upon which chamber is expanded. The shift means further works in cooperation with a releasable detent which will releasably retain the clutch members in the position to which driven by the shift means independently of the expansion and contraction of the compartments.
The above and other objects, advantages and features of the present invention will become more readily understood and appreciated from a consideration of the following detailed description of a preferred embodiment of the present invention when taken together with the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of the power train of a vehicle employing a clutch mechanism at each front wheel for the purpose of engaging and disengaging the power train with respect to the front wheels;
FIG. 2 is a schematic illustration of the power train of a four-wheel drive vehicle having a single axle disconnect for engaging and disengaging the power train at the axle disconnect location of a front axle;
FIG. 3 is a sectional view of a preferred form of clutch mechanism in which the upper half of the section illustrates the mechanism in two-wheel drive mode and the lower section in four-wheel drive mode;
FIG. 4 is an exploded view of a preferred form of power shift assembly and the means for attaching the power shift assembly to the vehicle;
FIG. 5 is an exploded view of the receiver gear of the clutch mechanism;
FIG. 6 is an exploded view of the preferred form of clutch mechanism with the parts and subassemblies aligned to show the sequence of application to the vehicle;
FIG. 7 is a sectional view of a modified form of clutch mechanism located within the axle and applied as an axle disconnect; and
FIGS. 8, 9 and 10 are schematic illustrations of a preferred form of control valve for effecting engagement and disengagement of the clutch mechanism under the complete control of the operator at all times.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring in more detail to the drawings, in FIG. 1 a preferred form of clutch assembly U is connected to each of the front ground-engaging wheels V of a motor vehicle; and in FIG. 2 the clutch assembly U is illustrated as an automatic axle disconnect associated with a front drive shaft of a vehicle, although it will become more readily apparent that the clutch assembly of the present invention has a number of other useful applications.
In FIG. 1, an engine J has a transmission T into a rear propeller shaft M and a transfer case L, the latter extending into front propeller shaft M' into front differential N and front axle housing O. The propeller shaft M is coupled with a rear differential P in the rear axle R for the rear wheels S. Engine power is transmitted through the transmission T via transfer case L and front propeller shaft M' to the front differential N and a drive shaft A within the axle housing O. When four-wheel drive is desired, the transfer case L is shifted to engage the front drive system to supply power through the front propeller shaft M' and differential N to the clutch assemblies U mounted at either end of the axle or shaft A; and when the clutch assemblies are engaged in a manner to be described will impart positive rotation to the front wheels V.
In FIG. 2, when the operator desires four-wheel drive, the transfer case L is shifted to engage the front drive system and apply power to the front propeller shaft M' and differential N to the front axle or shaft portions within the housing O so as to drive the front drive shaft A in a manner described in more detail with reference to FIG. 7.
Referring to FIG. 3, the drive shaft A is housed within a non-rotating spindle B at each end of the axle housing O, and opposite ends of the shaft A include circumferentially spaced, axially extending splines A' as well as smaller diameter, smooth surfaced extensions E which are inserted into and radially supported by the bearings 19.
Referring to FIGS. 3 and 6, the spindle B is a fixed tubular member which is externally threaded for a limited distance along each external surface at opposite ends, each threaded portion being interrupted by a keyway K extending parallel to the axis of the spindle B. Radial bearings C are disposed in surrounding relation to the spindle B for the purpose of radially supporting a wheel hub D. A receiver housing W is mounted on the wheel hub by means of fasteners in the form of cap screws F. A thrust washer G is interposed between an external shoulder Q of the shaft A and an end surface B' of the spindle B and, in conjunction with washer Y and retaining ring Z, maintains the relative axial location of the shaft A within the spindle B. A needle bearing H is interposed between the spindle B and shaft A adjacent to the washer G.
As illustrated in FIGS. 3 and 5, the receiver housing W is comprised of a thick-walled, hollow cylindrical portion 10 having a flange 11 extending radially outwardly from the inboard end of the portion 10 with circumferentially spaced openings for threaded connection of the cap screws F and into threaded bores in the wheel hub D in order to mount the receiver housing W in fixed relation to the wheel hub. The outboard end of the cylindrical portion 10 is closed by an end cap 12 which is of shallow, cup-shaped configuration and pressfit onto the end of the cylindrical portion 10. The inner wall of the cylindrical portion 10 is provided with circumferentially spaced, axially extending splines 14 extending from the outboard end of the cylindrical portion 10 for approximately one-half the length of the cylindrical portion 10. A retainer ring 15 is inserted in pressfit relation to a groove at the outboard end of the portion 10 to act as a seat for a circular retainer element 17 provided with a central sleeve-like hub 18 for insertion of the bearing 19 for the outport extremity of the shaft A. The retainer 17 is preferably in the form of a thin-walled disk which is sized to fit closely within the smaller diameter of the internal splines 14 of the cylindrical portion 10. The radial bearing 19 is in the form of a split sleeve having opposite flanged end portions 20 and 21, and the bearing is of sufficient resiliency that it may be compressed for insertion into the hub 18, as shown, and expanded outwardly into fixed engagement with the hub.
The receiver gear 22 is disposed within the receiver housing W and is of heavy-walled tubular configuration provided with external, axially extending ribs or splines 23 at equally spaced circumferential intervals to interengage with the internal splines 14 in the receiver housing for axial slidable movement between the outboard retaining element 17 and an inboard retaining ring 16. The receiving gear 22 is provided with radially inwardly projecting tooth elements 25 and which are arranged at equally spaced circumferential intervals around the inner surface of the gear 22 but of a limited length with respect to the total length of the gear. The receiver gear 22 is normally biased or urged in an inboard direction so as to bear against the inboard retainer ring 16 under the urging of a coiled return spring 26 which is interposed between inner tooth elements 25 and the retainer element 17.
As further seen from FIGS. 3 and 6, a drive gear 30 is of thick-walled tubular configuration figuration having a smaller external diameter, smooth-surfaced portion 31 at one end and a larger diameter, toothed external surface portion 32 at its inboard end, the individual tooth elements 33 aligned for intermeshing engagement with the internal tooth elements 25 on the receiving gear 22. Axially directed splines 34 on the internal surface of the drive gear 30 are complementary with the external splines A' on the drive shaft A. In this way, the drive gear 30 is keyed for rotation with the drive shaft A but is axially slidable or displaceable independently of the drive shaft toward and away from the receiver gear 22. The inboard face of the drive gear is recessed as at 35 to define a shoulder portion 36 on the inner surface of the toothed section 32, and a retaining ring 37 is pressfit within a groove on the inner shoulder of the toothed section to establish locking engagement with the shift assembly 40 in a manner to be hereinafter described.
In order to positively control the movement of the drive gear 30 into and away from engagement with the receiver gear 22, in accordance with the present invention, the power shift assembly 40 is mounted on a common axis with that of the drive gear 30 and driven gear 22. From a consideration of FIGS. 3 and 4, the power shift assembly 40 is broadly comprised of a housing tube 41, keyed washer 42, drive tube 43, first and second expandable chambers 44 and 44', a divider washer 45, confinement washer 46 and a retaining ring 47.
Referring to FIG. 4, the housing 41 is of tubular configuration and provided with narrow, elongated slots extending axially from the inboard end of the tube including three shorter slots 51 and a pair of longer slots 52. The slots 51 are of corresponding width and length and disposed at equally spaced circumferential intervals, while the slots 52 are spaced between two of the shorter slots 51. For example, the slots 52 as shown are spaced on the order of 60° apart and each being spaced inwardly on the order of 30° from one of the respective shorter slots 51. Rectangular apertures 53 are located at equally spaced circumferential intervals equidistant from the inboard end of the tube 41 with one of the apertures 53 located intermediately between the longer slots 52 as illustrated in FIG. 4.
The keyed washer 42 is a thick-walled annular member whose outer diameter establishes a snug fit with the inside diameter of the housing 41 and whose inner diameter establishes a snug fit with the threaded external surface of spindle B. A radially inwardly directed tab 54 on the inner surface of the washer 42 interlocks with the keyway K of the spindle B. In turn, radial bores 55 extend through the washer 42 on either side of the tab 54 and correspond to the circumferential spacing and location of the slots 52 on the housing tube 41.
The drive tube 43 is of thin-walled tubular configuration with an outwardly flared end portion 58 at one end which fits closely within the inner diameter of the housing tube 41, there being three equally spaced tabs 59 on the outer periphery of the end portion 58 which are sized and spaced to fit slidably into the shorter slots 51 of the housing tube 41. A pair of annular, roll-formed ribs 60 and 61 on the external surface of the drive tube 43 are axially spaced to correspond with opposite end limits of the shift length of the assembly. In this relation, the ribs form internal, circularly extending grooves in the wall of the drive tube 43 for releasable engagement with the retaining ring 49. Radially outwardly directed tabs 62 are located intermediately between rib 61 and outwardly flared end portion 63 of the drive tube, the retaining ring 47 being inserted in snap-fit relation between the tabs 62 and the confinement washer 46.
The inflatable chambers 44 and 44' are of generally doughnut-shaped or annular configuration and are separated by the common divider washer 45, there being thick-walled flexible tubes 65, 65' communicating with the sealed interior of a respective chamber 44, 44' and each tube extending away from its respective chamber through one of the longer slots 52 of the member 41 for insertion into radial bores 55 of the key member 42. Each of the chambers 44 and 44' is of a unitary molded construction having inner and outer spaced circumferential walls 67 and 68 which are directionally collapsible and expandable in an axial direction rather than a radial direction toward and away from the drive gear 30. The divider washer 45 is split or divided by a circumferential space or gap 70 and has external tabs 71 at spaced circumferential intervals for insertion into the apertures 53 on the tube member 41 so as to lock the washer 45 into position with respect to the member 41.
The confinement washer 46 has an outer diameter dimensioned for close-fitting insertion into the tube member 41, and the inner diameter of the washer 46 being great enough to clear the flared end portion 63 of the driver tube 43. The retaining ring 47 is circumferentially divided or split as shown so as to be radially expandable to a sufficient size to clear the end portion 63 as well as the tube 62 and to snap into position behind the tabs 62.
FIG. 4 depicts the sequence of assembling the shift mechanism 40 wherein the drive tube 43 is inserted into the left end of housing 41 with the tabs 59 inserted into slots 51. The thick-walled keyed washer 42 is next to be inserted and is permanently affixed to and within the housing 41, with the radial bores 55 aligned with slots 52 so that the flat face of the keyed washer 42 is flush with the end of the housing 41. Continuing the assembly the balance of the parts 44, 45, 44', 46 and 47 are inserted into the opposite end of the housing 41 to that of the washer 42. When the inflatable chambers 44 and 44' are inserted with the divider 45 therebetween, the tubes 65 and 65' are inserted within slots 52 and, with a coating of gasketing adhesive, are inserted into respective bores 55 of keyed washer 42.
Further referring to FIGS. 4 and 6, the nut assembly 56 consists of a nut 48 and a snap ring 49. The internal diameter of nut 48 is threaded onto the spindle B and has a series of circumferentially spaced keyways 48' at equal intervals which extend linearly within the inside diameter, interrupting the threads, which keyways are sized to match the keyway width of keyway K at spindle B. An annular groove 49' is cut into the outside diameter of nut 48, adjacent to the outboard end of the nut. Groove 49' is dimensioned to a width and depth to enable snap ring 49 to be fully compressed to a diameter less than the outside diameter of the nut. Snap ring 49 is formed of a round spring wire and sized to an outside diameter which exceeds the inside diameters of annular detent ribs 60 and 61 of the drive tube 43.
Referring to the overall disposition and assembly of the shift mechanism 40 relative to the spindle B, as shown in FIGS. 3, 4 and 6, after shaft restraint washer Y is placed against the outer face of spindle B and looked in position by retaining ring Z, the shift assembly 40 is next installed with the tab 54 of washer 42 interengaging the keyway K as the assembly 40 is slidably pushed onto spindle B. In this relation, the inner surface of washer 42 snugly engages the spindle B and the face of the washer 42 abuts the cone race member of bearing C.
With continued reference to FIG. 6, which shows the sequence of application of parts and subassemblies to the vehicle wheel end, the nut assembly 56 is screwed onto the spindle B within shift assembly 40 and against the inside face of washer 42. As commonly practiced in vehicle assembly, the nut 56 is tightened then slightly released to establish minimal wheel bearing end play. One keyway 48' is aligned with keyway K of spindle B thereby allowing for the insertion of key 75 which locks the nut 48 against rotation on the spindle and further locks the shift assembly 40 into a non-rotating linear position.
As viewed from the upper section of FIG. 3, when the outboard chamber 44' is contracted and the inboard chamber 44 is expanded, it will cause inboard movement of the drive tube 43, and the flared end 63 of the tube 43 will engage the ring 37 to retract the drive gear 30 in a direction away from the receiver gear 22. Conversely, as viewed in the lower section half of FIG. 3, when the lefthand or inboard chamber 44 is contracted and the righthand or outboard chamber 44' is expanded it will axially displace the drive tube 43 away from the washer 42 causing the leading end 63 of the drive tube to bear against the end face of the drive gear 30 and to axially displace it in an outboard direction into intermeshing engagement with the tooth elements 25 of the receiver gear 22.
A preferred method and apparatus for activating the power shift assembly 40 is schematically illustrated in FIGS. 8, 9 and 10 wherein a flow control, dual selection valve 80 can be operated to control movement of the drive gear 30 into and out of engagement with the receiver gear 22. To this end, the valve 80 includes a source of fluid under pressure which communicates with a common port 81, and a sliding core element 82 includes an annular flow groove 83 which communicates with the port 81. Fluid return ports 85 and 86 communicate with a fluid reservoir via the common return line 87, and the control lines or tubes 65 and 65' into the chambers 44 and 44', respectively, are connected into the valve 80 as shown. In FIG. 8, the sliding core valve 80 is shown in the neutral position. The valve will move to an alternate position for the time required to shift the drive gear from one mode to another, such as, from an engaged to disengaged position with respect to the driven or receiver gear 22. After a shift has been completed the valve is then returned to its normal or neutral state as illustrated in FIG. 8.
Referring again to FIG. 3, the upper section illustrates the shift assembly with the drive gear in disengaged or the two-wheel drive mode. In order to shift to the four-wheel drive mode, the valve 80 is advanced to the position shown in FIG. 9 whereby fluid under pressure is directed through the port 81 and flow groove 83 to the flow tube 65' for the chamber 44'; and simultaneously the chamber 44 is opened through its flow tube 65 for return flow from that chamber through port 85 into the reservoir via line 87. Expansion of the chamber 44' will advance the drive tube 43 in an outboard direction thereby thrusting the drive gear 30 into engagement with the receiver gear 22. Should there be a substantial difference in revolutions per minute between the drive gear 30 and receiver gear 22, the receiver gear 22 is able to move in an outboard direction against the return spring 26 until the revolutions are nearly synchronized at which time the gear 30 will be aligned to advance into intermeshing engagement with the receiver gear 22. Recognizing that the shift assembly is not triggered by torque or engine power but functions independently of other power train components, this engagement can be caused prior to the application of torque to the drive or power train and with the high forces available from the pressure chamber to overcome the rebound force of the spring 26. Thus, the axial forces necessary to assure engagement between the gears 30 and 22 are considerably higher than the frictional resistance resulting from any drive line motoring torque. Prefunction engagement prior to applying engine or vehicle torque enables the transfer case gears to become synchronized before attempting engagement and accordingly enables relatively smooth, synchronous low force engagement of the transfer case.
Upon shifting to four-wheel drive, FIG. 9, the core valve 80 will return to its neutral position and no longer pressurize the chamber 44'. The valve 80 may incorporate any conventional form of bleed or bypass to permit a gradual reduction of the pressure and gradual relaxation of pressure within the chamber.
Shifting from the four-wheel drive mode to the two-wheel drive mode is illustrated in the upper section of FIG. 3 and in FIG. 10 when the valve 80 is shifted to a position in which the fluid under pressure is directed from the port 81 via the flow groove 83 to the tube 65 leading to the inboard chamber 44 and the chamber 44' is exhausted through its tube 65' to the reservoir. When this occurs, the drive tube 43 will retract the drive gear 30 away from engagement with the receiver gear 22 with the drive tube 43 axially displaced such that the ring 49 moves out of engagement with the inboard rib 60 and into engagement with the outboard rib 61.
For the purpose of illustration, as shown in FIGS. 3 and 6, the spindle B is provided with suitable passageways for extension of the pressure tubes 65 and 65' between the expansion chamber 44 and 44' and the flow control valve 80, the valve 80 being suitably positioned so as to be either directly or remotely controllable by the vehicle operator. The high pressure source of fluid may be derived from a power steering pump or other source of pressure in the vehicle; and a compressed gas, air or hydraulic fluid may be utilized. A most important consideration is that the power shift mechanism 40 is essentially confined within and integral to the wheel hublock envelope and can be remotely but positively controlled by the operator to advance and retract the drive gear 30 into and out of engagement with the receiver gear 22.
Description of Modified Form of the Present Invention
There is illustrated in FIG. 7 a modified form of clutch assembly U incorporated into an axle disconnect and specifically for the purpose of selectively engaging and disengaging one end of the drive shaft A with respect to the wheel hub D. As illustrated in FIGS. 2 and 7, the clutch assembly U' is incorporated as a unitary part of an axle disconnect in which axle portions A1 and A2 are selectively engaged and disengaged by the clutch assembly U' which is housed at the interface between differential N and the axis housing O. The drive shaft portions A1 and A2 are coaxially arranged in end-to-end relation to one another with a reduced end A3 journaled by a bearing 87 within a counterbored portion 88 at the end of the portion A1. In addition, the portion A1 is journaled with respect to non-rotating spindle B1, by bearing H. In this relation, like parts to those of the preferred form of FIGS. 1 to 6 and 8 to 10 are correspondingly enumerated, although it will be appreciated that their relative locations differ. Thus, a receiver gear 22' has internal splines 89 which interengage with external splines 90 on the shaft portion A2 and is axially displaceable between an annular cup-shaped ring 92, seated against retaining ring 93 at one end of the splines 90, and a retainer ring 94 at the opposite end of the splines 90. A return spring 26' is disposed for extension between the cup-shaped limit stop 92 and an end surface of the receiver gear 22' to bias the gear 22' in a direction toward the shaft portion A1.
The drive gear 30' is disposed in outer concentric relation to the receiver gear 22' and is provided with internal splined portions which engage external splines 96 on the shaft portion A1 and are slidably displaceable with respect to the splines 96 in an axial direction toward and away from the receiving gear 22' by the power shift mechanism 40'. An annular shim G1 is interposed between the confronting ends of the shaft portions A1 and A2. The modified form of power shift assembly 40' includes outer housing tube 41', inner drive tube 43', first and second chambers 44 and 44' separated by a divider washer 45' which extends radially between the outer housing tube 41' and inner drive tube 43'.
The outer housing tube 41' is mounted within axially spaced retainer cups 98 and 99, and a confinement washer 46' is disposed at one end of the chamber 44' and retained in position by a sprung extension tab 100 which projects radially and outwardly from the surface of the drive tube 43'. The drive tube is extended in outer concentric surrounding relation to the drive gear 30 ' and is affixed at one end, such as, by means of a rivet 101 to the gear 30', and the opposite end of the drive tube 43' is bent outwardly as at 102 to confine the end of the chamber 44. The chambers 44 and 44' function in the same manner as described with respect to the preferred form: Briefly, when the chamber 44' is contracted and the chamber 44 expanded it will cause movement of the drive gear 30' in a direction away from the receiver gear 22' into the relationship illustrated at the upper section of FIG. 7. As seen from the lower section of FIG. 7, when the chamber 44 is contracted and the chamber 44' is expanded, the drive tube 43 is displaced causing engagement of gear 30' with the receiver gear 22'. The manner and means for operating the power shift mechanism is the same as described with reference to the preferred form by remote activation through a selection valve as illustrated in FIGS. 8 to 10. Accordingly, when the mechanism has shifted the axle disconnect clutch assembly either to the engaged or disengaged position with respect to the receiver gear, the valve 80 will return to its neutral position in preparation for the next shifting operation. In both forms, the divider washer 45' is fixed in place to establish a stationary support for movement of the chambers 44 and 44' away from the common divider and so that the thrust of the chamber is confined to an axial direction; and in the course of expanding and contracting through each sequence it will be apparent that the total cubic inch displacement of the combined chambers does not vary. Again, recognizing that the clutch assembly is not triggered by torque or engine power and functions independently of other power train components, engagement can be effected before the application of torque to the drive train and with high forces available from high fluid pressure sources can readily overcome the biasing force of the spring 26 or 26' and any frictional resistance that may be present. Prefunction engagement in this manner enables the transfer case gears to become synchronized before attempting engagement and enables relatively smooth, synchronous low force engagement of the transfer case.
For the reason that the overall combined displacement of the chambers 44 and 44' does not vary in shifting the drive gear between engaged and disengaged positions, it therefore does not require venting to the atmosphere with the related problems of inhaling moisture or contaminants; nor does the invention require special filters or seals or impose undue pressure on existing seals of the system.
It should be noted that when the clutch mechanism of the present invention is applied to an axle disconnect, as shown in FIG. 7, it is not subject to substantial thrusting caused by steering or turning as occurs when the clutch mechanism is mounted or incorporated into the wheel hubs at opposite ends of a drive shaft, as shown in FIGS. 1 to 6. Thus, in the form of invention shown in FIGS. 1 to 6, when the front wheels of a vehicle are turned, the center line of the U-joint interconnecting the drive shafts A will tend to move in at least two different planes as well as reactivate third plane of movement caused by suspension flex or jounce. Thus, the shaft A must be permitted to move axially or linearly to a degree sufficient to not overstress; yet at the same time must be limited in such movement to avoid locking under applied torque or preventing or resisting steering in the opposite direction. Thus, the shafts A and clutch assembly are permitted to undergo a limited amount of reciprocal thrusting movement by virtue of the size and spacing of the ribs 60, 61 in cooperation with the ring 49. Moreover, the pressure chambers 44 and 44' in FIGS. 1 to 6 serve to shift the mechanism under high pressure to override any friction of the gears interfacing under torque. However, once shifted, there is no need for continued application of force but only to maintain the relative position of the gears while in the four-wheel drive mode and the pressure need not be maintained. In two-wheel drive, the detent 49 serves only to maintain the gears from accidentally sliding outwardly under certain impact, turning or steering forces. Typically, in an axial disconnect the shaft portions A1 and A2 are fixed axially with respect to one another by snap rings, not shown, and to some extent by the shim or thrust washer G1. As a result, the detenting is not required for the clutch mechanism in an axle disconnect as it is for the wheel hub application.
It is accordingly to be understood that while preferred and modified forms of the present invention are herein set forth and described that various other modifications and changes may be made without departing from the spirit and scope of the present invention as defined by the appended claims.
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A clutch assembly for automotive vehicle four-wheel drives either in association with an axle disconnect or wheel hub incorporates a power shift mechanism which can be remotely activated either when the vehicle is static, in motion and during either forward or reverse direction of movement to positively drive the clutch members into and out of engagement with one another. The power shift mechanism includes sealed envelopes in the form of expandable and contractable compartments which in response to a remote control valve will positively shift the clutch members into and out of engagement, and the members will remain in the shifted position without the continued application of force until positively shifted away from that position by the power shift mechanism.
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This invention was made with Government support under contract No. DE-FG22-88PC88945 awarded by the Department of Energy. The Government has certain rights in this invention.
BACKGROUND OF THE INVENTION
The present invention relates to the removal of NO x from gases such as flue gases. The gas containing the oxides of nitrogen is contacted with a culture of facultatively anaerobic bacteria capable of using nitrate as a terminal electron acceptor to effect the chemical reduction to elemental nitrogen.
A need exists for new technology for the disposal of concentrated gas streams containing oxides of nitrogen, NO x (NO and NO 2 ), as obtained from certain regenerable, dry scrubbing processes for flue gas desulfurization, such as the NOXSO process (Yeh et al, "The NOXSO Process: Simultaneous Removal of SO 2 and NO x from Flue Gas", paper presented at the AICHE Spring National Meeting, Houston, Tex. (March, 1987)), and the removal and disposal of NO x from more dilute gas streams such as produced by nitric acid plants.
Combustion in air inevitably produces oxides of nitrogen due to the reaction at high temperatures of elemental nitrogen or fuel nitrogen with oxygen. Roughly 90-95% of the oxides of nitrogen emitted in combustion processes is in the form of nitric oxide (NO). The remainder is predominately nitrogen dioxide (NO 2 ). In the atmosphere NO is converted in time to NO 2 . Since NO and NO 2 generally coexist in varying proportions in flue gases and in the atmosphere, they are frequently lumped together under the generic formula NO x .
In urban metropolitan areas where NO x emission sources are concentrated, NO x reacts with hydrocarbons in the atmosphere in photochemical reactions to produce smog. The chemical components of smog, particularly organic peroxy nitrates and ozone have a direct adverse effect on human health and plant life.
NO x emissions may be controlled in basically two ways. First, emissions may be reduced by decreasing the residence time of combustion gases at peak flame temperatures (high temperature favors NO x formation) and reducing the availability of oxygen. However, these measures can be expensive to implement and, in the latter case, result in increased emissions of carbon monoxide, another serious pollutant. Where combustion control is not feasible, NO x must be removed from the cooled flue gases before they are released into the atmosphere. However, flue gas cleaning for NO x removal has been severely limited by the low reactivity of nitrogen oxides and the large volume of gas to be treated at most stationary combustion sources.
Thiobacillus denitrificans is a strict autotroph and facultative anaerobe first described in detail by Baalsrud & Baalsrud (Arch. Microbiol., 20, 34 (1954)). Under anaerobic conditions, nitrate may be used as a terminal electron acceptor with reduction to elemental nitrogen. Thiosulfate, elemental sulfur and sulfide may be used as energy sources with oxidation to sulfate. Nitric oxide (NO) has been shown to be an intermediate in the reduction of nitrate to elemental nitrogen in T. denitrificans. Ishaque & Aleem (Arch. Mikro, 94, 269 (1973)) and Baldensparger & Garcia (Arch. Mikro., 103, 31 (1975)) have demonstrated that whole cells of T. denitrificans will catalyze the reduction of nitric oxide to elemental nitrogen with a concomitant oxidation of thiosulfate (electron donor). However, these experiments utilized "resting cells"; that is, the cells were not actively growing and reproducing. Since nitric oxide reduction in T. denitrificans would be directly linked to the energy metabolism of the cell, the highest specific activity for NO reduction should occur when cells are actively growing and reproducing.
SUMMARY OF INVENTION
The current invention consists of a process by which a gas containing nitric oxide is contacted with an anaerobic microbial culture containing one or more denitrifying bacteria to effect the chemical reduction of nitric oxide (NO) to elemental nitrogen. The bacteria are in a suitable medium conducive to cell viability and growth but lacking any source of terminal electron acceptor except nitric oxide. The current invention is particularly well suited for the disposal of concentrated streams of NO x (NO and NO 2 ) as may be obtained from certain regenerable, dry scrubbing processes for flue gas desulfurization, such as the NOXSO process, and the removal and disposal of NO x from more dilute gas streams such as produced by nitric acid plants.
Although the invention will be described with reference to the use of Thiobacillus denitrificans, other facultatively anaerobic bacteria capable of using nitrate as a terminal electron acceptor with reduction to elemental nitrogen can be used. Examples of other bacteria include but are not limited to species of the genera Pseudomonas, Paracoccus, Micrococcus, Rhodopseudomonas, Rhodobacter, Alcaliqenes, Achromobacter, and Bacillus.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are graphs showing the reduction in thiosulfate and ammonium ions and the increase in optical density and biomass protein over a period of time employing the present invention.
FIG. 3 is a schematic flow diagram illustrating the present invention in the removal of NO x from a gas stream.
DESCRIPTION OF PREFERRED EMBODIMENT
It has been discovered that nitric oxide will support the anaerobic growth of T. denitrificans as a terminal electron acceptor. The following description of the preferred embodiment of the invention describes the best means known to apply the current invention and the results of the application of the invention to the removal and disposal of nitric oxide from a gas stream.
T. denitrificans (ATCC 23642) was obtained from the American Type Culture Collection (Rockville, Md.). In a typical batch experiment the organism was grown in a B. Braun Biostat M fermenter (culture volume 1.4 l) in the thiosulfate medium described in Table 1.
TABLE 1______________________________________Thiosulfate maintenance medium for Thiobacillus denitrificans.Component Per Liter______________________________________Na.sub.2 HPO.sub.4 1.2 gKH.sub.2 PO.sub.4 1.8 gMgSO.sub.4.7H.sub.2 O 0.4 gNH.sub.4 Cl 0.5 gCaCL.sub.2 0.03 gMnSO.sub.4 0.02 gFeCl.sub.3 0.02 gNaHCO.sub.3 1.0 gKNO.sub.3 5.0 gNa.sub.2 S.sub.2 O.sub.3 10.0 gTrace metal solution 15.0 mLMineral Water 50.0 mL______________________________________
In this medium, thiosulfate is the energy source, nitrate is the terminal electron acceptor, carbon dioxide or bicarbonate is the carbon source and ammonium ion (NH 4 + ) the source of reduced nitrogen. The culture was incubated at 30° C. (with pH control at 7.0) to a cell density of approximately 5×10 8 cells/ml. At this time, cells were harvested aseptically by centrifugation at 5000×g for 10 min and resuspended in the same medium without nitrate. A gas feed of 0.48% NO, 5% CO 2 and the balance nitrogen was then initiated at 10.5 l/hr corresponding to a molar NO feed rate of 2.0 mmoles/hr. An agitation rate of 800-900 rpm was used. Cumulative outlet gas flow was measured with a Precision Wet Test Meter. The culture medium and outlet gas were sampled periodically as the cultures were maintained on a NO feed for up to 7 days.
Thiosulfate was determined in culture medium samples by titration with standard iodine (Meites, Handbook of Analytical Chemistry, McGraw-Hill, N.Y. (1963)). Biomass protein was determined by sonication to break cells followed by spectrophotometric analysis by the micro-Folin method (Lowry et al. J. Biol. Chem., 193, 265 (1951)). Ammonium ion was determined by the Nessler's test without distillation (American Public Health Association, Standard Methods for the Examination of Water & Wastewater, 14th Ed., APHA, NY (1976)). Nitrite was determined by the diazotization method using chromatropic acid and sulfanilic acid (American Public Health Association, Standard Methods for the Examination of Water & Wastewater, 14th Ed., APHA, NY (1976)). NO in the outlet gas was determined by Gastech Analyzer tubes (Gastec Corp., Yokohama, Japan). These tubes had a range of 0-200 ppm NO and an accuracy as given by the manufacturer of ±25%.
When NO introduced into T. denitrificans cultures previously grown on thiosulfate with nitrate as the terminal electron acceptor, the NO content of the feed gas was typically reduced to 100-200 ppm in the outlet gas and remained at this level throughout the course of the experiment. As NO was removed from the feed gas the concentrations of thiosulfate and ammonium ion were reduced in the culture medium with a corresponding increase in optical density and biomass protein as shown in FIGS. 1 and 2. Growth of T. denitrificans on thiosulfate as an energy source and NO as a terminal electron acceptor is clearly indicated. In control experiments without biomass, NO broke through almost immediately at concentrations comparable to the feed gas and no oxidation of thiosulfate was observed. Nitrite accumulated in the absence of biomass; however, little or no nitrite was detected in the culture medium in the presence of T. denitrificans.
In a typical experiment the oxidation of 45.8 mmoles of thiosulfate was accompanied by the reduction of 190.1 mmoles NO, the utilization of 4.7 mmoles of NH 4 + and the production of 188 mg of biomass protein. The NO/S 2 O 3 -2 ratios for four duplicate experiments given in Table 2. The average ratio was 4.1. The purely chemical reduction of NO by S 2 O 3 -2 would be given by
S.sub.2 O.sub.3.sup.-2 +4NO 2 SO.sub.4.sup.-2 +2 N.sub.2
Therefore the chemical reduction of NO by S 2 O 3 -2 has a stoichiometry of 4 (NO/S 2 O 3 -2 ). Given that NO supports the growth of T. denitrificans as a terminal electron acceptor, a NO/S 2 O 3 -2 ratio of less than 4 would be expected since some electrons derived from S 2 O 3 -2 would be used as reducing equivalents to support biosynthesis (growth). The discrepancy between this analysis and the data presented in Table 2 is likely due to errors in gas analysis for NO.
TABLE 2______________________________________Stoichiometry of NO Reduction by T. denitrificanswith Thiosulfate as Electron DonorExp. no. NO/S.sub.2 O.sub.3.sup.-2______________________________________1 3.62 4.23 4.44 4.2 4.1 average______________________________________
It has been clearly demonstrated that nitric oxide will support the growth of T. denitrificans as a terminal electron acceptor with thiosulfate as the energy source (electron donor). The low solubility of NO in water resulted in incomplete removal of NO from the feed gas in one contacting stage. However, up to 96% removal of NO was observed. Complete removal could be achieved with multiple stage contacting.
Although thiosulfate has been described as the energy source for T. denitrificans. the current invention is not limited to thiosulfate. Elemental sulfur and inorganic soluble sulfides (H 2 S, HS - , S -2 ) could be used as the energy source within the concept of the current invention. The invention is also not limited to the wild-type strain of T. denitrificans (ATCC 23642) used in these experiments. Any wild-type strain of T. denitrificans and any mutant thereof could be used within the context of the present invention, as well as the denitrifying species of the previously mentioned genera Pseudomonas, Paracoccus, Micrococcus, Rhodopseudomonas, Rhodobacter, Alcaliqenes, Achromobacter, and Bacillus. Referring now to FIG. 3, the present invention is illustrated in the context of a combustion process in a boiler 10. In this particular example, the NOXSO process previously referred to is used for illustration. The flue gas from the combustion process containing the nitric oxide is cooled at 12 to a temperature appropriate for the following adsorbtion process, typically to about 120° C. The cooled gas from 12 is fed to the fluidized bed adsorber 14 where the NO x and SO 2 are both adsorbed by an adsorbant which consists of Na 2 CO 3 deposited on the surface of an alumina substrate.
The Na 2 CO 3 deposit is unstable in the presence of alumina at between 400° and 700° C. In this temperature range, sodium combines with alumina to form sodium aluminate (NaAlO 2 ). NaAlO 2 adsorbs SO 2 and NO x simultaneously to form sodium sulfate (Na 2 SO 4 ), sodium nitrite (NaNO 2 ) and sodium nitrate (NaNO 3 ). Both sodium and alumina chemisorb SO 2 from the flue gas. It has also been demonstrated that NO x chemisorbs on Lewis acid sites (aluminum ions) on gamma-alumina.
The regeneration of active adsorption sites in the NOXSO process is accomplished first by heating the spent sorbent to about 600° C. at 16. The product of chemisorption of NO x is unstable at temperature above 400° C. By heating the sorbent to the sulfur regeneration temperature of 600° C., a concentrated stream 18 of NO x is generated. This concentrated stream 18 of NO x is then treated in the bioreactor 20 according to the present invention. The subsequent treatment of the adsorbent from the heater 16 is in the regenerator 22 with the reducing gas from the bioreactor containing the nitrogen and methane to yield a mixture of SO 2 and H 2 S. The sulfide produced remains on the sorbent after treatment and is subsequently removed by treatment with steam at 24 to yield further SO 2 and H 2 S. The H 2 S thus generated may be burned to produce a concentrated stream of SO 2 for the formation of sulfuric acid. Alternatively, the mixture of SO 2 and H 2 S obtained from the regeneration process can be used as feed to a Claus reactor to form elemental sulfur. The regenerated adsorbent is then recycled to the fluidized bed adsorber 14 through the cooler 26.
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Disclosed is a process by which a gas containing nitric oxide is contacted with an anaerobic microbial culture of denitrifying bacteria to effect the chemical reduction of the nitric oxide to elemental nitrogen. The process is particularly suited to the removal of nitric oxide from flue gas streams and gas streams from nitric acid plants. Thiobacillus dentrificians as well as other bacteria are disclosed for use in the process.
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CROSS REFERENCE
This application is a divisional application of U.S. Ser. No. 12/738,580 filed Apr. 16, 2010, which is a §371 application of international application number PCT/US08/081,520 filed on Oct. 29, 2008, which claims priority from U.S. provisional application Ser. No. 60/983,503 filed on Oct. 29, 2007, herein incorporated by reference.
BACKGROUND
Existing methods for detection of small RNAs such as small interfering RNAs (siRNAs) and micro RNAs (miRNAs) often involve multiple steps: for example, immobilizing RNA on a filter (Northern blot), hybridization with a specific probe if the small RNA is a single-stranded miRNA, washing steps to remove the probe, and exposure of the filter to a film. Alternatively, small single-stranded RNAs (ssRNAs) such as micro RNAs (miRNAs) can be detected using solution hybridization of a probe to the miRNAs, RNAse treatment and gel electrophoresis to analyze the miRNA/probe product. Detection of miRNA using a DNA array requires fluorescent-labeling of total RNA. Labeling of samples adds complexity and variability to the results. Methods that require DNA amplification are sensitive but need corrections related to efficiency of amplification. These methods are not appropriate for rapid diagnostics or high throughput screening because of the multiple steps involved in the analysis.
Evidence is accumulating that small RNAs such as miRNAs are involved in human disease such as neurological diseases, cardiomyopathies, and cancers (Alvarez-Garcia et al. Development 132:4653-4662 (2005)). Patterns of altered miRNA expression in tissue biopsies may serve as diagnostic markers for these diseases. For example, the use of a reliable quantitative method for detecting the differential expression of certain miRNAs in various tumors would be valuable for diagnosis and treatment of cancer.
SUMMARY
In an embodiment of the invention, a recombinant protein is provided having at least 90% sequence homology to SEQ ID NO:33, and being capable of binding a small double-stranded RNA (dsRNA). The recombinant protein may be additionally labeled by means of a fluorescent label, a radioactive label, a chemiluminescent label, a protein label or a small molecule label. In another embodiment of the invention, a DNA encoding the recombinant protein and a vector for expressing the recombinant protein in a host cell are provided.
In a further embodiment of the invention, a method is provided that includes mixing a target RNA with a p19 fusion protein capable of binding small dsRNA, wherein either the p19 fusion protein or the target RNA is labeled, the label being (i) directly linked to the protein or RNA, or (ii) indirectly linked by means of a molecule capable of binding to the p19 fusion protein or the target RNA. The method further includes immobilizing the p19 fusion protein bound to the target RNA on a matrix for detecting the target RNA. The detectable label is exemplified by a member of the group consisting of a fluorescent label, a radioactive label, a chemiluminescent label, a protein label and a small molecule label.
The target RNA may be an ssRNA having a size in the range of 18 nucleotides to 24 nucleotides where the ssRNA hybridizes to a complementary polynucleotide probe to form a double-stranded hybrid polynucleotide for binding to the p19 fusion protein. The complementary polynucleotide probe may extend at the 3′ end beyond the target RNA.
The polynucleotide probe may be an RNA, a DNA or a locked nucleic acid. The target RNA may be a single-stranded molecule such as a miRNA. The target RNA may be a double-stranded RNA such as an siRNA.
In an embodiment of the invention, the p19 fusion protein is immobilized prior to binding the target RNA. Alternatively, the target RNA may be immobilized prior to binding the p19 fusion protein. Alternatively, the p19 fusion protein may be bound to the target RNA in solution and the p19 fusion protein dsRNA complex immobilized on a matrix.
In embodiments of the invention, the matrix is a bead which may be coated with a carbohydrate or other ligand to which the p19 fusion protein binds. The bead may be magnetic. The bead may be colored or fluorescent in a manner that differs from the label on the p19 fusion protein or polynucleotide probe.
In an embodiment of the invention, immobilization of target RNA provides a diagnostic test for an abnormal condition in a cell in which the target RNA is isolated from total RNA obtained from the cell.
In an embodiment of the invention, a method is provided for detecting a target RNA in a mixture of RNAs, such that if the target RNA is (i) single-stranded, then a complementary polynucleotide probe is added to the mixture for forming a dsRNA and allows the dsRNA to bind to a p19 fusion protein; or (ii) double-stranded, in which case dsRNA binds directly to the p19 fusion protein.
In either case, one of the complementary polynucleotide probes or the p19 fusion protein is associated or linked to a label selected from a fluorescent label, a radioactive label, a chemiluminescent label, a protein label and a small molecule label.
In a further embodiment of the detection method, p19 fusion protein can be immobilized on a matrix for binding small dsRNA and removing unbound RNA. Alternatively, small dsRNAs can be immobilized on the matrix either by hybridizing a target ssRNA to a matrix bound polynucleotide probe or by directly binding the target dsRNA. In this case, the p19 fusion protein is preferably labeled.
In a further embodiment of the invention, a kit is provided that contains the recombinant p19 fusion protein described above, instructions for detecting a small RNA, and optionally a matrix for binding p19 fusion protein or a polynucleotide probe. The p19 fusion protein may be bound to a matrix in the kit. Alternatively, a polynucleotide probe may be bound to the matrix, in which case, the kit may additionally contain a labeled unbound p19 fusion protein.
If a matrix is included in the kit, it may be a bead, for example, a colored or fluorescent bead. The bead may be coated with a carbohydrate for binding the p19 fusion protein. The bead may be magnetic.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a summary of the biogenesis of miRNAs (Esquela-Kerscher & Slack, Nature Reviews Cancer 6:259-269 (2006)). Transcription (1) of DNA results in the formation of a primary miRNA (pri-miRNA) (SEQ ID NO:3). This is a dsRNA hairpin structure that is cleaved by Drosha (2), a nuclear enzyme with RNase III domains to form a pre-miRNA (3). The cleaved hairpin is transported to the cytoplasm (4) by exportin 5. Secondary cleavage occurs with Dicer (5) to generate a dsRNA of about 20 to 22 bases in length. This RNA then enters the RNA-induced silencing complex where it is unwound to form ssRNA that hybridizes with the 3′ untranslated region of the miRNA (6). The bound miRNA reduces protein expression either by blocking translation or causing cleavage of the miRNA (7).
FIGS. 2A-2C show properties of the molecule used for discovery or detection of miRNA.
FIG. 2A shows a cartoon of a fusion protein consisting of a maltose-binding protein (MBP) fused to p19 which is fused to a chitin-binding domain (CBD).
FIG. 2B shows a gel containing the p19 fusion protein. The figure demonstrates that this protein can be made in large quantities.
FIG. 2C shows the crystal structure of the p19 fusion protein bound to dsRNA. The view is looking down the center of the RNA helix.
FIG. 3 demonstrates that the p19 fusion protein (MBP-p19-CBD) preferentially binds dsRNA of 21 nucleotides (nt) but does not bind dsRNA of 25 nucleotides or 17 nucleotides long. 0.5 μg of MBP-p19 fusion protein bound to 30 ng of the 21-mer dsRNA in a 20 μl reaction. The reaction also contained 30 ng of the 17-mer and 25-mer dsRNA. Lanes 1-9 show use of increasing amounts of MBP-p19-CBD fusion protein (μg) and lane 10 is a size marker.
FIGS. 4A-4B show additional characterization of the p19 fusion protein.
FIG. 4A shows that 10 ng, 20 ng, 30 ng and 40 ng of dsRNA can be bound to chitin magnetic beads that contain 3 μg of the p19 fusion protein. The fusion protein is attached to the beads via the CBD. When treated with SDS, the dsRNA is released from the beads and can be detected on the ethidium stained gel.
FIG. 4B shows that a small amount of dsRNA of 21 nucleotides can be purified from a large excess of cytoplasmic RNA using p19 fusion protein. Chitin magnetic beads with 5 μg of the bound p19 fusion protein were mixed with 27.5 μg of total rat liver RNA and 5 ng of 21-mer dsRNA.
Lane 1 shows target dsRNA prior to mixing with non-target RNA.
Lane 2 shows the RNA that did not bind to the p19 fusion protein chitin magnetic beads.
Lane 3 shows 20 μl aliquot of the first 600 μl wash of the p19 fusion protein chitin magnetic beads.
Lane 4 shows a 20 μl aliquot of the sixth 600 μl wash of the p19 fusion protein chitin magnetic beads.
Lane 5 shows the dsRNA eluted from the beads. The top staining band is material trapped in the well.
Lane 6 contains a 17-mer, 21-mer and 25-mer dsRNA marker.
FIGS. 5A and 5B show a competitive gel shift assay to measure the relative affinity of RNA and DNA to the p19 fusion protein.
FIG. 5A shows binding of radiolabeled dsRNA (21 nt) to p19 fusion protein in the presence of increasing amounts of the same unlabeled dsRNA (21 nt). Each reaction contained 16 μg of p19 fusion protein and 1 ng of radioactive dsRNA.
FIG. 5B shows binding of radiolabeled dsRNA (21 nt) to fusion protein in the presence of increasing amounts of unlabeled double-stranded DNA (dsDNA) (21 nt).
FIG. 5C shows binding of radiolabeled dsRNA (21 nt) to p19 fusion protein in the presence of increasing amounts of unlabeled ribosomal RNA.
FIG. 5D shows binding of radiolabeled dsRNA (21 nt) to p19 fusion protein in the presence of increasing amounts of unlabeled ssRNA (21 nt).
FIGS. 6A-6B show the results of eluting 20 ng of 21 nt dsRNA from 20 μl p19 fusion protein precoated beads (containing 3 μg p19 fusion protein).
FIG. 6A shows that p19 fusion protein is stable when stored at 4° C. for at least 8 weeks such that the 21 nt RNA can be released after the specified time.
FIG. 6B shows that 21-mer dsRNA is stable when bound to p19 fusion protein stored at 4° C. or −20° C. The absence of RNA in the supernatent shows efficient binding of RNA. The elution demonstrates quantitative recovery of dsRNA from p19 fusion protein beads stored for different times and temperatures.
FIG. 7 shows the relative binding affinities of p19 fusion protein to various RNA and DNA substrates. The binding of a labeled siRNA to MBP-p19-CBD in the presence of increasing concentrations of nucleic acids described in column 1 was measured by a gel mobility shift assay. In each competitive assay, a control was included in which 50% reduction in binding of the radiolabeled 21 mer siRNA was observed in the presence of unlabeled 21 mer siRNA. This was assigned a value of one. The identity of the polynucleotide, its sequence, its structure and its relative binding affinity to MBP-p19-CBD are listed. The gaps in the structure of the microRNAs in 13, 14 and 15 denote mismatched base pairs.
FIG. 8 describes various approaches to labeling RNA. Radioactive labeling is very sensitive and gives low background but is not suitable for high throughput analysis and also has regulatory issues. Fluorescence and chemiluminescence labeling are both user friendly labeling methods and can be used in a 96 well format with or without magnetic beads and are scaleable and can be automated.
FIG. 9 shows how MBP-p19-CBD (measured in ng) when bound to fluorescent dsRNA increases fluorescence polarization which can be quantitatively measured (mP). Fluorescence polarization is defined by the following equation: P=(V−H)/(V+H) where P equals polarization, V equals the vertical component of the emitted light, and H equals the horizontal component of the emitted light of a fluorophore when excited by vertical plan polarized light. The term mP stands for 1/1000 of the polarization P. It is not dependent upon concentration (Lundblad et al. Mol. Endocrinol. 10:607-612 (1996)).
FIGS. 10A-10B show how the p19 fusion protein can be used for discovery of novel endogenous siRNAs.
FIG. 10A shows the results of loading 350 μg of total unc-22 RNA extracted from C. elegans onto a 20% acrylamide TBE gel. Extraction of RNA from the gel in the 15 to 30 base pair range yields 6.1 μg of small RNA.
FIG. 10B shows the results from binding the gel purified small RNA to the p19 fusion protein chitin magnetic beads, washing the beads and then eluting the RNA. The mobility of the eluted RNA is indicated by an arrow at the right of the figure.
FIG. 11 shows the isolation of endogenous siRNA from a filiarial parasite D. immitis using p19 fusion protein chitin magnetic beads. 50,000 fold enrichment was obtained. The mobility of the eluted RNA, in lane 9, is indicated by an arrow.
Lane 1 is double-stranded siRNA marker.
Lane 2 is 10 ng of a 21 mer dsRNA.
Lane 3 is gel purified D. immitis small RNA.
Lane 4 is gel purified RNA plus p19 fusion protein.
Lane 5 is RNA not bound to chitin magnetic beads with p19 fusion protein.
Lane 6 is the first wash of the p19 chitin magnetic beads.
Lane 7 is the result of wash 2.
Lane 8 is the result of wash 3.
Lane 9 is the first elution from the beads.
Lane 10 is the second elution from the beads.
FIG. 12 shows a protocol for detecting dsRNA using biotin-labeled p19 fusion protein. A polynucleotide probe (9) is covalently linked to beads (8). Small ssRNAs (tRNAs, rRNAs etc.) (10) hybridize to the polynucleotide probe (9) to form a stable RNA hybrid on the bead (8). A biotin-labeled p19 fusion protein (12) binds to RNA hybrids on the beads (8). The p19 fusion protein can be labeled using biotin, which can bind tightly to streptavidin (13). The streptavidin can be detected by linkage via a second biotin molecule to an enzyme, like alkaline phosphatase or peroxidase, or by means of a fluorescent-labeled protein. Substrates for the enzyme will give a colored or fluorescent product that can be detected with a laser. The beads to which p19 fusion protein attaches can be identified with a laser which detects the bar code signature of dyes. The amount of miRNA bound to a specific bead can be measured by the amount of p19 fusion protein bound to the beads.
FIG. 13 shows p19 fusion protein capture of dsRNA hybrid and detection with a miRNA specific probe. An ssRNA polynucleotide (9) labeled with (5-[(N-(3′-diphenylphosphinyl-4′-methoxycarbonyl)phenylcarbonyl)aminoacetamido]fluorescein (FAM) binds specifically to miRNA (10) in a background of total RNA including tRNA, rRNA and mRNA (11) to form a dsRNA that binds to a p19 fusion protein (12) which is attached to a solid support, like an ELISA plate (14) or a bead for detection.
FIG. 14 shows a p19 fusion protein-based miRNA detection method. Total cellular RNA, which includes miRNA, rRNA and mRNA (11), is hybridized to a specific probe complementary to a miRNA (9). The double-stranded miRNA/RNA probe is then selectively and tightly bound to p19 fusion protein (12) chitin magnetic chitin beads (8). The unbound probe can be removed rapidly by washing the p19 fusion protein beads and then isolating them with the aid of a magnetic rack (15). The dsRNA is then eluted from the beads in the presence of a protein denaturing agent.
FIGS. 15A and 15B show a diagnostic test for miRNAs.
FIG. 15A shows p19 fusion protein (12) attached to a bead (8) and binding dsRNA where a single strand of the duplex is labeled with biotin (9). Streptavidin (13) is bound to the biotin and with the help of a suitable enzyme label (15) and a substrate (16), a chemiluminescent or fluorescent reaction can be initiated.
FIG. 15B shows a standard curve assay for quantifying the results from the detection method described in FIG. 15A . The biotin-labeled RNA probe is linked, via a streptavidin bridge, to alkaline phosphatase. The enzyme is detected using the substrate CDP-Star, #N7001S from New England Biolabs (NEB, Ipswich, Mass.), which generates light.
FIG. 16 shows a biotin-labeled ssRNA (9) immobilized on a streptavidin (13) coated solid substrate (14). Target miRNA (10) is hybridized to the immobilized polynucleotide (9). The dsRNA is subsequently recognized and bound by a labeled p19 fusion protein (12) for detection.
FIGS. 17A-17D show the quantitative measurement of the liver specific miRNA (miRNA122a) from rat liver total RNA.
FIG. 17A shows a non-denaturing gel with increasing amounts of synthetic miRNA122a in picograms (pg), hybridized to 1 ng of a radioactive RNA probe complementary to miR-122a. The dsRNA is bound to p19 fusion protein chitin magnetic beads, washed, eluted and analyzed on a 20% non-denaturing acrylamide gel. The radioactivity is associated with the miRNA/RNA probe.
FIG. 17B shows a standard curve for miR122 that was calculated from radioactivity eluted from the p19 fusion protein beads.
FIG. 17C shows a non-denaturing gel of miRNA/RNA probe eluted from p19 fusion protein beads using a miR122 specific probe and different amounts of rat liver RNA.
FIG. 17D gives the results for 2, 5 and 10 μg of rat liver total RNA containing between 38 and 68 μg of miRNA122a/μg of total RNA.
FIG. 18 shows detection of Let-7 miRNA in total JURKAT cell RNA using an autoradioagraph of an acrylamide gel in which the labeled RNA corresponds to the miRNA/RNA probe hybrid, which is shown to increase according to the total RNA. A radioactive RNA probe complementary to Let-7 was hybridized to different amounts of JURKAT cell RNA, bound to p19 fusion protein magnetic beads, washed and eluted. Lanes 2-4 show 2 μg, 5 μg and 10 μg of total JURKAT RNA respectively.
FIG. 19 shows the DNA and amino acid sequences (SEQ ID NOS:32 and 33) for CBD-p19-MBP where MBP corresponds with amino acid 1 to 394 and nucleotide 1 to 1183, p19 corresponds with amino acid 395 to 565 and nucleotide 1184 to 1698, a polylinker corresponds with amino acid 566 to 575 and nucleotide 1698 to 1726 and CBD corresponds with amino acid 576 to 626 and nucleotide 1727 to 1878.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Existing methods for detection of small RNAs are often complex and require ligation and amplification or gel electrophoresis steps. A fusion protein is described here that can be used in a simplified, sensitive and quantitative assay to detect and/or isolate small RNAs.
The fusion protein described here is exemplified by a p19 fusion protein which binds a dsRNA regardless of the sequence but in a size-specific manner, is capable of being immobilized on a substrate, and can be readily purified.
RNAs of interest can be isolated from biological samples using the p19 fusion protein. This protein may also be used to detect specific endogenous RNAs of a specific size in physiological samples that contain a wide variety of RNAs normally associated with cells. The amounts of the RNAs of interest can be determined using quantitative assays (see for example, FIGS. 9 , 15 and 17 ).
DEFINITIONS
The term “small” RNA as used here and in the claims refers to RNA fragments containing or capable of forming a double-stranded region of a size of greater than about 17 nucleotides and less than about 25 nucleotides, for example 21-23 nucleotides. The dsRNA may result from two complementary strands in a linear duplex or a single-stranded molecule that is folded to form a hairpin.
Where a small RNA is single-stranded, it can be hybridized to a complementary polynucleotide probe to create either a completely dsRNA molecule or RNA/DNA hybrid or a partial dsRNA. The RNA/RNA or RNA/DNA hybrids may include a single-stranded polynucleotide tail at one end of the polynucleotide probe that extends beyond the duplex region containing the target RNA.
Examples of small RNAs include miRNAs, siRNAs, repeats associated RNAs (rasiRNAs). rasiRNAs are found for example in C. elegans and may prevent migration of transposons.
The “p19 fusion protein” refers to a member of the p19 family of RNA binding proteins (Silhavy et al. Embo J. 21:3070-80 (2002)) fused to one or more additional proteins which surprisingly retains the binding properties of the native enzyme where the fusion protein binds small dsRNA in a sequence-unspecific but size-specific manner (see for example, FIGS. 2-6 ). The binding properties of the p19 fusion protein was determined for various substrates using competitive gel shift analysis. The results confirmed that the p19 fusion protein does not bind ssRNAs or dsDNA but does bind dsRNA in a size specific manner ( FIG. 7 ).
P19 proteins are highly conserved in Tombus plant viruses. Related proteins have been isolated from many plant viruses such as Carnation Italian ringspot virus p19 (NP 612584), Tomato bushy stunt virus (CAC01278), Artichoke mottled crinkle virus (NP 039812), Lettuce necrotic stunt virus (CAC01267), Lisianthus necrosis virus (CAM98056), Grapevine Algerian necrosis virus (AAX76895), Cucumber necrosis virus (CAC01089), Pelargonium necrotic spot virus (NP 945118), Cucumber Bulgarian virus (AA033943), Maize necrotic streak virus (AAG21219), Pear latent virus (AAM49806), Grapevine Algerian latent virus (AAX76895), and Cymbidium ringspot virus (CAA33535) (accession numbers in parenthesis).
The p19 proteins described above includes a fusion to one or more proteins where at least one of the proteins has a size greater than 10 amino acids. Examples of proteins for fusion to p19 include carbohydrate-binding proteins exemplified by MBP, CBD and cellulose-binding domain; enzymes such as 06-alkylguanine-DNA alkyltransferase (U.S. Patent Applications 2006/0292651; 2006/0024775; 2004/0115130; 2007/0082336; 2007/0207532; 2007/0243568) or luciferase that are capable of responding to a substrate to produce fluorescence or a detectable color signal; enzyme substrates such as biotin; antibodies; and protein epitopes.
A “polynucleotide probe” refers to a ssDNA, ssRNA or a locked nucleic acid that may be synthetic and is complementary at least in part to the target RNA if the target RNA is single-stranded (Vester & Wengel Biochemistry 43(42):13233-41 (2004)). The probe may be labeled. Alternatively, the probe is not labeled and is used in an assay in which the p19 fusion protein is or becomes labeled during the assay.
Methods of Making p19 Fusion Proteins
The formation of fusion proteins can be readily achieved using DNA vectors available in the art such as those described in the New England Biolabs (NEB, Ipswich, Mass.) catalog. Example 1 which is not intended to be limiting describes a method of making a p19 fusion protein from Carnation Italian ring spot virus in which the protein is fused at the amino end to an MBP, which permits purification of the protein, and at the carboxy end to the CBD, for tightly binding the magnetic chitin beads ( FIG. 2 ).
Labeling the p19 Fusion Protein or Polynucleotide Probe
Labeling a target molecule may be achieved either directly or indirectly by labeling a molecule capable of binding the target molecule. These labels may be attached to a reagent polynucleotide probe for binding the target RNA, or to the p19 fusion protein. Any suitable label known in the art can be used such as a radioactive label (for example, 32 P), a fluorescent label, a chromogenic label such as phycoerythrin, an enzyme label or a modified base for reacting with an enzyme (biotin-strepavidin).
Examples of methods of detection using fluorescent labels include FAM. Another method is Fluorescence Resonance Energy Transfer (FRET). This involves two different fluorescent molecules (or proteins), one for linking to the p19 fusion protein and the other for linking to the RNA probe. When the dsRNA binds to the p19 fusion protein, the two molecules are in close enough proximity for efficient energy transfer to generate a fluorescent signal. This method does not require removal of the unbound RNA probe and is therefore suitable for large scale screening. Another method is Fluorescent Polarization (FP) where the two subunits of the MBP-p19-CBD protein are about 10× the molecular weight of the 17-25 base-paired dsRNA. This difference in size between the bound and unbound RNA can be detected by FP. Another method is quantum dot analysis such as described by Yezhelyev et al. J Am Chem. Soc. 130(28):9006-12 (2008)), which may also be used for detection of dsRNAs.
Examples of enzyme labels include methods in which for example a luciferase, green fluorescent protein or alkyl guanine DNA alkyl transferase are used. Small molecules such as biotin may be used. Biotin is linked to the polynucleotide probe, and avidin-bound enzymes, like horseradish peroxidase or alkaline phosphatase react with biotin through streptavidin to signal the presence of a molecule of interest. This is a standard method for ELISA detection of antibodies.
Immobilization of Reagents
The target RNA may be immobilized either directly or indirectly on or in a matrix. Indirect immobilization of the target RNA may occur by means of (a) hybridizing a target ssRNA to a matrix bound polynucleotide probe to form a small dsRNA which is subsequently recognized by a p19 fusion protein in solution; or (b) binding small dsRNA to p19 fusion protein bound to a matrix; or (c) binding dsRNA with p19 fusion protein in solution and then binding the complex to a matrix.
The p19 fusion protein can be readily immobilized on a matrix if that solid substrate is coated with a molecule with which the fusion protein binds, for example, chitin for binding chitin-binding domain or amylose for binding MBP. A polynucleotide probe can be bound to a matrix by means of a ligand such as biotin.
Examples of matrices include beads, columns, microtiter plates, a chip, or other 2-dimensional or three-dimensional formats known in the art. In addition, channels coated with chitin in microfluidic devices may be used to immobilize RNAs of interest.
Sensitivity of the Assay
Levels of enrichment of dsRNA of any sequence having a size preferably of greater than 17 nucleotides and less than 25 nucleotides can be achieved of greater than 20,000 fold and as much as 100,000 fold from total RNA. Moreover, as little as 10 μg of miRNA can be detected in a million-fold excess of total RNA and 50 μg of miRNA can be measured in total cell RNA from a tissue. Competitive gel shift data demonstrate that neither unbound single-stranded probe nor cytoplasmic RNA blocks binding of a miRNA and RNA probe in a p19 fusion protein detection assay.
Uses of the Assay
A specific polynucleotide probe may be attached to a substrate such as a plate or beads using standard methodology (for example biotin-steptavidin labeling) and exposed to a cell lysate from, for example, a biopsy. Only ssRNA of a specific sequence contained in the cell lysate will bind the immobilized polynucleotide probe. Labeled p19 fusion protein may then bind to the dsRNA or RNA/DNA hybrid and can be detected. FIGS. 17 and 18 demonstrate the feasibility of this approach for the quantitative detection of mir122a miRNA in total RNA extract from rat liver. Examples 4 and 5, FIGS. 17 and 18 illustrate how radioactive labeling or fluorescent-labeling is effective in detecting small amounts of the target miRNA in total lysate.
The labeled p19 fusion protein may either be in solution and optionally subsequently immobilized or already immobilized on a coated matrix (for example, chitin) where for example, the matrix is magnetic beads or the well of a microtiter plate. Accordingly, unbound material can be removed and the target RNA can be subsequently eluted from the matrix for analysis.
This approach can be adapted for high throughput screening of samples for target miRNAs ( FIG. 14 ). Automation of detection can be facilitated using magnetic beads. For example, a biotinylated probe, previously hybridized to a miRNA target, can be linked to a plate coated with streptavidin. In this way, a labeled p19 fusion protein provides a signal for detecting miRNA ( FIG. 16 ).
In an embodiment, automation of detection for high throughput processing of samples is facilitated by scanning an ELISA plate for binding of modified p19 fusion protein with labeled double-stranded miRNA. The ELISA plate can be coated with chitin to which p19-CBD fusion proteins bind. The unbound RNA can be removed by washing the plate and the remaining bound RNA can be detected by means of the attached probe. If the probe contains biotin, then it can be linked to a chromogenic readout using avidin conjugated to alkaline phosphatase or horseradish peroxidase ( FIG. 15 ). An ELISA plate format for miRNA detection has many advantages. There exists an extensive amount of instrumentation for washing, reading and handling of ELISA plates. High throughput analysis is an important feature of analyzing clinical samples.
The methods and compositions described herein may be used to quantitatively determine the presence and amounts of endogenous miRNAs for purposes that include diagnosis or analyzing a wide range of pathologies such as cancers including determining the tissue of origin of the metastasized cancer, neuropathologies, and pathologies in other organs. These methods provide rapid, cost effective, efficient and scaleable detection of miRNAs in vitro.
All references cited herein, as well as U.S. provisional application Ser. No. 60/983,503 filed Oct. 29, 2007 and international application number PCT/US08/081,520 filed on Oct. 29, 2008 are incorporated by reference.
EXAMPLES
Example 1
Cloning of the D19 Fusion Protein and Binding to Size-Specific dsRNA
The p19 protein from the Carnation Italian ringspot virus codes for a 19 kDa protein and has a binding preference for 17-25 bp RNAs (Vargason et al. Cell 115:799-811) (2003)).
Sequence of the p19 protein from the Carnation Italian ringspot virus is as follows:
(SEQ ID NO: 1)
1
MERAIQGNDT REQANGERWD GGSGGITSPF KLPDESPSWT EWRLYNDETN SNQDNPLGFK
61
ESWGFGKVVF KRYLRYDRTE ASLHRVLGSW TGDSVNYAAS RFLGANQVGC TYSIRFRGVS
121
VTISGGSRTL QHLCEMAIRS KQELLQLTPV EVESNVSRGC PEGIETFKKE SE
The plasmid vector pMAL-c2G from New England Biolabs (NEB, Ipswich, Mass.), was cleaved with PstI and HindIII, within the multiple cloning site. The following two PCR primers were used to amplify the chitin-binding domain, CBD, from the plasmid pTYB1 from New England Biolabs (NEB, Ipswich, Mass.): 5′ G ACT CTG CAG ACG ACA AAT CCT GGT GTA TCC GCT 3′ (SEQ ID NO:34) CBD (PstI) forward primer and 5′ T AGG AAG CTT TCA TTG AAG CTG CCA CAA GGC AGG AAC 3′ (SEQ ID NO:35) CBD (HindIII) reverse primer. After amplification the PCR product was cleaved with Pst I and Hind III and cloned into the plasmid pMAL-c2G. The new vector was then cleaved with BamHI. The p19 fusion protein coding sequencing, accession number NC 003500, was amplified with two primers containing BamHI sites. The PCR products was cleaved with BamHI and then cloned into the MBP CBD vector described above. The resulting plasmid construct coded for a fusion protein that contained an amino terminal MBP and a carboxy terminal CBD.
The MBP-p19-CBD fusion protein was isolated in high yields by binding and elution from amylose resin. The fusion protein was shown to be functionally active as described below.
The MBP-p19-CBD fusion protein ( FIG. 19 ) was shown to bind an siRNA in a size-dependent sequence-independent manner where the size was preferably greater than 17 nucleotides and smaller than 25 nucleotides ( FIG. 3 ). It was concluded that the presence of a large, 42 kDa, fusion partner like MBP does not have a major effect on siRNA binding to p19 fusion protein ( FIG. 2 ).
The affinity of the p19 fusion protein for different substrates was determined by gel shift analysis ( FIGS. 5 and 7 ). The affinity of p19 fusion protein was greater for siRNAs than for miRNAs which contained mismatched base pairs. The p19 fusion protein bound to 21-mer dsRNA/DNA hybrid but not to dsDNA of the same size or ssRNA, single-stranded DNA or ribosomal RNA. Binding of RNA to p19 was also detected by fluorescence-polarization studies that used fluorescent-labeled RNA ( FIGS. 5 , 7 and 9 ).
The MBP-p19-CBD fusion protein was used for siRNA isolation ( FIGS. 12 and 13 ). Small RNAs that bound to the p19 fusion protein were purified with chitin magnetic beads. The CBD portion of the p19 fusion protein attached the dsRNA:protein complex to the beads ( FIGS. 14 to 16 ). Background binding could be reduced with the addition of bovine serum albumin (BSA). The small RNAs were eluted from the chitin beads by denaturing the protein with 0.5% SDS.
In a reconstruction experiment, a defined amount of siRNA was added to total rat liver RNA, bound to p19 fusion protein, concentrated with chitin magnetic beads and eluted. Greater then 5,000× enrichment was obtained using this approach ( FIGS. 3 and 4 ).
Example 2
Determination of the Sensitivity and Quantification of the Detection Method for RNAs Using p19 Fusion Protein and Liquid Scintillation
A method was developed using 32 P-labeled polynucleotide probes to detect and quantify the abundance of endogenous miRNA in a total RNA sample. The p19 fusion protein specifically detected a hybrid between a miRNA and a labeled radioactive RNA probe in a one million-fold excess of cytoplasmic RNA. This was demonstrated using the abundant liverspecific miRNA, miR122a. A standard curve was made using increasing amounts of synthetic miR122a mixed with a large excess of JURKAT total RNA (T lymphocyte cell) to mimic assay conditions. JURKAT cell total RNA did not contain any detectable miR122a by this method. Variable amounts of miR122a oligo were hybridized to a constant amount or radioactive RNA probe, which was complementary to miR122a. A background standard lacking any added miR122a oligo was processed in the same as the samples ( FIG. 17 ).
A quantitative measurement of endogenous miR122a was made by incubating rat liver total RNA with the miR122a specific probe. Three assays with different amounts of rat liver total RNA were performed to ensure concordance of the results. After hybridization, each sample was incubated with p19 fusion protein-coated magnetic beads to allow for binding of the miR122a-probe duplex. To remove the unbound RNA, p19 fusion protein beads were washed 5 times and the miR122a duplex was eluted from the beads by denaturing p19 fusion protein with an elution buffer containing 0.5% SDS. The eluted radioactive duplex was counted and the background control was subtracted from each sample. To demonstrate that the radioactivity corresponded to the miR122a/probe, the eluent was loaded on an acrylamide gel ( FIG. 5A ) and exposed to X-ray film. As observed on the autoradiograph, the eluted RNA was double-stranded, not single-stranded probe.
After subtracting the control radioactive count from each result, the standard counts corresponding to the miR122a duplex were plotted as a function of synthetic miR122a amount ( FIG. 5B ). A linear curve demonstrated the proportionality between the radioactive signal and the amount of miR122a complex. Comparison to the standard curve provides a relative measurement of the miR122a abundance in a physiological sample ( FIGS. 5C and 5D ). A value of 50 pg+/−12 μg of miR122a per μg of rat liver total RNA was obtained for the three concentrations of RNA. The detection is linear over two orders of magnitude and has a sensitivity of 2-5 pg of miRNA.
(a) Labeling miR122a Probe Using γ- 32 P-ATP
In a microfuge tube, 300 ng of miR122a probe (5′ OH-aacaccauugucacacuccaua) was added to 2 μL of T4 polynucleotide kinase reaction buffer (70 mM Tris-HCl (pH7.6), 10 mM MgCl2, 5 mM dithiothreitol from New England Biolabs (NEB, Ipswich, Mass.)) and 3 μL of miliQ water. Then, 10 μL of γ- 32 P-ATP (PerkinElmer, Waltham, Mass.) at 6,000 Ci/mmol and 2 μL of T4 polynucleotide kinase (10,000 units/mL) from New England Biolabs (NEB, Ipswich, Mass.) were added to the labeling reaction. The reaction tube was placed in a 37° C. heat block for 40 to 60 minutes, and then the reaction was stopped by inactivating the enzyme at 65° C. for 20 minutes. After stopping the reaction, the entire labeling reaction was loaded onto a CentriSep column (Princeton Separation, Freehold, N.J.) and centrifuged for 2 minutes at 3,000 rpm to remove the excess γ- 32 P-ATP. The specific activity of labeled probe was determined by counting 1 μL of a ten-fold dilution of the purified labeling reaction in a scintillation counter.
(b) Total RNA Extraction from JURKAT Cells
JURKAT total RNA was obtained using Trizol (Invitrogen, Carlsbad, Calif.) as recommended by the manufacturer. 10 mL of Trizol were added to the JURKAT cell pellet. The sample was transferred in a 30 mL tube and cells were disrupted by homogenization using a syringe. After complete homogenization, the tube was incubated 5 minutes at room temperature to permit the complete dissociation of nucleoprotein complex. 2 mL of chloroform was added to the sample, vortexed for 15 seconds and incubated at room temperature for 2 to 3 minutes and centrifuged at 4° C. for 15 minutes at 12,000 g. To precipitate the RNA sample, the aqueous phase was transferred to a new tube containing 5 mL of isopropanol, placed at room temperature for 10 minutes and centrifuged at 4° C. for 10 minutes at 12,000 g. The RNA pellet was then washed with 10 mL 75% ethanol and thoroughly drying. The pellet was resuspended with 200 μL of sterile Tris-EDTA. The total RNA concentration was estimated via optical density using the nanodrop spectrophotometer and the purity was evaluated by the ratio A260 nm/A280 nm.
(c) Assay for Small RNAs
RNA samples were added to loading buffer and loaded into pre-rinsed wells of a TBE Gel 20% acrylamide (Invitrogen, Carlsbad, Calif.) as well as the RNA size marker (siRNA Marker, New England Biolabs (NEB, Ipswich, Mass.)). After running at 100V for 2 hours, the gel was stained with SybrGold (Invitrogen, Carlsbad, Calif.) and visualized on a fluorimager. In the competitive binding assays of RNA/DNA to p19 fusion protein, the gels were exposed to X-ray film and the bands scanned to determine relative binding affinities.
(d) Quantification of Endogenous miR122a Using p19 Fusion Protein-Based Liquid Scintillation miRNA Detection Method
Quantification of sensitivity was determined by (1) varying amounts of total rat liver RNA (2, 5 and 10 μg) incubated with 1 ng of specific probe; and (2) varying amounts of miRI22a RNA (target RNA) (500 pg to 0.32 pg).
A miR122a complementary sequence was synthesized and labeled with a radioactive label. Specifically, 5′ γ- 32 P aacaccauugucacacuccaua (SEQ ID NO:2) was labeled at the 5′ end using γ- 32 P-ATP. Incubation was performed 2 hours at 65° C. in 1×p19 fusion protein binding buffer (20 mM Tris HCl, 100 mM NaCl, 1 mM EDTA and 1 mM TCEP, pH 7 at 25° C.). The labeled probe was mixed with miR122a RNA and total JURKAT RNA and incubated for 2 hours at 65° C. to allow hybridization between the target miR122a and the probe.
Hybridized dsRNA was allowed to bind to p19 fusion protein coated beads. These beads were made as follows: Chitin magnetic beads (NEB#E8036) were pretreated with BSA by washing the beads in 1×BSA buffer (20 mM Tris HCl, 100 mM NaCl, 1 mM EDTA, 1 mM TCEP and BSA at 1 mg/mL pH 7 at 25° C.) twice using a magnetic rack (New England Biolabs #S1506S (NEB, Ipswich, Mass.)) and resuspended in the same buffer and incubated overnight at 4° C. p19 fusion protein-bound magnetic beads were made by mixing p19-CBD fusion protein with pretreated chitin beads (30 μg p19 fusion protein for 200 μl beads suspension) in 200 μL 1×p19 fusion protein binding buffer with 1 mg/mL BSA and incubated at 4° C. overnight. The subsequent protein beads were stored at 4° C.
Binding of miR122a-probe duplex to p19 fusion protein occurred when 10 μL of the p19 fusion protein-coated magnetic beads were incubated for 1.5 hours at room temperature in an orbital shaker in 1×p19-binding buffer containing RNAse inhibitor and BSA at 1 mg/mL. Unbound RNA was eliminated by washing the beads 5 times with 500 μL 1×p19 fusion protein wash buffer prewarmed at 37° C. (20 mM Tris HCl, 100 mM NaCl, 1 mM EDTA and 1 mM TCEP, pH 7 at 25° C.) shaking for 5 minutes at room temperature.
miR122a-probe duplex was eluted from the beads with 20 μL of 1×p19 fusion protein elution buffer (20 mM Tris HCl, 100 mM NaCl, 1 mM EDTA and 0.5% SDS, pH 7 at 25° C.) after incubation 10 minutes at 37° C. followed by mixing 10 minutes at room temperature. The beads were spun down and the supernatant was removed. 18 μL of the elution were loaded on 20% acrylamide gel (Invitrogen, Carlsbad, Calif.) using TBE buffer and 2 μL of the eluted RNA were used for radioactive counting. The results are shown in FIG. 17 .
(E) Qualitative Detection of Let-7a Using p19 Fusion Protein-Based Liquid Scintillation miRNA Detection Method
miRNA Let-7a was detected in JURKAT total RNA as follows: Three samples were prepared containing different amounts of JURKAT total RNA. JURKAT total RNA was incubated with the Let-7a specific probe to allow hybridization between the target and probe. The probe was a synthetic Let-7a complementary sequence labeled at the 5′ end using γ- 32 P-ATP. After hybridization, the three samples containing the potential Let-7a complex were incubated with p19 fusion protein-coated beads.
To remove the unbound RNA and the excess single-stranded probe, p19 fusion protein coated beads were washed 5 times and the Let-7a complex was eluted from the beads by denaturing p19 fusion protein with an elution buffer containing 0.5% SDS. The radioactivity in each sample was measured using liquid scintillation counting. To ensure that the radioactive count corresponded to the signal of the Let-7a duplex, the rest of the elution was separated and autoradiographed ( FIG. 7 ).
The results confirmed that Let-7a miRNA was present in the JURKAT cell line at detectable levels by gel electrophoresis and scintillation counting.
Different samples containing various amount of JURKAT total RNA were incubated with 600 μg of a specific RNA probe (synthetic Let-7a complementary sequence, 5′ γ- 32 P-cuauacaaccuacuaccucaaa) (SEQ ID NO:2) labeled at the 5′ end using γ- 32 P-ATP. Incubation was performed for 2 hours at 65° C. in 1×p19 fusion protein binding buffer (20 mM Tris HCl, 100 mM NaCl, 1 mM EDTA and 1 mM TCEP, pH 7 at 25° C.) to allow hybridization between the target Let-7a and the RNA probe. In order for the p19 fusion protein-coated beads to recognize the Let-7a-probe duplex, the solution containing miRNA duplex was incubated with p19 fusion protein beads (from 10 μL of a suspension of p19 fusion protein coated beads) for 1.5 hours at room temperature in 1×p19 fusion protein binding buffer containing RNAse inhibitor and BSA at 1 mg/mL. Unbound RNA was eliminated by washing the beads 5 times with 500 μL 1×p19 fusion protein wash buffer pre-warmed at 37° C. (20 mM Tris HCl, 100 mM NaCl, 1 mM EDTA and 1 mM TCEP, pH 7 at 25° C.) shaking for 5 minutes at room temperature. The Let-7a-probe duplex was eluted from the beads with 20 μL of 1×p19 fusion protein elution buffer (20 mM Tris HCl, 100 mM NaCl, 1 mM EDTA and 0.5% SDS, pH 7 at 25° C.) after incubation 10 minutes at 37° C. followed by mixing 10 minutes at room temperature. The beads were spun down and the supernatant was removed. 18 μL of the elution were loaded on TBE 20% acrylamide gel (Invitrogen, Carlsbad, Calif.) and 2 μL were used for radioactive counting. The results are shown in FIG. 18 .
(f) Binding of p19 Fusion Protein to miRNA/RNA polyA-Tail Probe
To improve the sensitivity of detection, p19 fusion protein binding to a miRNA hybridized to a longer RNA probe was tested. Synthetic miR122a was hybridized to a FAM-labeled probe containing a 20 to 30 base poly A-tail. The hybrid obtained was incubated with p19 fusion protein and separated by PAGE electrophoresis and stained by SybrGold (Invitrogen, Carlsbad, Calif.). A mobility shift was observed when the hybrid was incubated with the p19 fusion protein. No shift was observed in the sample without p19 fusion protein. This result demonstrated that p19 fusion protein binds a miRNA/RNA polyA-tail probe ( FIG. 8 ) and may be used in future detection methods. An increase in the length of the polynucleotide probe allows for increased sensitivity of detection.
10 ng of synthetic miR122a was hybridized to 10 ng of probe containing a non-radioactive 3′ polyA-tail (5′ P-aacaccauugucacacuccaua-polyA tail) (SEQ ID NO:2) at 65° C. for 10 minutes. The hybrid obtained was incubated with 1.5 μg of p19 fusion protein (New England Biolabs (NEB, Ipswich, Mass.)) at room temperature for 1.5 hours in binding buffer (20 mM Tris HCl, 100 mM NaCl, 1 mM EDTA, 1 mM TCEP, pH 7 at 25° C.), to allow binding. A sample without p19 fusion protein was performed in identical condition as a control. The two samples were loaded on 20% acrylamide gel in TBE buffer (Invitrogen, Carlsbad, Calif.) and stained by SybrGold (Invitrogen, Carlsbad, Calif.).
Example 3
A p19 Fusion Protein-Based RNA Detection Method Using a Fluorescent-Labeled Polynucleotide Probe
A standard curve using a synthetic FAM-labeled RNA probe ( FIG. 9 ) complementary to miR31 was created. A background standard without synthetic miR31 was processed in a similar way. The hybridization step was performed in presence of a large excess of JURKAT total RNA. JURKAT cells do not have miR31. Each sample was processed in triplicate to ensure concordance of the results. After hybridization, each sample was incubated with p19 fusion protein-coated magnetic beads to allow recognition between miR31-probe duplex and p19 fusion protein protein. To remove unbound RNA, p19 fusion protein beads were washed twice and the miR31 duplex was eluted from the beads by denaturing p19 fusion protein with an elution buffer containing 0.5% SDS. Fluorescence of the samples was read with an excitation wavelength of 485 nm, an emission wavelength of 520 nm and a cutoff of 495 nm. The background signal was subtracted from each standard to remove the signal due to non-specific binding to the beads. For each triplicate, we calculated the average and standard deviation. The average of standard Relative Fluorescence Unit (RFU) corresponding to the miR31 duplex was plotted as a function of synthetic miR31. A linear graph demonstrated the proportionality between the fluorescent signal and the amount of the miR31 complex.
To increase the sensitivity and reduce the variability, each component of the buffer was analyzed to determine which reagents might cause a shift or a quenching of the specific fluorescence signal. To reduce the fluorescent background, each buffer and sample were maintained in the absence of UV absorbing compounds and dust. Excitation scans obtained demonstrated that the [tris (2-carboxyethyl)phosphine] (TCEP) contained in each buffer quenched the fluorescent signal ( FIG. 11A ). Unmodified binding buffer absent TCEP and BSA (20 mM Tris-HCl, 100 mM NaCl, 1 mM EDTA, pH 7.0 at 25° C.) was used. Sensitivity tests were performed to define the best conditions for optimal sensitivity. The sensitivity was higher when the miRNA was in an elution buffer containing 0.1M NaOH (detect 5 μg) compared with an elution buffer containing SDS 0.5% (detect 40 μg) ( FIG. 12 ). Elution of the miRNA complex from the p19 fusion protein beads was performed using an alkaline buffer containing 0.1 M NaOH.
Fluorescence of the samples was read with an excitation wavelength of 492 nm, an emission wavelength of 520 nm and a cutoff of 515 nm. The background signal was subtracted from each sample. Reactions were in triplicate. The average of standard Relative fluorescence units (RFU) corresponding to the miR31 duplex was plotted as a function of synthetic miR31 amount. The detection is linear. The variability of the detection protocol was markedly reduced in alkaline buffer with a detection limit of 10 μg compare to 5 ng for the previous experiment suggesting reduced fluorescence background and a higher sensitivity of detection.
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Methods and compositions are provided for detecting small target RNAs where the target RNA may be single-stranded or double-stranded and may be contained in a mixture of RNAs of different types and sizes. The methods and compositions utilize a p19 fusion protein that is capable of binding double-stranded RNA in a size-specific but sequence-independent manner and is further capable of binding to a matrix such as beads or plastic microwell plates. By labeling the p19 fusion protein or the target RNA in a polynucleotide duplex either directly or indirectly, low levels of target RNA including microRNAs can be detected from cells. This can be applied to diagnosis of pathological conditions.
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CROSS-REFERENCE TO RELATED APPLICATION
This application derives from and claims the benefit of U.S. Provisional application Ser. No. 60/007,304, filed on 6 Nov., 1995.
CROSS-REFERENCE TO RELATED APPLICATION
This application derives from and claims the benefit of U.S. Provisional application Ser. No. 60/007,304, filed on 6 Nov., 1995.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The instant invention relates generally to processes for preparing a polyester copolymer resin and more specifically it relates to a process for dispersing a crude polyester copolymer resin and separating out, via continuous multi-stage filtration, the smallest size particles present in the crude starting material.
2. Description of the Prior Art
It is known in the art to utilize filter systems to separate polyester copolymer resin dispersions. Speaking generally, these methods use inert filter aides such as diatomaceous earth. The most common filter press design consists of alternate plates and frames hung on a rack and forced tightly together with a hydraulic closing mechanism. Feed slurry is then pumped to the press under pressure. As the filtration proceeds, filter cakes build up on the filter cloths until the cakes form a nearly solid mass, requiring that they be removed for further processing. With these processes, the finished product (the polyester resin) is obtained in the form of the filter cake removed from the filter press, and the filtrate solution is the by-product. In the instant invention, however, the filtrate is the desired product and the removed sediment is the by-product.
SUMMARY OF THE INVENTION
The present invention is concerned with a process for preparing a dispersion of high grade polyester copolymer resin in water comprising 1) combining a crude polyester copolymer resin, having particles of various sizes, with water; 2) heating and agitating the resin/water mixture; 3) cooling the mixture; 4) continuously filtering the mixture to remove the largest size resin particles; 5) allowing the mixture to stand undisturbed so that any undispersed particles settle out as a sediment; and 6) removing the sediment, leaving a dispersion of the smallest resin particles in water. By using a plurality of filters and sequentially finer filter mesh sizes, a high grade product is attained.
A primary object of the present invention is to provide a process for preparing a dispersion of high grade polyester copolymer resin in water.
Another object of the present invention is to provide a process for preparing a dispersion of high grade polyester copolymer resin in water via a continuous serial filtration system.
An additional object of the present invention is to provide a process for preparing a dispersion of high grade polyester copolymer resin in water, which resin is suitable for use in manufacturing PET films.
A further object of the present invention is to provide a process for preparing a dispersion of high grade polyester copolymer resin in water which is environmentally friendly.
A still further object of the present invention is to provide a process for preparing a dispersion of high grade polyester copolymer resin in water that is easy and economical to implement using existing machinery.
The foregoing and other objects, advantages and characterizing features will become apparent from the following description of certain illustrative embodiments of the invention.
The novel features which are considered characteristic for the invention are set forth in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of the specific embodiments when read and understood in connection with the accompanying drawings. Attention is called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated and described within the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
Various other objects, features and attendant advantages of the present invention will become more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views.
FIG. 1 is a diagrammatic view of an apparatus for practicing the process of the present invention.
FIG. 2 is a flowchart illustrating the preferred, detailed steps of the process of the present invention.
FIG. 3 is a flowchart illustrating, in general terms, the steps of the process of the present invention.
FIG. 4 is a flowchart illustrating, in intermediately detailed terms, the steps of the process of the present invention.
FIG. 5 is a bar graph illustrating the relationship between the turbidity of the polymer/water mixture and the filter sequence being utilized.
FIG. 6 is a line graph illustrating the relationship between the turbidity of the polymer/water mixture and the filter sequence being utilized.
FIG. 7 is a table showing the various physical and chemical characteristics for the final water/polymer mixture after being processed according to the present invention, for a variety of different batches.
LIST OF REFERENCE NUMERALS UTILIZED IN THE DRAWINGS
10 mixing kettle for dispersing copolymer resin 12 in water 14
12 crude copolymer resin from which an extremely fine, high quality resin is to be extracted
14 water
16 dispersion of resin 12 in water 14, contained in the mixing kettle 10
18 application of heat plus agitation to the resin 12 and water 14 mixture within mixing kettle 10 acts to create dispersion 16, which is then cooled prior to filtering
20 conduits through which the cooled dispersion 16 is pumped to and from the filter system 22
22 individual sequential filter in filter system
24 switch valve for directing the dispersion 16 either to the filter system 22 or to a settling tank 28
26 conduit through which the dispersion 16 is pumped to the settling tank 28
28 settling tank for allowing any undispersed particles 32 to settle out of the dispersion 16
30 final dispersion which contains the desired fine copolymer particles
32 undispersed particles which settle to bottom of the settling tank 28
34 conduit for removing settled, undispersed particles 32 from the desired dispersion 30
36 conduit for drawing off the desired dispersion 30
40 initially, the crude copolymer resin 12 is combined with water 14 in the mixing kettle 10
42 the resin 12 and water 14 mixture is heated, preferably to a temperature of from about 180° to 200° F.
44 the resin 12 and water 14 mixture is thoroughly agitated in order create dispersion 16
46 the dispersion 16 is then cooled, preferably to a temperature of from about 65° to 90° F.
48 the cooled dispersion 16 is then filtered through a sequential filter system 22 in order to filter out the larger, unwanted particles of resin 12
50 the turbidity of the resultant dispersion is measured to determine if it is within desired guidelines; the less turbid the dispersion, the finer the particle size of the resin within the dispersion
52 if the turbidity is higher than desired, filtering is continued, either with the same filter system, or through a filter system of finer mesh
54 if the turbidity is within the desired range, the particle size of the resin within the dispersion is acceptable and the remaining resin in dispersion is separated from the supernatant liquid and packaged for use
60 the initial step of the process is to produce a dispersion of the crude copolymer resin in water
62 the dispersion of resin in water is filtered until the dispersion achieves a predetermined turbidity
72 the mixture of resin in water is heated to assist dispersion
74 the mixture of resin in water is agitated to assist dispersion
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, the Figures illustrate a process for for preparing a dispersion of high grade polyester copolymer resin in water.
As shown diagrammatically in FIG. 1, and as illustrated in FIGS. 2 through 4, the process of the present invention begins with a crude polyester copolymer resin. By "crude," it is meant that the resin, produced via conventional polymerization methods, is made up of polymer particles which vary greatly in size. There are some applications, however, which require that the polymer particles be of the smallest size only. Such applications include, for example, the manufacture of high-grade polyester PET film.
In the first step 40, the crude copolymer resin 12 is mixed with an appropriate amount of water 14. For example, a typical range is from about 10 to about 20% solids, more commonly about 12 to about 15% solids.
Next, the mixture 16 of resin 12 and water 14 is heated 42 and agitated thoroughly 44 in order to disperse the dispersible polymer in the mixture. It is expected that a temperature in the range of about 180° to about 200° F. will be sufficient for this. With regard to the agitation, there is no specific requirement, but a high speed mixing for one to two hours generally proves adequate.
Prior to filtering, it is preferred to cool the polymer/water mixture 16, generally to a temperature of from about 65° to about 90° F. 46, although some variance from this range will not significantly affect the efficiency of the process.
At this point, the mixture 16 is filtered 48 through a continuous serial filter system 22. The filtering system preferred in the process of the present invention consists of a combination of liquid filter bags at various mesh sizes. It is preferred to use a plurality of filter systems, each capable of containing a plurality of filter bags. In its most preferred embodiment, the process utilizes two filter systems, each capable of containing from 1 to at least 5 filter bags. The mixture 16 is circulated, in a continuous manner, through the filter system, thus removing the copolymer particles large enough to be trapped within the filter bags. With regard to the filter bag mesh size, the first filter system in the process will generally have a mesh size of at least 200 microns.
Over the course of the filtration, the filter bags are preferably changed at periodic intervals, with smaller mesh sizes being used in each subsequent filtration. In addition, it has been found that the process will proceed more efficiently when each filter system in the series contains a filter or filters having a smaller mesh size than the one preceding it. For example, when two filter systems are connected in series, it has been found that, for the initial filter sequence, a first filter having a single filter bag of 300 micron mesh size and a second filter having a single filter bag of 200 micron mesh size can be effectively employed. When two filter systems are utilized, it is preferred that the second filter system utilize filter bags having a mesh size the same as or smaller than the first filter system. As a general guideline, the ratio of the mesh size of the first filter system to the second filter system will most often be between 1:1 and 5:1.
Eventually, these initial filters will have removed all or nearly all of the largest copolymer particles from the mixture, so replacement of the filter bags with smaller mesh size filter bags is in order. For example, in the above instance, it would be appropriate to replace the single 300 and 200 micron filter bags with dual 150 and 100 micron mesh size filter bags, respectively. With regard to the filter bag mesh sizes before and after a filter bag change, it is anticipated that a ratio of the second filter system mesh size before a filter bag change is made to the first filter system mesh size after a filter bag change is made will generally be from 1:1 to 5:1. For example, if a filter sequence is using two filter systems, a first with filter bags of 150 micron mesh size and a second with filter bags of 100 micron mesh size, then after a filter change, the first filter system would most often have filter bags with a mesh size of from 100 microns to 20 microns.
This process, of using progressively smaller mesh size filter bags,can be repeated, for example, down to 1 micron or smaller mesh size. Use of multiple bags in each filter systems improves the efficiency of the process. For example, the intermediate mesh sizes (from about 5 to about 50 microns) can effectively employ up to 5 or more filter bags per unit.
The progress of the filtration can be monitored, for example, by measuring the turbidity 50 of the mixture. As the larger particles are removed by the filtration, the turbidity decreases accordingly. For example, the initial copolymer/water mixture will often have an initial turbidity of about 1000 NTU or more, while the final product, after filtering with filter bags from 300 to 1 micron, will often yield a dispersion having a turbidity of 120 NTU or less. It is generally expected that a turbidity value of under 120 NTU will provide a copolymer resin of suitable quality. Accordingly, the turbidity is measured at various intervals. If the turbidity is higher than desired and remains the same or nearly the same over consecutive measurements, then the filter bags should be changed to a smaller mesh size and the filtration continued. Once the turbidity reaches the desired level, however, the resulting dispersion contains copolymer particles of an acceptable size.
Optionally, the mixture is then transferred to a settling tank 28, so that any undispersed particles can settle out of solution, forming a sediment 32, which can easily be drained off the bottom of the settling tank, leaving only the desired dispersion 30. Due to the continuous nature of the filtration, it can be readily appreciated that some large particles might not have been sent through the filtration system. This sedimentation will allow these particles to be readily removed.
EXAMPLE 1
Initially, 12-15% of the polyester copolymer resin is slowly added to a reaction kettle containing water at a temperature of 195°-200° F. and mixed at high speed for 11/2 to 2 hours. After cooling, the mixture is filtered, using series filtration (two units) as shown in Table 1, below, with filter bags varying in mesh size. After a total of about 14 hours of filtering (each filtering run lasting from about 11/2 hours to 31/2 hours) with filters ranging in micron mesh size from 300 to 1 micron, a finish product with a final turbidity reading of 120 NTU is yielded.
TABLE 1______________________________________Filter 1 Filter 2 Ending TurbidityMicron Size # of Bags Micron Size # of Bags (NTU)______________________________________(initial mixture prior to filtering) ˜1000300 1 200 1 ˜850150 2 100 2 ˜780 50 5 25 5 ˜500 25 5 10 5 ˜380 5 2 5 2 ˜280 1 1 1 1 ˜120______________________________________
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of applications differing from the type described above.
While the invention has been illustrated and described as embodied in a process for preparing a dispersion of polyester copolymer resin in water, it is not intended to be limited to the details shown, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the formulation illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of this invention.
What is claimed as new and desired to be protected by letters patent is set forth in the appended claims.
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The present invention relates to a process for preparing a dispersion of high grade polyester copolymer resin in water comprising 1) combining a crude polyester copolymer resin, having particles of various sizes, with water; 2) heating and agitating the resin/water mixture; 3) cooling the mixture; 4) continuously filtering the mixture to remove the largest size resin particles; 5) allowing the mixture to stand undisturbed so that any undispersed particles settle out as a sediment; and 6) removing the sediment, leaving a dispersion of the smallest resin particles in water. By using a plurality of filters and sequentially finer filter mesh sizes, a high grade product is attained.
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RELATED APPLICATIONS
This application is related to U.S. patent application Ser. No. 07/955,970, pending filed Oct. 2, 1992 in the name of Steigerwald and J. N. Park, and to U.S. patent application Ser. No. 07/956,131, pending filed Oct. 2, 1992 in the name of Park, R. L. Steigerwald, G. D. Goodman and D. B. Stewart, both filed concurrently herewith and incorporated by reference herein.
FIELD OF THE INVENTION
The present invention relates to thrusters for space applications and, more particularly, to an efficient and lightweight resonant power supply therefor.
BACKGROUND OF THE INVENTION
An arcjet thruster provides a thrust to a spacecraft by heating a gas with an electric arc and expanding the heated gas through a nozzle. Over a practical operating range, the arc has a negative resistance characteristic, i.e., arc voltage decreases with increasing arc current, and is thus inherently unstable. A typical power supply for an arcjet thruster employs a pulse width modulated (PWM) converter operating in a current-controlled mode. Disadvantageously, however, operation of such converters involves hard, i.e., lossy, switching, such that operating frequencies are relatively low (e.g., 20 kHz), thus necessitating the use of relatively large and heavy magnetic and capacitive components.
Accordingly, it is desirable to provide an efficient and lightweight power supply for an arcjet thruster.
SUMMARY OF THE INVENTION
A power supply for a thruster (e.g., an arcjet thruster) comprises a resonant converter having a resonant tank circuit with an inherently adjustable load quality (Q) factor which accommodates changes in arc voltage from initiation through steady-state operation. In particular, a higher voltage at a lower current is needed to initiate the arc; and, stable steady-state operation is in a range from relatively low arc voltage and relatively high arc current to a relatively high arc voltage and relatively low arc current. Effectively, the resonant tank circuit acts as a ballast by matching the arc during initiation thereof through steady-state operation. In a preferred embodiment, the resonant converter comprises a series/parallel resonant converter. Furthermore, the resonant converter operates in a soft-switching mode so as to allow high-frequency operation and maximize efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the present invention will become apparent from the following detailed description of the invention when read with the accompanying drawings in which:
FIG. 1 schematically illustrates a resonant power supply for an arcjet thruster in accordance with the present invention;
FIG. 2 graphically illustrates (a) resonant inductor current, (b) active device current, and (c) active device drain-source voltage for the resonant power supply of FIG. 1;
FIG. 3 graphically illustrates normalized output voltage versus frequency for different ratios of series to parallel capacitances for the resonant power supply of FIG. 1;
FIG. 4 schematically illustrates an alternative embodiment of a resonant power supply for an arcjet thruster of the present invention employing a push-pull converter configuration;
FIG. 5 schematically illustrates another alternative embodiment of a resonant power supply for an arcjet thruster of the present invention employing a full-bridge converter configuration; and
FIG. 6 schematically illustrates yet another alternative embodiment of a resonant power supply for an arcjet thruster of the present invention employing a full-bridge converter configuration.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a power supply for driving a thruster for space applications, such as, for example, an arcjet thruster, in accordance with the present invention. The power supply of FIG. 1 includes a series/parallel resonant converter 12 employing two switching devices Q1 and Q2 coupled in series in a half-bridge configuration across an input dc voltage Ein and a resonant tank circuit. The resonant tank circuit comprises: a resonant inductor Lr, a series resonant capacitor Cs (comprising two capacitors Cs/2 coupled dynamically in parallel), and a parallel resonant capacitor Cp. A transformer T1 provides isolation and impedance transformation between converter 12 and the load. Transformer T1 has a primary winding 14 (with a number of turns N1) coupled between the resonant inductor Lr and the junction between switching devices Q1 and Q2; and a secondary winding 16 (with N2 turns) coupled across parallel resonant capacitor Cp. Although resonant inductor Lr is shown as being situated on the primary side of transformer T1, it could alternatively be situated on the secondary side. The resonant load circuit is coupled across parallel resonant capacitor Cp and comprises a combination of a diode rectifier 18, a filter inductor Lo for smoothing the dc current supplied to the arc, and the arcjet load 20.
In operation, transistors Q1 and Q2 are switched alternately at high frequency by gate drive circuitry 22 to supply an approximate square wave voltage to the resonant load circuit. Preferably, the resonant converter is operated slightly above the resonant frequency of the tank circuit in order to maintain soft, i.e., nearly lossless, zero-voltage switching, as described in "A Comparison of Half-Bridge Resonant Converter Topologies" by R. L. Steigerwald, IEEE Transactions on Power Electronics, Vol. 3, No. 2, April 1988, which is incorporated by reference herein; and the frequency is varied to control the output current in accordance with a current command I* as described hereinbelow
FIG. 2 graphically illustrates ideal waveforms of (a) resonant inductor current, (b) switching device (Q1 and Q2) current, and (c) switching device drain-source voltage for the resonant power supply of FIG. 1. As shown, the resonant inductor current is nearly sinusoidal, and the transistor currents are sections of sinusoids. Furthermore, because the inherent inverse parallel diode (not shown) of each transistor Q1 and Q2 is conducting just before the respective transistor turns on, zero-voltage switching is achieved, allowing for high frequency operation. In addition, the parallel resonant capacitor Cp acts as a substantially lossless snubber across rectifier bridge 18, so that low-loss, zero-voltage switching of the rectifier bridge is also achieved. As a result, the resonant converter operates with low-loss switching.
The output filter inductor Lo comprises the secondary winding of a high-voltage pulse transformer T2 which generates a high voltage pulse (e.g., up to 5000 V) to initiate the arc. The high start-up voltage can be generated, for example, by a direct transformer step-up of a voltage pulse applied to the primary winding 24 of transformer T2, or by storing energy in inductor Lo and releasing it in a flyback manner to generate the pulse, such as in the manner described in Gruber U.S. Pat. No. 4,766,724, issued Aug. 30, 1988 and incorporated by reference herein.
Once the arc is initiated, the arc voltage drops significantly (e.g., as low as 20 V), at which time it is desirable to supply the arc with a controllable current. In response to the controllable current, the arc voltage increases toward its steady-state operating value. In particular, the steady-state operating value is in a steady-state operating range which extends from a lower arc voltage to a higher arc voltage.
Once the steady-state is achieved, the arc current is usually controlled such that constant power is delivered to the arc, i.e., Varc×Iarc=constant, where Varc represents the arc voltage and Iarc represents the arc current. Thus, at a lower arc voltage (e.g., approximately 100 V), more current is needed and the resonant tank is relatively highly loaded, such that the resonant tank effectively operates as a series resonant circuit.
At a higher arc voltage (e.g., 140 V), less arc current is needed and the tank circuit is relatively lightly damped, such that the resonant tank circuit effectively acts as a parallel resonant converter.
FIG. 3 shows the output voltage as a function of normalized resonant frequency with Qs, the series loaded Q factor ##EQU1## as a parameter for a series/parallel resonant converter. (Normalized frequency is actual frequency divided by the series resonant frequency, i.e., the frequency at which series resonant capacitor Cs resonates with resonant inductor Lr.) For the particular example of FIG. 3, Cs=Cp; however, other capacitance ratios are possible. Qs is low for light loads (small tank damping) and is higher for heavy loads (large tank damping). FIG. 3 shows that the output voltage attainable at light load currents (i.e., at higher arc voltages) is higher than that attainable at heavy load currents (i.e., lower arc voltages) for a given output power. The converter circuit is matched to the arc characteristics.
Referring back to FIG. 1, frequency is adjusted in order to control the load current in response to the current command I*. In particular, the load current is measured by a current sensor 30, shown as a current transformer in FIG. 1. The output of current transformer 30 is rectified by a rectifier 32, resulting in a signal representative of the dc current in inductor Lo and the arc. The current signal from rectifier 32 is compared in an error amplifier 34 to the current command I*, and the resulting current error signal Ie is provided to a voltage-controlled oscillator (VCO) 36 for adjusting the operating frequency of the resonant converter, via gate drive circuitry 22.
FIG. 4 illustrates an alternative embodiment of an arcjet thruster power supply of the present invention wherein the resonant converter comprises switching devices Q1 and Q2 coupled together in a push-pull configuration. In the embodiment of FIG. 4, an input filter capacitor Ci is coupled across dc source voltage Ein, and transformer T1 comprises a center-tapped primary winding with input voltage Ein coupled to the center tap thereof. As shown, series resonant capacitor Cs and resonant inductor Lr are connected in series with secondary winding 16 of transformer T1. (However, series resonant capacitor Cs and resonant inductor Lr could be located on the primary side of transformer T1 as in FIG. 1, if desired.)
FIG. 5 illustrates another alternative embodiment of an arcjet thruster power supply of the present invention wherein the resonant converter comprises four switching devices Q1-Q4 coupled together in a full-bridge configuration. For the full-bridge configuration, the control means may involve phase shift control 50 as well as frequency control. In particular, phase shift control involves phase-shifting the two phase legs of the bridge converter in order to control the fundamental component of voltage driving the resonant tank circuit in well-known manner. Advantageously, therefore, both resonant tank voltage and frequency can be controlled to regulate the output current. Commonly assigned U.S. Pat. No. 4,642,745 of Steigerwald and Kornrumpf, issued Feb. 10, 1987, which is incorporated by reference herein, describes exemplary frequency and phase shift controls.
Although the arcjet power supply of the present invention has been described as comprising a series/parallel resonant converter, other resonant converter topologies may be employed, such as series resonant or parallel resonant converter topologies. The series resonant or parallel resonant converter topologies may be particularly suitable for applications wherein the dynamic range of the arc voltage drop is limited. For example, as shown in the embodiment of FIG. 5, a parallel resonant converter is employed.
FIG. 6 illustrates an alternative embodiment an arcjet thruster power supply employing a full-bridge converter configuration. In the embodiment of FIG. 6, a series/parallel resonant converter is employed with series resonant capacitor Cs and resonant inductor Lr situated on the secondary side of transformer T1.
While the preferred embodiments of the present invention have been shown and described herein, it will be obvious that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those of skill in the art without departing from the invention herein. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims.
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A power supply for a thruster for space applications (e.g., an arcjet thruster) comprises a series/parallel resonant converter wherein the load quality (Q) factor of the resonant tank circuit inherently varies with arc voltage so as to accommodate changes in arc voltage from initiation thereof through steady-state operation. Effectively, the resonant tank circuit acts as a ballast by matching the arc during initiation thereof through steady-state operation. Furthermore, the resonant converter operates in a soft-switching, low-voltage switched mode so as to maximize efficiency.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the priority of German Patent Application, Serial No. 103 16 245.3, filed Apr. 9, 2003, pursuant to 35 U.S.C. 119(a)–(d), the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a spindle unit for machine tools that facilitates switching of the rotation speed of the spindle unit. The present invention also relates to a method for operating a spindle unit of this type.
Spindle units are employed, for example, in motor-driven milling machines. A motor-driven milling spindle can be made as a single-piece or of separable components and typically includes an electric motor with a shrink-fit rotor. The rotor is supported between two bearings blocks. A tool tensioning system that typically includes a chucking head, a tie rod and a disk spring arrangement is arranged in the interior of the shaft. A tensioning system sensor located on the tie rod and a tool loosening rod are typically also attached at the end of the spindle unit.
In particular applications of a motor-driven spindle, a greater torque may be necessary than can be supplied by the electric motor. For this purpose, a dual-stage planetary drive is typically connected between the electric motor and the spindle head. Advantageously, the drive unit can be decoupled from the spindle head or the anterior milling spindle. Advantageously, the gear can be used if required, or may not be used. However, it would be undesirable to require removal of the anterior spindle from the drive unit for increasing the rotation speed or torque of the spindle. In particular, since the tie rod for the tool chucking system on the side of the drive unit facing away from the tool would then also have to be removed. A motor-driven milling spindle of this type is known in the art.
A commonly used rotatable hollow processing spindle formed as one piece and supported in a housing is described in the German patent publication DE 199 37 447. A tie rod is arranged in the processing spindle for clamping and/or loosening a tool chuck. The tie rod can rotate and axially move with the processing spindle. The rotor of the driving electric motor is mounted on the hollow processing spindle.
It would therefore be desirable and advantageous to provide an improved spindle device for machine tools and a corresponding method for operating a spindle device, which obviates prior art shortcomings and facilitates adjustment of the torque and/or or the rotation speed of the spindle.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, a spindle unit for a machine tool includes a drive unit having a drive shaft, a spindle head assembly constructed to receive a tool and having a hollow spindle head shaft which is driven by the drive unit, a gear mechanism arranged between the drive unit and the spindle head assembly, and a shifting unit for axially moving the drive shaft in such a way that in a first position the drive shaft is connected by interference fit with the spindle head assembly through intervention of the gear mechanism, and in a second position is directly connected by interference fit with the spindle head assembly.
According to another aspect of the invention, a method for operating a spindle unit for machine tools includes the steps of operating a drive shaft in a first position for driving a spindle head shaft through intervention of a gear mechanism, axially shifting the drive shaft to a second position in which the spindle head shaft is connected directly by interference fit, without intervention of the gear mechanism, and driving the spindle head shaft by the drive shaft in the second position.
In accordance with the present invention, the entire drive shaft can thus be moved without need for additional a mechanical switching mechanism. The provision of an axially displaceable support is sufficient.
According to another feature of the present invention, the gear mechanism can be constructed to include a planetary gear mechanism. In this way, torque transferred to the tool can be increased.
According to another feature of the present invention, the drive unit can include an electric motor with a rotor mounted, in particular shrink-fit, on the drive shaft. The electric motor can also include a stator that completely surrounds the rotor in both the first position and the second position of the drive shaft. With this approach, there is sufficient magnetic interaction with the stator even when the rotor is displaced with the drive shaft.
According to another feature of the present invention, the spindle head assembly can be constructed for removal from the drive unit. This allows different spindle heads and/or anterior spindles to be used with different tool chucks.
According to another feature of the present invention, the spindle unit can also include an axially displaceable bearing assembly that supports the drive shaft. In particular, the bearing assembly can include a bearing sleeve on each end of the drive shaft, supporting the drive shaft. This type of support in bearing sleeves required for thermal reasons can hence be maintained.
The shifting unit can be constructed to operate by using a hydraulic, pneumatic and/or electromechanical mechanism. In particular, a hydraulic shifting mechanism is advantageous because the bearing sleeves are normally already hydraulically pretensioned.
BRIEF DESCRIPTION OF THE DRAWING
Other features and advantages of the present invention will be more readily apparent upon reading the following description of currently preferred exemplified embodiments of the invention with reference to the accompanying drawing, in which:
FIG. 1 shows a cross-sectional view of a segmented motor-driven spindle with a gear mechanism according to the present invention;
FIG. 2 shows a cross-sectional view of the motor-driven spindle of FIG. 1 in a first position of the gear mechanism;
FIG. 3 shows a cross-sectional view of the motor-driven spindle of FIG. 1 in a second position of the gear mechanism; and
FIG. 4 is a block diagram showing interrelation between components of the motor-driven spindle.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Throughout all the Figures, same or corresponding elements are generally indicated by same reference numerals. These depicted embodiments are to be understood as illustrative of the invention and not as limiting in any way. It should also be understood that the drawings are not necessarily to scale and that the embodiments are sometimes illustrated by graphic symbols, phantom lines, diagrammatic representations and fragmentary views. In certain instances, details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted.
This is one of two applications both filed on the same day. Both applications deal with related inventions. They are commonly owned and have the same inventive entity. Both applications are unique, but incorporate the other by reference. Accordingly, the following U.S. patent application is hereby expressly incorporated by reference: “SPINDLE FOR A MACHINE TOOL WITH IMPROVED TOOL EJECTION FEATURE”, filed Apr. 8, 2004 and having application Ser. No. 10/820,441.
Turning now to the drawing, and in particular to FIG. 1 , there is shown schematically a motor-driven milling spindle which includes a spindle head assembly and/or anterior spindle 1 and a drive unit 2 . Both components are depicted separate from each other in the drawing. The anterior spindle 1 includes essentially a spindle head shaft 3 that is non-rotatably connected with the axles of planetary wheels 4 of a planetary drive. A hollow wheel 5 with the same tooth pattern as that of the planetary wheels 4 is located intermediate between the planetary wheels 4 .
The drive unit 2 includes essentially an electric motor with a rotor 6 that is shrink-fit on a drive shaft 7 . The stator 8 of the electric motor is mounted in a housing 9 of the drive unit 2 . Bearing sleeves 10 and 11 which are movable in the axial direction are disposed in the housing 9 . The drive shaft 7 is supported in the bearing sleeves 10 and 11 by bearings 12 , 13 . The bearing sleeves 10 and 11 can be moved in the axial direction by a hydraulic system (not shown).
The sun wheel 14 of the planetary gear is mounted on an end face of the drive shaft 7 . The hollow wheel 15 of the planetary gear is connected with the bearing sleeves 10 . The hollow wheel 15 , which can be moved together with the drive shaft 7 and the bearing sleeve 10 , respectively, is secured in the circumferential direction by an engaging tooth or spline pattern 16 .
A rotary encoder 17 which is secured to the bearing sleeves 11 is located on the side of the drive shaft 7 facing away from the anterior spindle. The rotary encoder 17 senses an encoder wheel 18 that is mounted on the drive shaft 7 for determining the rotation speed and/or rotation position of the drive shaft 7 . The rotary encoder 17 follows the movement of the bearing sleeve 11 and the drive shaft 7 in the axial direction.
FIG. 2 shows the anterior spindle 1 and the drive unit 2 in an assembled state. A piston space 19 of the hydraulic system is pressurized by pressure fluid from a hydraulic or pneumatic pressure fluid source S ( FIG.4 ). The bearing sleeve 11 together with the drive shaft 7 with the rotor 6 that is shrink-fit on the drive shaft 7 and the other bearing sleeve 10 then move inside the housing 9 of the drive unit 2 in FIG. 2 away from the anterior spindle 3 , i.e., to the right in FIG. 2 . The sun wheel 14 engages with the planetary wheels 4 , so that a force is transmitted along the force path K 1 , shown as a dotted line in FIG. 2 , from the drive shaft 7 via the sun wheel 14 , the planetary wheels 4 to the spindle head shaft 3 .
For sake of clarity, only components necessary to describe the indicated state are labeled in FIG. 2 with a reference character. The same applies to FIG. 3 described below.
FIG. 3 shows a pressurized piston space 20 wich is located on the other side of the electric motor and receiving pressure fluid from the pressure fluid source S. A portion of the bearing sleeve 10 facing the anterior spindle operates as a piston surface. The bearing sleeves 10 together with the drive shaft 7 , including the rotor 6 and the bearing sleeve 11 , then move toward the anterior spindle 1 , i.e., to the left in FIG. 3 . This shifting process causes the sun wheel 14 to non-positively engage with the hollow wheel 5 of the spindle head shaft 3 . The hollow wheel 15 of the planetary gear, on the other hand, disengages from the planetary wheels 4 . This removes the planetary gear from the force transmission, and the drive shaft 7 it is directly connected non-positively with the spindle head shaft 3 . This is indicated in FIG. 3 by the force path K 2 shown as a dotted line. The pressure fluid source S together with the piston spaces 19 , 20 thus jointly form a shifting unit for axially moving the drive shaft 7 . As an alternative, the shifting unit may be constructed by electromechanical means.
Even after the shift, the rotor 6 is still located below the stator 8 , since the stator 8 has sufficient length. As also seen in FIG. 3 , the rotary encoder 17 is shifted forward with the drive shaft 7 towards the anterior spindle, so that the rotation of the drive shaft 7 can be measured as before.
The stroke during the shifting operation depends on the gear characteristic, i.e., the width of the toothed gears. The hydraulic pressure required for moving and shifting the drive shaft is negligible compared to the pressure required for axially pretensioning the bearing sleeves, since only the switching forces have to be overcome. The size of the hydraulic system can therefore remain unchanged. Only two limit stops, which limit the displacement of the sleeves 10 and 11 , have to be provided for the switching process. As a result, automatic switching of the motor-driven spindle drive does not require additional complex constructive measures.
While the invention has been illustrated and described in connection with currently preferred embodiments shown and described in detail, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention. The embodiments were chosen and described in order to best explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims and includes equivalents of the elements recited therein:
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A system and a method are described that facilitate gear switching of a motor-driven spindle. A spindle head shaft is driven by a drive shaft via a gear mechanism in a first gear position. The drive shaft, including a rotor, can be switched from the first gear position to a second gear position where the spindle head shaft is connected by interference fit directly with the drive shaft without the interposed gear mechanism. The spindle head shaft can then be directly driven by the drive shaft in the second gear position. This eliminates the need to dismantle an anterior spindle from the drive unit.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of PCT application No. PCT/EP2009/060202, entitled “Fractionating Arrangement”, filed Aug. 6, 2009, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to an arrangement for fractionating a fibrous material suspension suitable for producing a web of paper, board, tissue or other fibrous material into a short fiber fraction with a high proportion of short and/or stiff fibers and/or vessel cells and a long fiber fraction with a high proportion of long and/or flexible fibers, including a screen element with screen openings which is led past at least one nozzle that directs a jet of the fibrous material suspension onto the screen element, the long fiber fraction being collected on the side of the screen element that faces the nozzle and the short fiber fraction being collected on the opposite side of the screen element.
[0004] 2. Description of the Related Art
[0005] When a new fibrous material suspension is prepared from wood or when recovered paper is converted into a fibrous material suspension, the fibers generally have very different lengths. It can then be advantageous to separate the short pulp fibers from long pulp fibers, primarily in order to be able to produce paper sheets with different qualities.
[0006] In this case, the aim is usually firstly to obtain a short fiber fraction, which predominantly contains short fibers whose maximum lengths are of the order of magnitude of one millimeter to one and a half millimeters, and secondly to obtain a long fiber fraction which predominantly contains long fibers whose minimum lengths are of the order of magnitude of one millimeter to one and a half millimeters. Obtaining a long fiber fraction which contains long fibers and is free of mineral contents can likewise be of interest.
[0007] Normally, however, such arrangements are used to prepare waste paper fiber raw materials to such an extent that they can be used again as raw material for the production of webs of fibrous material.
[0008] Mixed waste paper often comprises different grades and, as compared with fresh pulp, has a relatively wide fiber length spectrum.
[0009] In this regard, DE 2018510 discloses the practice of spraying the fibrous material suspension onto a perforated screen, but the holes tend to block.
[0010] In WO 01/29297 it is therefore proposed to lead a screen element past a nozzle. Here, the screen element is formed from wires or the like, which run in the direction of movement of the screen. The nozzle is located outside the loop of the screen element. This can also be unsatisfactory with respect to the fractionating effect.
[0011] What is needed in the art is to configure the fractionation to be simpler and, if possible, also more efficient.
SUMMARY OF THE INVENTION
[0012] The present invention provides firstly that the screen element is of cylindrical design and is mounted such that it can be rotated about the cylinder axis.
[0013] Irrespective of the configuration of the screen openings, this is associated with advantages in production and function. In addition, this permits a stable shape of the screen element.
[0014] Here, the predominant part of the screen openings, preferably all the screen openings, should be formed as elongated slots. At least in some sections, these can be inclined in the direction of movement of the screen element, i.e. in the direction of rotation or at an angle to the latter, in particular run at right angles to the latter.
[0015] For the removal of the short and long fiber fraction, it is advantageous if the cylinder axis of the screen element runs approximately vertically. In this arrangement, at least one fraction can at least to some extent be collected simply underneath the cylinder.
[0016] The slots can be formed by rods spaced apart from one another, it being possible for the slots to be bounded by spacers between the lands. In this case, the rods extend over a part of the length of the cylinder but preferably over the entire length of the cylinder.
[0017] Here, the rods can have a round cross section or else a multi-angled, in particular a rectangular cross section with two long side surfaces. A round cross section is to be preferred if blockage of the slots is to be feared.
[0018] In the case of a rectangular cross section, there is the possibility of arranging the rods such that the long side surfaces run radially. In this way, the slots extend in the radial direction over the long side surfaces, which is conducive not only to the stability of the screen element but also to the fractionation.
[0019] In order to make it easier to remove the fibrous material accumulating in the cylindrical screen element, the cylindrical screen element can be designed to be open at the bottom.
[0020] The nozzles can be arranged inside or else outside the cylindrical screen element.
[0021] Above all if the rods have a rectangular cross section with radially oriented, long side surfaces, the arrangement of the nozzles inside the cylindrical screen element has advantages. In this case, the slot width widens radially toward the outside, even if only slightly, which reduces the risk of blockage of the slots.
[0022] The fibrous material which does not pass through the slots forms the long fiber fraction. In the case of an arrangement of the nozzles inside the screen element, a collecting trough for the long fiber fraction should therefore be arranged underneath the cylindrical screen element.
[0023] In this case, it is possible for the long fibers to be caught on the rods. In order to detach these from the rods, at least in each case a pressurized fluid nozzle should be arranged outside the cylindrical screen element after a nozzle in the direction of movement which pressurized fluid nozzle directs a fluid, in particular steam, water or compressed air, onto the screen element. The long fibers detached from the rods then fall into the collecting trough.
[0024] Accordingly, at least one collecting trough for the short fiber fraction should be arranged outside the cylindrical screen element, opposite and/or underneath a fibrous material suspension nozzle.
[0025] If the fibrous material suspension nozzles are arranged outside the cylindrical screen element, then the short fibers inside the cylindrical screen element must be picked up by a collecting trough for the short fiber fraction. In order to assist this, this collecting trough can be connected to a vacuum source, so that the vacuum sucks the short fibers into the collecting trough. In order to detach the long fibers hanging on the rods, then at least in each case a pressurized fluid nozzle should be arranged inside the cylindrical screen element after a nozzle in the direction of movement which pressurized fluid nozzle directs a fluid, preferably water, steam or compressed air, onto the screen element. The long fibers detached from the rods can thus be collected by at least one collecting trough for the long fiber fraction outside the cylindrical screen element, opposite and/or underneath the corresponding fluid nozzle.
[0026] Irrespective of the formation of the screen element, it is important to the invention that the predominant part of the screen openings, preferably all the screen openings, are formed as elongated slots which, at least in some sections, run at an angle to the direction of movement of the screen element, in particular at right angles to said direction.
[0027] This is therefore advantageous in particular since the fibers are preferably oriented in the flow direction by the acceleration in the suspension nozzle and thus, in the case of lands running transversely, the probability that they are caught on the latter is high.
[0028] In order to simplify fabrication and in the interest of uniform fractionation, the predominant part of the slots, preferably all the slots, of the screen element should be formed identically.
[0029] In this connection, it is furthermore advantageous if the predominant part of the slots, preferably all the slots, of the screen element are oriented identically.
[0030] Depending on the desired fractionation result, the width of the slots of the screen element should be between 0.3 and 3 mm, preferably between 0.5 and 1.5 mm.
[0031] Irrespective of the shape of the screen element, it is likewise important to the invention that the screen element has a honeycomb structure. The honeycomb structure provides high stability with a large open area as compared with parallel rods.
[0032] Irrespective of the shape of the screen openings, it can be advantageous if the screen element is formed as an endlessly circulating, flexible screen belt, which preferably consists of plastic because of the bending stress. In this case, the screen belt can be guided in the open or in a housing. Although guidance in a housing is more complicated, it is also cleaner.
[0033] Alternatively, it can be advantageous if the screen belt is formed by rods spaced apart transversely with respect to the direction of movement and from one another, which are preferably connected to one another at the ends and/or at specific intervals transversely with respect to the direction of movement of the screen belt, and consist of metal. In this way, slots running virtually over the entire length of the rods are formed between the rods.
[0034] The connection between the rods can be made via flexible plastic connections.
[0035] In order to limit the loading of the screen belt, the latter should be deflected over rotating guide rolls.
[0036] For the purpose of fractionation, the fibrous material suspension nozzles should be arranged only on one side of the screen belt and in each case direct a fibrous material suspension jet preferably into the inlet pocket between the screen belt and a guide roll. While the short fibers pass through the screen openings to the greatest extent, the long fibers are caught on the lands of the screen belt.
[0037] During the wrap around the guide roll, the screen openings on the side of the screen belt that is located on the outside during the wrap are also spread out. The enlargement of the screen openings on this side improves the throughput of the short fibers.
[0038] After this guide roll, the screen belt should then be curved in the opposite direction, preferably by wrapping around a following guide roll. In this way, the screen openings on the side of the screen belt on which the long fibers have caught spread out, which makes the removal of the latter easier.
[0039] In this case, it is also possible to use pressurized fluid nozzles, which are arranged on the side of the screen belt opposite to the fibrous material suspension nozzles and are arranged after the latter and direct the fluid onto the screen belt. The fluid flows through the screen openings and tears the long fibers away from the screen belt on the opposite side.
[0040] Ideally, the belt does not rest directly with the lands on the guide rolls but, for this purpose, has elevated running surfaces, which can preferably be formed by the plastic connections.
[0041] Accordingly, at least one collecting trough for the fibrous material should be arranged in each case on each side of the screen belt. While it is the long fibers on the side of the screen belt having the fibrous material suspension nozzles that are enriched, it is the short fibers on the opposite side.
[0042] An increase in the throughput is easily possible, for example, if a plurality of fibrous material suspension nozzles are arranged one after another in the direction of movement of the screen belt and/or beside one another transversely with respect to the direction of movement.
[0043] Advantageously, irrespective of the shape of the screen openings and the configuration of the screen element, the total area of the screen openings should be more than 50% of the total area of the screen element.
[0044] Because of the large open area of the screen element, in conjunction with a large number of screen openings having a small extent necessary for the fractionation, the result is a small land width between the screen openings.
[0045] The small land width permits efficient fractionation, the average land width between the screen openings being less than 2 mm, preferably less than 1 mm and in particular between 0.3 and 0.8 mm.
[0046] In order to impart sufficient stability to the screen element despite the low land width, it is advantageous if the thickness of the screen element is more than two times, preferably three times, the average land width between the screen openings.
[0047] In the interest of a high throughput of the fibrous material suspension to be fractionated, a plurality of nozzles should in each case direct at least one jet of fibrous material suspension onto the screen element.
[0048] Since vessel cells and also short and/or stiff fibers pass through the screen openings more easily, it is possible not only for enrichment of short fibers but also of stiff fibers, i.e. in particular of fibers with a high lignin content, to take place in the short fiber fraction, as it is known.
[0049] The long fibers, but in particular the flexible fibers, are predominantly deposited on the lands between the screen openings and form what is known as the long fiber fraction.
[0050] Since fibers with a low lignin content are flexible, these can be enriched in the long fiber fraction.
[0051] Accordingly, by using the fractionator, it is possible for fractionation to be carried out not only according to the fiber lengths but also according to the lignin content.
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
[0053] FIG. 1 shows a schematic illustration of a fractionator;
[0054] FIG. 2 shows a cross section through the latter;
[0055] FIG. 3 shows a detail of a screen element 1 having a honeycomb structure;
[0056] FIG. 4 shows a screen belt having rods 2 ;
[0057] FIG. 5 shows a plan view of a fractionator having a screen belt;
[0058] FIG. 6 shows a screen element 1 having spacers 13 ;
[0059] FIG. 7 shows another form of a screen opening 3 ;
[0060] FIG. 8 shows a horizontal section along I from FIG. 9 of a fractionator;
[0061] FIG. 9 shows a vertical section along II of the apparatus from FIG. 8 ;
[0062] FIG. 10 shows another vertical section along III of the apparatus from FIG. 8 ;
[0063] FIG. 11 shows a horizontal section of another fractionator; and
[0064] FIG. 12 shows an enlarged partial cross section through a screen element 1 .
[0065] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate embodiments of the invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
[0066] Referring now to the drawings, and more particularly to FIG. 1 , there is shown a fractionator which is formed by a rotating cylindrical screen element 1 . Here, the vertically arranged cylinder jacket comprises rigid rods 2 of metal running axially and spaced apart from one another, which are fixed to the upper cylinder side disk 10 via fixing elements 9 .
[0067] The rods 2 run over the entire length of the cylinder and in each case form between themselves screen openings 3 in the form of a very long gap or slot.
[0068] The slots have a width between 0.3 and 3, preferably between 0.5 and 1.5 mm, and thus extend at right angles with respect to the direction of rotation 8 of the screen element 1 .
[0069] As can be seen in FIG. 2 , the rods 2 have a rectangular cross section with two long side surfaces which run radially with respect to the cylinder.
[0070] Within the cylindrical screen element 1 here, by way of example, there are three nozzles 4 arranged distributed over the circumference, which in each case direct a jet of the fibrous material suspension toward the screen element 1 . The nozzles 4 are able to direct the jet onto the slots 3 perpendicularly or at an angle.
[0071] Here, the short fibers 20 pass through the slots 3 without difficulty, while the long fibers 19 bounce off or are caught on the rods 2 . Since the screen element 1 rotates, the long fibers 19 that are caught move out of the range of the nozzle 4 , which prevents blockage of the slots 3 .
[0072] On the side of the screen element 1 opposite to the nozzles 4 there is in each case a collecting trough 7 for receiving and transporting away the short fibers 20 and the part of the water from the fibrous material suspension that has passed through the slots 3 .
[0073] In order to detach the long fibers 19 from the rods 2 , air nozzles 5 in each case arranged outside the cylindrical screen element 1 after a nozzle 4 in the direction of movement 8 direct compressed air onto the screen element 1 . The long fibers 19 detached in this way, together with the long fibers 19 that have already bounced off during the spraying, and the remainder of the water from the fibrous material suspension is picked up by a collecting trough 6 arranged under the cylindrical screen element 1 .
[0074] As an alternative to the rods 2 , the screen element 1 can also have a honeycomb structure, as illustrated in FIG. 3 , which likewise permits low land widths.
[0075] If the screen element 1 is not subjected to any bending, then the honeycomb structure can consist of metal, in another case of plastic.
[0076] According to the illustration in FIG. 6 , the slots 3 can also be interrupted by rings, running radially here, which function as spacers 13 to stabilize the structure and to fix the slot width.
[0077] Depending on the location of use and the requirements, the slots 3 can also run at an angle or at an angle in sections, so that the result is a zigzag-shaped slot 3 , for example, as can be seen in FIG. 7 .
[0078] In the embodiment shown in FIGS. 4 and 5 , the screen element 1 is formed by an endlessly circulating, flexible screen belt.
[0079] This screen belt can have a honeycomb structure or else, as can be seen in FIG. 4 , can have rigid rods 2 of metal. In this case, the mutually spaced rods 2 run transversely with respect to the direction of movement 8 of the screen belt. The connection between the rods 2 is made via a flexible plastic connection 11 at the ends of the rods 2 and in the middle.
[0080] The plastic connections 11 can be used as elevated running surfaces during the deflection on the guide rolls 12 and/or can be arranged at specific intervals transversely with respect to the direction of movement 8 of the screen belt.
[0081] On its path, the screen belt is deflected repeatedly over rotating guide rolls 12 . At least before one guide roll 12 , a nozzle 4 directs a jet with fibrous material suspension to be fractionated into the inlet pocket between screen belt and guide roll 12 .
[0082] The short fibers 20 of the fibrous material suspension pass through the screen openings 3 and are picked up by a collecting trough 7 on this side. After that, the screen belt wraps around a guide roll 12 on the opposite side, which is intended to lead to the detachment of the long fibers 19 of the fibrous material suspension that have been caught on this side.
[0083] Accordingly, the collecting trough 6 for the long fibers 19 is also located on the side of the screen belt having the nozzles 4 . In order to further assist the detachment of the long fibers 19 , a pressurized fluid, for example water or compressed air, can be directed by fluid nozzles 5 at the side of the screen belt that is opposite to the fibrous material suspension nozzles 4 .
[0084] In every case, the open area of the screen element 1 formed by the screen openings 3 corresponds to more than 50% of the effective surface of the screen element 1 . In conjunction with a multiplicity of relatively small screen openings 3 required to retain the long fibers 19 , the result in this case is also very narrow land widths of on average or at least predominantly at most 2 mm.
[0085] As a result, this permits very efficient fractionation.
[0086] In order to ensure adequate stability, the screen element 1 is designed to be correspondingly thick.
[0087] The fractionator shown in FIGS. 8 to 10 for separating pulp fibers contained in a liquid such as water in accordance with their size has a screen element 1 in the form of a cylindrical drum, whose wall is formed by a plurality of individual vertical lands in the form of rods 2 .
[0088] In this case, the upper ends of the rods 2 are fixed to the circumference of an upper horizontal circular cylinder side disk 10 , and the lower ends are fitted to a lower horizontal circular ring 22 , which is spaced apart from the side disk 10 .
[0089] The circular side disk 10 is fixed to the lower end of a vertical shaft 16 , which is connected to a rotary drive motor 17 , shown schematically.
[0090] The vertical lands are identical and distributed regularly on the circumference of the cylindrical drum, in order to form between themselves screen openings in the form of regularly distributed vertical slots 3 . Here, the vertical lands have rectangular cross sections and are arranged in the manner of rays, their long sides also extending between the inside and the outside of the drum.
[0091] For instance, the diameter of the cylindrical drum can lie in the range from 500 to 800 mm, the rectangular cross section of the lands can be such that their width lies in the range from 0.4 to 0.6 mm and their length lies in the range from 4 to 6 mm.
[0092] Furthermore, the length of the lands between the side disk 10 and the ring 22 lies in the range from 150 to 600 mm, and the width of the vertical slots between the lands lies in the range from 1.4 to 1.6 mm.
[0093] The rods 3 can be fixed via cutouts 23 , 24 in the side disk 10 and in the ring 22 . The cutouts 23 in the side disk 10 are preferably open toward the bottom and radially toward the inside or outside, and the cutouts 24 in the ring 22 are open toward the top and radially toward the inside or outside.
[0094] The fixing of the lands in the positioning cutouts 23 and 24 can be ensured by any known means, for example by adhesive bonding, by clamping with force or with the aid of conventional retaining elements.
[0095] The distance between the lands can also be defined via spacer plates.
[0096] At a feed station, the separating apparatus contains nozzles 4 in order to lead the fibrous material suspension toward the inner face of the cylindrical drum, tangentially with respect to this surface and in the rotational or circumferential direction 8 of the cylindrical drum.
[0097] These nozzles 4 contain a vertical container, which is arranged in the drum and by means of which a line is connected to a source for the fibrous material suspension to be treated.
[0098] Here, the nozzles 4 point in the direction of movement 8 of the drum and have a nozzle opening in the form of a vertical slot, this vertical nozzle slot being located in the vicinity of the inner surface of the cylindrical drum.
[0099] Thus, the fibrous material suspension to be treated leaves the nozzle slot tangentially with respect to the inner surface of the cylindrical drum and in the direction of rotation 8 of the drum. The fibrous material suspension in so doing forms a thin suspension layer 18 on the inner surface of the cylindrical drum. Such an arrangement is designed to form a thin suspension layer 18 at the outlet from the vertical nozzle slot, in which layer the fibers, in particular the long fibers 19 , are for the most part oriented in the rotational or circumferential direction 8 of the cylindrical drum 8 .
[0100] For instance, the vertical nozzle slot extends over the major part of the height of the vertical lands or rods 2 ; the width thereof can lie in the range from 1.3 to 1.7 mm.
[0101] At a first separating station, the separating apparatus has a large deflecting wall 14 , which is arranged vertically and at a distance from the outer surface of the cylindrical drum. This deflecting wall 14 begins approximately in the region of the opening of the nozzle 4 and extends further in the direction of movement 8 of the drum. Arranged under the deflecting wall 18 is a collecting trough 7 for the short fibers 20 .
[0102] At a second separating station, which follows the first separating station in the direction of movement 8 , the separating apparatus has a fluid nozzle 5 arranged outside the drum.
[0103] This fluid nozzle 5 also has a nozzle opening in the form of a vertical slot but which is oriented radially in the direction of the drum. The vertical slot extends over the major part of the height of the drum and directs a fluid under pressure, for example compressed air, onto the drum.
[0104] At this second separating station, the separating apparatus has a large deflecting wall 15 , which is arranged vertically and at a distance from the inner surface of the cylindrical drum, opposite the fluid nozzle 5 . Installed under the deflecting wall 15 is a collecting trough 6 for the long fibers 19 .
[0105] The separating apparatus described here can operate in the following way.
[0106] The speed of the cylindrical drum and of the fibrous material suspension fed in is the same at the outlet from the fibrous material suspension nozzle 4 . For example, the circumferential speed of the cylindrical drum can lie in the range from 5 to 20 meters per second.
[0107] At the first separating station, the fibrous material suspension to be treated, which is deposited on the inner surface of the drum, is at least partly driven through the vertical slots of the drum under the action of centrifugal force and carries with it the short fibers 20 and mineral particles or contents 21 contained therein, while the long fibers 19 are retained within the drum by means of the vertical lands, as shown in FIG. 12 .
[0108] This retention of the long fibers 19 by means of the vertical lands is made considerably easier by the fact that they are at least for the major part oriented in the rotational or circumferential direction 8 of the drum when the thin suspension layer 18 is formed at the outlet from the nozzle 4 .
[0109] The liquid splashes outside the drum, which contain the short fibers 20 and the particles 21 , are stopped by the deflecting wall 14 and fall into the collecting trough 7 .
[0110] At the second separating station, under the action of the blown stream which originates from the fluid nozzle 5 and flows through the vertical slots 3 in the drum, the long fibers 19 are detached in the direction of the interior of the drum and are thereby stopped by the deflecting wall 15 , falling into the collecting trough 6 .
[0111] From the description just given, it emerges that the separating apparatus is able to operate continuously by virtue of an uninterrupted flow of a fibrous material suspension to be treated, which emerges from the nozzle 4 , the uninterrupted rotation of the cylindrical drum and the uninterrupted blown stream at the outlet from the fluid nozzle 5 .
[0112] Because of the relatively fast actions of the centrifugal force and of the blowing, the equipment described above, which is assigned to the cylindrical drum at the feed station and at the first and at the second separating station in order to form a separating apparatus, needs to extend only over part of the circumference of the cylindrical drum. It is then possible to provide a plurality of separating apparatuses which are assigned to the cylindrical drum and distributed on the circumference.
[0113] In a design variant shown in FIG. 11 , a separating apparatus contains a cylindrical drum which is assigned the following equipment, which replaces the equipment from the preceding example.
[0114] At a feed station, the separating apparatus contains a nozzle 4 arranged outside the drum for feeding in a fibrous material suspension, having a nozzle opening in the form of a vertical slot. Via this nozzle 4 , the fibrous material suspension to be treated is applied in an analogous way to the outer surface of the drum in the direction of rotation 8 of the drum, a suspension layer 18 being formed on the outer surface.
[0115] At a first separating station, the separating apparatus inside the drum, beginning approximately opposite the nozzle 4 in the direction of rotation 8 , has a collecting trough 7 in the form of a suction bell that is connected to a vacuum source and extends vertically over the drum.
[0116] This suction bell is intended to permit at least some of the thin suspension layer 18 , which carries the short fibers 20 and the particles 21 therewith, to be sucked through the vertical slots 3 of the drum, while the long fibers 19 are retained by the vertical lands on the outer surface of the drum.
[0117] At a second separating station, which is located after the suction bell in the direction of rotation 8 of the drum, the long fibers 19 are released and thrown outward under the action of centrifugal force. The separating apparatus here contains a vertical deflecting wall 15 , which is arranged outside the drum and is intended to stop these splashes. As in the preceding example, the long fibers 19 can fall into a collecting trough 6 .
[0118] At the second separating station, the separating apparatus within the drum can also have a fluid nozzle 5 having a nozzle opening in the form of a vertical slot, which directs a pressurized fluid radially onto the drum.
[0119] This fluid nozzle 5 can, for example, produce a stream of water which flows through the vertical slots of the drum, in order to make it easier to detach the fibers and to ensure cleaning of the drum.
[0120] In another design variant, the drum could also be formed by a perforated cylindrical screen element 1 , the perforation being formed by slots, drilled holes or the like.
[0121] Furthermore, it can be advantageous to arrange the drive 17 under the drum. In this case, the fibers would have to be carried away out of the region of the drive 17 .
[0122] While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
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The invention relates to an arrangement for fractionating a suspension of fibrous material suitable for creating a web of paper, board, tissue or some other fibrous material into a short fiber fraction with a high proportion of short and/or stiff fibers and/or vessel cells and a long fiber fraction with a high proportion of long and/or flexible fibers, comprising a screen element with screen openings which is taken past at least one nozzle which directs a jet of the fibrous material suspension onto the screen element, wherein the long fiber fraction is collected on the side of the screen element that is facing the nozzle and the short fiber fraction is collected on the opposite side of the screen element. In this case it is intended to make the fractionating easier and/or more efficient by the screen element being cylindrically formed and mounted rotatably about the cylinder axis and/or by most of the screen openings, preferably all the screen openings, being formed as elongated slits which extend, at least over part of their length, in an inclined manner in relation to the direction of movement of the screen element, or by the screen element having a honeycomb structure.
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This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 08/583,562 which was filed on Jan. 5, 1996, pending.
FIELD OF THE INVENTION
The present invention relates generally to filamine-like integrin binding proteins and more particularly to the cloning and expression of a novel filamine-like protein, FLP-1.
BACKGROUND
A significant characteristic of the immune and inflammatory responses is the movement of leukocytes from the bloodstream into specific tissues in response to various physiological signals. For example, certain subsets of lymphocytes "home" to various secondary lymphoid tissues such as lymph nodes or Peyer's patches, and eventually return to circulation. Other leukocytes such as granulocytes and monocytes, however, do not return to circulation after transmigration from the bloodstream. Movement of leukocytes from circulation is effected by a series of receptor/counter-receptor interactions which are coordinated by various specific membrane adhesion molecules.
Extravasation of leukocytes from the bloodstream for review, see McEver, Curr. Opin. Cell Biol. 4:840-849 (1992)! is initially effected by a family of membrane glycoproteins termed selections which are either expressed constitutively or induced in response to specific cytokines. Binding of selections to their counterpart ligand brings leukocytes into close, but not static, contact with vascular endothelial cells. The "tethered" leukocyte then begins a "rolling" process along the endothelium which continues until additional molecular interactions firmly stabilize a specific cell/cell interaction. One of the molecular binding activities which results in the stable interaction is effected by a second family of surface glycoproteins called integrins which possess a higher binding affinity for their respective ligands than selectins.
The integrins are heterodimeric surface molecules comprised of an α and a β subunit in non-covalent association. All integrins are transmembrane proteins with counter-receptor binding activity localized in the extracellular domain. Integrins also possess relatively short cytoplasmic regions which participate in transmembrane signaling events. Integrins are capable of interacting with other cell-bound counter-receptors and components of the extracellular matrix, as well as soluble factors. Binding of extracellular ligands leads to crosslinking and localized clustering of integrins Miyamoto, et al., Science 267:833, 1995! and formation of focal adhesions wherein the clustered integrin cytoplasmic domains associate with cytoskeletal components including, for example, actin filaments Pavalko and Otey, Proc. Soc. Exp. Biol. Med. 205:32767, 1994, and Gumbiner, Neuron 11:551, 1993!. While most investigations into integrin physiological activity have focused on identifying specific counter-receptors using immunological methodologies as discussed infra, less is known about the specific interactions of integrins with cytoplasmic components. Mutation studies, however, have indicated that the cytoplasmic sequences are required for integrin association with focal contacts and integrin dependent cell adhesion LaFlamme, et al., J. Cell. Biol. 117:437 (1992)!. Other data discussed infra support this observation.
While numerous integrins have been identified, certain subsets are unique to leukocytes, with each member of the subset having characteristic cell-specific expression and counter-receptor binding properties. Of leukocyte-specific integrins, at least three β 2 integrins are known, each comprised of a unique α subunit in association with a β 2 subunit (designated CD18) Kishimoto, et al., Cell 48:681-690 (1987)!. For a recent review of the state of the art with regard to β 2 integrins, see Springer, Cell 76:301-314 (1994). CD11a/CD18, also known as α L β 2 or LFA-1, is expressed on all leukocytes and has been shown to bind to ICAM-1, ICAM-2, and ICAM-3. CD11b/CD18, also know as α M β 2 or Mac-1, is expressed on polymorphonuclear neutrophils, monocytes and eosinophils and has been shown to bind to ICAM-1, complement factor iC3b, factor X, and fibrinogen. CD11c/CD18, also known as α X β 2 or p150,95, is expressed on monocytes, polymorphonuclear neutrophils and eosinophils and has been shown to bind to complement factor iC3b and fibrinogen. In addition, a fourth human β 2 integrin, designated α d β 2 , has recently been identified Van der Vieren, et al., Immunity 3:683-690 (1995)!. Recently, it has been demonstrated that the actin-binding protein, filamin, directly binds to a cytoplasmic portion of β 2 subunits Sharma, et al., J. Immunol. 154:3461-3470 (1995)! which suggests a role for one or more of the β 2 integrins in formation of focal contacts and cell motility in general see review in Arnaout, Blood 75:1037 (1990)!.
A second subset of leukocyte specific integrins may be referred to as the α 4 integrins in view of the fact that both members of the family are comprised of a common α 4 subunit in association with either a , β 1 or β 7 subunit. For a recent review, see Springer, supra. VLA-4, also referred to as α 4 β 1 or CD49d/CD29, is expressed on most peripheral blood leukocytes except neutrophils and specifically binds VCAM-1 and fibronectin. LPAM-1, also known as α 4 β 7 , is expressed on all peripheral blood leukocytes and has been shown to bind MadCAM-1, fibronectin and VCAM-1. Expression of either of the α 4 integrins has also been demonstrated in a wide range of leukocyte cell types in lymphoid organs and in various tissues Hemler et al, Immunol. Rev. 114:45-60, 1990; Kilshaw et al., Eur. J. Immunol 20:2201-2207, 1990; Schweighoffer et al., J. Immunol 151:717-729, 1993; and Lazarovits and Karsh, J. Immunol. 151:6482-6489, 1993). Consistent with the observed participation of β 2 integrins in formation of focal contacts, presumably through filamin binding, it has previously been shown that cytoplasmic portions of β 1 integrins directly bind β-actinin in vitro. While this interaction has not been demonstrated in vivo, it suggests physiological involvement of β 1 integrins in cell mobility and/or maintenance of cell morphology see review in Clark and Brugge, Science 268:233-238 (1995)!.
A number of in vitro and in vivo studies utilizing anti-α 4 monoclonal antibodies have indicated a role for the α 4 integrins in various pathophysiological conditions see review, Lobb and Hemler, J. Clin. Invest. 94:1722-1728 (1994)!. For example, several investigations have provided evidence that α 4 integrins are involved in leukocyte emigration from peripheral blood into regions of inflammation (Weg, et al., J. Exp. Med. 177:561-566, 1992; Winn and Harlan, J. Clin. Invest. 92:1168-1173, 1993). These observations suggest that anti-α 4 antibodies may be capable of ameliorating integrin-associated disease states, and this therapeutic potential has been demonstrated in several animal disease state models. For example, bolus injection of antibodies to α 4 integrins delayed the onset of paralysis in rat and murine experimental allergic encephalomyelitis (Yednock, et al., Nature 356:63-66, 1992; Baron, et al., J. Exp. Med. 177:57-68, 1993). Prophylactic administration of anti-α 4 antibodies reduced ear swelling in murine contact hypersensitivity models (Ferguson, et al., J. Immunol. 150:1172-1182, 1993; Nakajima, et al., J. Exp. Med. 179:1145-1154, 1994). Further, anti-α 4 antibodies were shown to reduce infiltration of pancreatic islets and delay the onset of diabetes in non-obese diabetic mice which are prone to spontaneous development of type I diabetes (Yang, et aL, Proc. Natl. Acad. Sci. (USA) 90:10494-10498. 1993; Burkly, et al., Diabetes 43:529-534, 1994; Baron, et al., J. Clin. Invest. 93:1700-1708, 1994). Still other in vivo studies using anti-α 4 antibodies suggest a role for α 4 integrins in allergic lung inflammation (Pretolani, et al., J. Exp. Med. 180:795-805 (1994); Milne and Piper, Br. J. Pharmacol. 112:82Pa(Abstr), 1994); inflammatory bowel disease (Podolsky, et al., J. Clin. Invest. 92:372-380, 1993); cardiac allograft rejection (Paul, et al, Transplantation 55:1196-1199, 1993); acute nephrotoxic nephritis (Mulligan, et al., J. Clin. Invest. 91:577-587, 1993); and immune complex mediated lung injury (Mulligan, et al., J. Immunol. 159:2407-2417, 1993).
Thus there exists a need in the art to identify molecules which bind to and/or modulate the binding and/or signaling activities of the integrins and to develop methods by which these molecules can be identified. The methods, and the molecules thereby identified, will provide practical means for therapeutic intervention in u integrin-mediated immune and inflammatory responses.
BRIEF DESCRIPTION OF THE INVENTION
In one aspect, the present invention provides novel purified and isolated polynucleotides (e.g., DNA and RNA transcripts, both sense and antisense stands) encoding a filamin-like β 7 integrin binding protein designated FLP-1, or variants thereof (i.e., deletion, addition or substitution analogs) which possess binding and/or immunological properties inherent to FLP-1. Preferred DNA molecules of the invention include cDNA, genomic DNA and wholly or partially chemically synthesized DNA molecules. Presently preferred polynucleotides include the DNA as set forth in SEQ ID NO: 1, encoding the polypeptide according to SEQ ID NO:2. Alternatively, a preferred polynucleotide encodes a polypeptide according to SEQ ID NO: 2 except that the amino acid at position 146 is a proline rather than a leucine, the amino acid at position 442 is a proline rather than an alanine and the amino acid at position 548 is a valine rather than a methionine. Such a polynucleotide would hybridize to the DNA set out in SEQ ID NO: 1.
Preferred polynucleotides of the invention comprise the cDNA set out in SEQ ID NO: 1 and DNAs which hybridize to the non-coding strands thereof under stringent conditions or which would hybridize but for the redundancy of the genetic code. Exemplary stringent hybridization conditions are as follows: hybridization at 42° C. in 5×SSPE and a final wash at 65° C. in 0.2×SSC. It is understood by those of skill in the art that variation in these conditions occurs based on the length and GC nucleotide content of the sequences to be hybridized. Formulas standard in the art are appropriate for determining exact hybridization conditions. See Sambrook, et al., Eds. 9.47-9.51 in Molecular Cloning, Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y. (1989).
Also provided are recombinant plasmid and viral expression constructs which include FLP-1 encoding sequences, wherein the FLP-1 encoding sequence is operatively linked to a homologous or heterologous transcriptional regulatory element or elements.
As another aspect of the invention, prokaryotic or eukaryotic host cells, transformed or transfected with polynucleotide sequences of the invention, are provided which express FLP-1 polypeptides or variants thereof. Host cells of the invention are particularly useful for large scale production of FLP-1 polypeptides which can be isolated from the host cell itself or the medium in which the host cell is grown.
Also provided by the present invention are purified and isolated FLP-1 polypeptides, including fragments and variants thereof. Novel FLP-1 polypeptides of the invention may be isolated from natural sources, but along with FLP-1 variant polypeptides, are preferably produced by recombinant procedures involving host cells of the invention. Variant FLP-1 polypeptides, including fully glycosylated, partially glycosylated, and wholly de-glycosylated forms of the FLP-1 polypeptide may be generated, depending on the host cell selected for recombinant production and/or post-isolation processing. Additional variant FLP-1 polypeptides include water soluble and insoluble FLP-1 polypeptides and fragments thereof, analogs wherein one or more amino acids are deleted from, replaced in, or added to the preferred FLP-1 polypeptide, polypeptide analogs with equal or enhanced biological activities and/or immunological characteristics specific for FLP-1, and analogs with modified ligand binding and/or signal transducing capabilities. Fusion polypeptides are also provided wherein FLP-1 amino acid sequences are expressed contiguously with amino acid sequences derived from other polypeptides. Fusion polypeptides of the invention include those with modified biological, biochemical, and/or immunological properties in comparison to the preferred FLP-1 polypeptide.
Also contemplated by the present invention are antibodies and other peptide and non-peptide molecules which specifically bind to FLP-1. Binding molecules of this type are particularly useful for purifying FLP-1 polypeptides, identifying cell types which express FLP-1 polypeptides, and assaying for presence or absence of FLP-1 polypeptides in a fluid. Binding molecules are also useful for modulating (i.e., blocking, inhibiting, or stimulating) in vivo binding and/or signal transduction activities of FLP-1. Antibodies of the invention include monoclonal, polyclonal, and recombinant (i.e., humanized, chimeric, etc.) forms and fragments thereof.
Also contemplated by the invention are hybridomas which secrete monoclonal antibodies specifically immunoreactive with FLP-1. Likewise, cell types modified by recombinant means so as to express and/or secrete genetically engineered FLP-1 binding molecules are also comprehended.
Assays to identify FLP-1 binding molecules are also provided, including immobilized ligand binding assays, solution binding assays, scintillation proximity assays, two hybrid screening assays, immunological methodologies and the like. In addition to identifying FLP-1 binding molecules, the same or similar assays are useful for identification of molecules which modulate FLP-1 specific binding. For example, assays to identify modulators (i.e., activators or inhibitors) of FLP-1 specific binding can involve a) contacting FLP-1 or a fragment thereof, with β 7 integrin or a fragment thereof; b) measuring binding between FLP-1 or a fragment thereof, and β 7 integrin or a fragment thereof; c) measuring binding between FLP-1 or a fragment thereof, and β 7 integrin or a fragment thereof in the presence of a test compound, and d) comparing the measurement in step (b) and the measurement in step (c) wherein a decrease in binding in step (c) indicates the test compound in an inhibitor of binding, and an increase in binding in step (c) indicates the test compound is an activator of binding.
Variations on the method to identify modulators of FLP-1 binding can include scintillation proximity assays comprising the steps of immobilizing either FLP-1 or its binding partner on a solid support, wherein the solid support contains a fluorescent agent; modifying the non-immobilized binding partner to include a compound that can excite the immobilized fluorescent agent; contacting the non-immobilized binding partner with the immobilized binding partner; determining the level of light emission for the fluorescent agent; and repeating the procedure in the presence of a putative modulator of FLP-1 binding.
As still another variation of the method, a two hybrid system may be utilized to identify genes encoding potential modulators. In this system, an integrin sequence is expressed in a host cell as a fusion protein with either a DNA binding domain or transactivation domain of a modular transcription factor. A binding partner protein is also expressed as a fusion protein with the transcription factor domain not utilized in expressing the integrin fusion protein. Interaction of the two fusion proteins results in reconstitution of the holo-transcription factor and permits expression of a reporter gene with a promoter specific for the transcription factor. Use of this system in the presence or absence of library cDNA can permit identification of genes that encode proteins which modulate the degree of reporter gene expression.
Additional methods comprehended by the invention include immunological assays including radio-immuno assays, enzyme linked immunosorbent assays, sandwich assays and the like. Co-precipitation methods are also comprehended wherein an antibody immunospecific for one binding partner is utilized in a method in which the other binding partner is detectably labeled. Immunological assays may also include use of labeled antibodies specifically immunoreactive with a complex between the desired binding partners.
Numerous compounds are contemplated as being candidates for testing in methods of the invention. For example, antibody products which are immunoreactive with one binding partner and which modulate binding between the two molecules can be identified by the claimed method. Antibody products contemplated are monoclonal antibodies, and fragments thereof, humanized antibodies, and/or single chain antibodies. Other molecules which can be screened in the claimed method include peptides, small molecules and libraries composed of either of the same.
Modulators of β 7 /FLP-1 and β 7 /flamin interaction identified by the methods of the invention are utilized in vitro or in vivo to affect inflammatory processes involving leukocytes. In addition, modulating compounds which bind to either the β 7 integrin, filamin or FLP-1 are useful to monitor the level of its binding partner, either in a body fluid or biopsied tissue.
Those of ordinary skill in the art will readily appreciate that numerous variations of the claimed method are encompassed by the invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is illustrated by the following examples relating to the isolation of a cDNA clone encoding FLP-1. Example 1 relates to identification of genes in a human B cell cDNA library that encode proteins which interact with β 7 integrin. Example 2 describes identification of genes in a human spleen cDNA library which encode proteins that interact with β 7 integrin. Example 3 addresses tissue specific expression of FLP-1. Example 4 describes specificity of interaction between filamin and β 7 and FLP-1 and β 7 integrin. Example 5 describes localization of β 7 sequences required for filamin or FLP-1 binding. Example 6 relates to applications for modulators of β 7 /filamin or β 7 /FLP-1 interactions.
EXAMPLE 1
Identification of Genes in a B Cell Library Encoding β 7 Interacting Proteins
The two-hybrid system developed in yeast Durfee, et al., Genes and Development 7:555-567 (1993)! was used to screen for proteins expressed in a human B cell cDNA library which interact with the carboxy-terminal cytoplasmic tail of the β 7 integrin. The yeast two-hybrid screen is based on in vivo reconstitution of the GAL4 transcription factor and subsequent expression of a reporter gene driven by a GAL4 promoter. Briefly, GAL4 DNA-binding and transcription-activating domains are encoded on separate plasmids as portions of fusion proteins. Expression of the fusion proteins and interaction of the expression products results in association of the two GAL4 domains and ultimate expression the ,β-galactosidase reporter gene under transcriptional control of the GAL4 promoter.
In the present investigation, a "bait" plasmid (pAS1) was constructed that contained sequences encoding the GAL4-binding domain, a trp - selection requirement, a hemagglutinin (HA) epitope tag and cytoplasmic amino acid sequences of β 7 integrin. The β 7 integrin cytoplasmic domain was amplified by PCR using β 7 primers set out in SEQ ID NO:3 and 4.
NHβ 7 5 CGGATCCTCGGATACCGGCTCTCGGTGAAG (SEQ ID NO: 3)
NHβ 7 3 CGGCTCCTCAGAGAGTGGGACTGTCTGCCT (SEQ ID NO: 4)
Reaction conditions included an initial incubation at 94° C. for four minutes, followed by thirty cycles of: 94° C. for one minute, 50° C. for two minutes, and 72° C. for four minutes. The resulting product was sequenced to rule out PCR-derived errors and subcloned into vector pAS1. A yeast strain, Y190, was transformed with β 7 /pAS1 by standard methods and grown in selective media (trp - ) to mid-log phase. Cells were lysed in lysis buffer (containing 100 mM Tris, pH 6.8, 2% SDS, 10% glycerol, 5% BME and 0.1% bromo phenol blue) and the equivalent of 5-6×10 6 cells of protein was separated on a 12% polyacrylamide gel. Proteins in the gel were transferred to a PVDF (Millipore, Bedford, Mass.) membrane by standard methods. Control lanes on the gel contained lysate from Y190 cells transformed with pAS1 vector alone (containing no β 7 integrin-encoding sequences). Western blotting was performed using antibody 12CA5, immunospecific for the HA epitope tag, (Boehringer Mannheim, Indianapolis, Ind.) and a goat anti-mouse IgG horse radish peroxidase (HRP) secondary antibody. Results, in combination with size determination using SDS-PAGE, confirmed that the fusion protein β 7 integrin cytoplasmic tail/HA/GALA DNA-binding domain was expressed at readily detectable levels.
A "target" vector was constructed with vector pACT modified to contain sequences encoding the GALA activation domain II fused to a B cell cDNA library and a leu - selection requirement. Lymphocyte cDNA library sequences were inserted at an XhoI site of the vector. β 7 /pAS1-transformed Y190 cells were transformed by standard methods with the pACT-lymphocyte library DNA and cells grown under selective conditions (leu - /trp - /his - 3-aminotriazole). Resulting colonies were tested for β-galactosidase (β-gal) activity by the blue/white selection method well known in the art and forty-four β-gal positive clones were obtained. Sequence analysis of the B cell cDNA-derived pACT inserts in each of the clones revealed twenty novel sequences and twenty four sequences encoding known proteins or portions of known proteins.
Five clones were of particular interest, all of which contained sequences encoding a portion of the non-muscle protein filamin, or actin-binding protein ABP280(emb/X53416), Gorlin, et al., J. Cell Biol. 111:1089-1105 (1990)!. All five clones were shown to encode the carboxy-terminal portions of filamin (SEQ ID NO: 7) and each clone extended into 3' untranslated portions of the filamin gene. Clone 411 corresponded to sequences in repeat 20 (beginning at nucleotide 6763 in SEQ ID NO: 7) and clones 514, 1521, 1271 and 722 beginning in repeat 23 (each beginning at nucleotide 7513, 7552, 7579, and 7579 in SEQ ID NO: 7, respectively). There was one discrepancy between the published sequence of filamin and the sequences determined in each of the positive clones: all positive clones had an aspartate residue at position 2634, while the published sequence of filamin had a histidine at that position. Of these clones, 1271, 514 and 411 were selected for subsequent analysis, and the nucleotide and amino acids sequences of 1271 are set out in SEQ ID NOs: 5 and 6, respectively.
EXAMPLE 2
Identification of Genes in a Human Spleen Library Encoding β 7 Interacting Proteins
The two-hybrid system described in Example 1 was repeated using human spleen cDNA library sequences (Clontech, Palo Alto, Calif.) cloned into an EcoRI site of the target vector pGAD10 (Clontech).
After transformation of the β 7 /pAS1 Y190 strain with the spleen/pGAD10 plasmid and selection as previously described, the resulting colonies were tested for β-gal activity and six positive clones were identified. Sequence analysis of the six β-gal positive clones that revealed five identical clones (from which clone S5 was selected for further analysis) along with clone S3, (the sixth positive clone and distinct from the other five) were identified.
DNA and protein alignments revealed that clones S3 and S5 encode different, but overlapping regions of the same protein, with the S3 insert beginning 5' of the S5 insert, and terminating before the 3' end of clone S5. The DNA sequences of clones S3 and S5 were compared to DNA databases using NCBI Blastn with default parameters on Oct. 16, 1995, and both clones were found to exhibit approximately 70% identity to filamin. The nucleotide and amino acid sequences of clone S3 are set out in SEQ ID NOs: 9 and 10, respectively. Sequences for clone S5 are set out in SEQ ID NOs: 11 and 12, respectively. The composite protein encoded by the overlapping clones S3 and S5 was designated FLP-1 (filamin like protein). Blastp search of protein database (NCBI Blastp) revealed that the composite protein FLP-1 has a 73% identity to fidamin. Alignment of FLP-1 to filamin shows that clones S3 and S5 represent carboxy terminal regions of FLP-1. When FLP-1 is aligned with filamin in the second hinge region between repeats 23 and 24, the putative glycoprotein binding region, the degree of identity drops to 38%, suggesting a difference in binding affinity between filamin and FLP-1 for membrane glycoproteins.
In addition, a region of clone S5 was further found to exhibit 100% identity to truncated actin-binding protein TABP (GP or GB/M62994), a protein previously shown to be a truncated, non-actin-binding filamin-like protein Leedman, et al., Proc.Natl.Acad.Sci.(USA) 90:5994-5998 (1993)! having 195 amino acids and a molecular weight of approximately 21 kDa. Identity was particularly high between nucleotides 950-1515 of clone 5 which were 95-99% identical to regions of TABP. TABP lacks an actin binding domain and 22 of 24 tandem repeats found in filamin, but contains sequences homologous to the carboxy terminal repeats numbered 23 and 24 found in filamin. The TABP hinge region, between repeats 23 and 24, contains a putative glycoprotein binding site and a Ca 2+ /calmodulin kinase II phosphorylation site Leedman, supra!. TABP is encoded by a 2.3 kb MRNA and a cDNA encoding TABP was cloned from a thyroid expression library from a Graves disease patient Leedmen, supra!.
In order to obtain a more complete FLP-1 sequence, the human spleen cDNA library was screened using S3 as a probe. The S3 clone was digested with EcoRI and a 1.2 kb fragment was isolated and labeled using the Random Primed Labeling Kit (Boehringer Mannheim, Indianapolis, Ind.) according to the manufacturer's suggested protocol. Unincorporated nucleotides were removed using a Centrisep column (Princeton Separations, Adelphia, N.J.). The probe was added to filters in hybridization solution (5×SSPE, 45% formamide, 5× Denhardts, 1% SDS) and hybridized overnight at 42° C. The filters were washed at a final stringency of 0.2× SSC/0.1% SDS at 65° C.
Primary positive clones were picked, diluted and replated on Hybond N + filters on LBM plates. Two duplicate filters were rehybridized with hybridization solution saved from the original hybridization described supra. Clones which were positive on both filters were picked, grown and their plasmids isolated and sequenced by standard methods.
Ten FLP-1 positive clones were detected and partial sequence data from these clones was compared to filamin and FLP-1 sequences derived from clones S3 and S5. Overlap of sequences from clones S3 and S5 with sequences from clones F3, F5 and F7 permitted determination of a more complete sequence for FLP-1, the more complete nucleotide and amino acid sequences set out in SEQ ID NOs: 1 and 2, respectively. In SEQ ID NO: 1, nucleotides 1-315 were derived from clone F5 (clone F5 was significantly longer than 315 nucleotides); nucleotides 316-738 from clone F3; nucleotides 739-816 from clone F7; nucleotides 817-1122 from clone S3 and nucleotides 1123-2574 from clone S5.
The longest clone, F5, was later sequenced in its entirety. There are five differences at the nucleotide level between SEQ ID NO: 1 and the F5 sequence. In the F5 sequence, nucleotide 437 is C rather than T changing amino acid residue 146 from leucine to proline. Nucleotide 1324 is C rather than G changing amino acid residue 442 from alanine to proline. Nucleotide position 1642 is changed G rather than A thus changing residue 548 from methionine to valine. In addition, nucleotide 2124 is C rather than T and nucleotide 2181 is A rather than T. The nucleotide differences at positions 2124 and 2181 do not alter the encoded amino residue. The sequence differences between the composite sequence of SEQ ID NO: 1 and the corresponding F5 FLP-1 sequence may arise from genetic polymorphism or the like.
EXAMPLE 3
Tissue Specific Expression of FLP-1
In order to determine size of a MRNA encoding FLP-1 in various tissues, a human immune system multiple tissue northern (Clontech) was probed with a random-primed portion of clone S3 (corresponding to nucleotides 255-777 in SEQ ID NO: 9) according to manufacturer's suggested protocol. The RNA utilized in the Northern blots included RNA from appendix, thymus, lymph node, spleen, bone marrow, fetal liver and peripheral blood leukocytes, and cell lines G361, SW480, K562, HeLa, HL60, MOLP-4, Raji and A549.
In spleen, lymph node, thymus, bone marrow, and fetal liver, mRNA of two distinct sizes hybridized to the FLP-1 probe: one just above and one just below the 9.5 Kb size marker. In appendix and peripheral blood leukocytes, only one band, just below the 9.5 Kb size marker, hybridized with the FLP-1 probe. These results suggest that the FLP-1 MRNA encodes a protein similar in size to filamin as reported in Gorlin, supra.
To determine whether filamin and FLP-1 are expressed in the same or in different cell types, Northern blots of mRNA isolated from various tissues and cell types were probed as described above. An antisense oligonucleotide filamin probe, GGTGGCCTTGGTCAGAGAGTCTACAAACAC (SEQ ID NO: 37), and an antisense oligonucleotide FLP-1 probe, GGCGCTATAGCAGGTCTCTGTAGACGACCT (SEQ ID NO: 38) were derived from hinge sequences between repeats 23 and 24 that differ in 23 out of a total of 30 nucleotides. These oligonucleotides possess approximately equivalent Tms, 81 and 82° C., respectively. The oligonucleotides were 5' labelled with 32 P and unincorporated nucleotides were removed using a G-25 Sephadex Quickspin column (BMB).
The FLP-1 probe was added to the hybridization solution (5× SSPE, 2×Denhardt's, 0.5% SDS, 100 μg/ml sheared salmon sperm DNA) and multitissue northems (Clontech) were hybridized overnight at 42° C. Filters were washed according to the manufacturer's suggested protocol at a final stringency of 2×SSC/0. 1% SDS at 42° C.
After exposure to film, the filters were stripped according to the manufacturer's suggested protocol and exposed to flow again to ensure that the signal due to the FLP-1 probe had been completely removed. The filters were then hybridized with the filamin probe.
The FLP-1 probe detected two mRNAs, of approximately 9.5 and 8.5 kb, in several lymphoid and non-lymphoid tissues and cell lines. The filamin probe hybridized to a mRNA of approximately 8.5 kb. The levels of filamin mRNA detected in appendix, as well as epithelial (G361) and myelomonocytic (HL60) cell lines, appear to be markedly greater than that of FLP-1 and can be visualized in a 16 hour exposure. In contrast, FLP-1 mRNA expression is lower and can be detected only by exposing the film for at least seven days. Thus, FLP-1 and filamin mRNA are similar in size but appear to be differentially expressed in some tissues or cell types.
EXAMPLE 4
Specificity of Filamin/β 7 and FLP-1/β 7 Interaction
The specificity of the interactions of filamin (clones 1271 and 514) and FLP-1 with the β 7 integrin cytoplasmic tail was verified by transforming filamin clone 1271 and FLP-1 clone S5 into Y190 strains containing any one of a variety of "baits" vectors (encoding β 2 , β 7 or α L integrin cytoplasmic tails) using standard methods described supra. Results from this assay, shown in Table 1, indicated that filamin clone 1271 specifically binds to β 7 integrins but not to other integrins and FLP-1 clone S5 interacts with β 7 integrins.
TABLE 1______________________________________Binding Specificity of Filamin and FLP-1SPECIFICITY OF INTERACTIONINTEGRIN "BAIT" FILAMIN FLP-1______________________________________β.sub.2 - -β.sub.7 + +α.sub.L - -______________________________________
In vivo interaction between endogenous filamin and β 7 integrin was also investigated by co-precipitation of a filamin/α 4 β 7 complex from JY cells, which express endogenous α 4 β 7 . Cells were initially permeabilized with 10 μg/ml lysolecithin (Sigma, St. Louis, Mo.) in PBS, pH 8.0, with 1 mM Ca ++ and 1 mM Mg ++ , for five minutes. Cellular proteins were crosslinked using DTSSP (921 μM) and labeled with biotin as described in Altin, et al., Anal. Biochem. 224:382-389 (1995). Crosslinked proteins were solubilized using 1% Triton-X100 and integrins were immunoprecipitated using monoclonal antibodies immunospecific for α 4 (antibody HP2/1, Immunotech, Westbrook, Me., or antibody B5G10, Upstate Biotechnology, Inc., Lake Placid, N.Y.), or β 2 (antibody 23 IIIb). A control antibody, PC21 (Sigma, St. Louis, Mo.) was also employed. Precipitated proteins were separated on a 6% SDS-PAGE gel, transferred to an Immobilon P membrane and probed with filamin antisera (Chemicon International, Inc. Temecula, Calif.).
These results demonstrate co-precipitation of naturally occurring filamin with an α 4 integrin. Also in this assay, filamin co-precipitated with the β 2 subunit, but was not precipitated with control antibody PC21. This implies that a portion of the filamin molecule not encoded by clone 1271 interacts with a β 2 integrin.
EXAMPLE 5
Localization of FLP-1 or Filamin Binding on β 7
In order to more fully characterize the binding between FLP-1 or filamin and the cytoplasmic tail of β 7 integrin, the two-hybrid assay was employed using various deletion derivatives of either of the individual binding partners.
Several cytoplasmic domain mutants of the β 7 integrin were created using site directed mutagenesis in order to map the site(s) of interaction observed as described above. Filamin truncates (ABPD1, ABPD2 and ABPD5) and clones 1271, 514 and 411 and FLP-1 clones S5 and S3 were employed to evaluate the degree to which mutations in the β 7 cytoplasmic domain affected binding. Following standard co-transformations of Y190 as described above, binding interactions were determined by β-gal assay, as described above. The β7 deletions utilized in these assays are set out in SEQ ID NOS: 14 to 18 and 39-41 below, and compared to the native β 7 sequence set out in SEQ ID NO: 13. In each expression construct, only the cytoplasmic portion of β 7 , or a truncation thereof, was subcloned.
β.sub.7 YRLSVEIYDRREYSRFEKEQQQLNWKQDSNPLYKSAITTTINPRFQEADSPTL (SEQ ID NO: 13)β.sub.7 D1 YRLSVEIYDRREYSRFEKEQQQLNWKQDSNP (SEQ ID NO: 14)β.sub.7 D2 YRLSVEIYDRREYSRFEKEQQQLNWKQDSNPLYKSA (SEQ ID NO: 15)β.sub.7 D3 YRLSVEIYDRREYSRFEKEQQQLNWKQDSNPLYKSAITTTINP (SEQ ID NO: 16)β.sub.7 D4 YRLSVEIYDRREYSRFEKE (SEQ ID NO: 17)β.sub.7 D5 YRLSVEIYDRREYSR (SEQ ID NO: 18)β.sub.7 D6 YRLSVEIYDRR (SEQ ID NO: 39)β.sub.7 D8 YRLSVEIYDRREYSRFEKEQQQLNWKQDSNPLYKSAITTTINPRFQEAD (SEQ ID NO: 40)β.sub.7 D9 YRLSVEIYDRREYSRFEKEQQQLNWKQDSNPLYKSAITTTINPRF (SEQ ID NO: 41)
Primers used to generate the various deletion mutants are set out in SEQ ID NOs: 19 to 23 and 42-46, below, and were individually utilized in an amplification reaction pairs with the primer set out in SEQ ID NO: 3. Reaction conditions were as described in Example 1. Deletions β 7 D8 and β 7 D9 were prepared using Quickchange site directed mutagenesis (Stratagene, La Jolla, Calif.) and all other deletions were prepared by standard single stranded site directed mutagenesis.
NHβ.sub.7 D1GATGGCACTTTTGTACTAAGGATTACTGTCCTG (SEQ ID NO: 19)NHβ.sub.7 D2ATTGATGGTGGTCGTCTAGGCACTTTTGTAGAG (SEQ ID NO: 20)NHβ.sub.7 D3GTCTGCCTCTTGAAACTAAGGATTGATGGTGGT (SEQ ID NO: 21)NHβ.sub.7 D4CCAGTTGAGTTGTTGCTACTCCTTCTCAAAGCG (SEQ ID NO: 22)NHβ.sub.7 D5GTTGCTGCTCCTTCTCCTAGCGACTGTATTCCCG (SEQ ID NO: 23)β.sub.7 D6:CTCAAAGCGACTGTACTACCGGCGGTCATAGATTTC (SEQ ID NO: 42)β.sub.7 D8:CTTTCAAGAGGCAGACTGACCCACTCTCTGAGGA (sense oligo) (SEQ ID NO: 43)β.sub.7 D8:TCCTCAGAGAGTGGGTCAGTCTGCCTCTTGAAAG (antisense oligo) (SEQ ID NO: 44)β.sub.7 D9:CATCAATCCTCGCTTTTGAGAGGCAGACAGTCCC (sense oligo) (SEQ ID NO: 45)β.sub.7 D9:GGGACTGTCTGCCTCTCAAAAGCGAGGATTGATC (antisense oligo) (SEQ ID NO: 46)
In addition, a series of β 7 substitution mutants were also constructed wherein the sequence changes are set out in SEQ ID NOs: 24 to 27 and 47-51, with the substituted amino acid residue underlined.
β.sub.7 S3AYRLAVEIYDRREYSRFEKEQQQLNWKQDSNPLYKSAITTTINPRFQEADSPTL (SEQ ID NO: 24)β.sub.7 E5QYRLSVQIYDRREYSRFEKEQQQLNWKQDSNPLYKSAITTTINPRFQEADSPTL (SEQ ID NO: 25)β.sub.7 R9AYRLSVEIYDAREYSRFEKEQQQLNWKQDSNPLYKSAITTTINPRFQEADSPTL (SEQ ID NO: 26)β.sub.7 S13AYRLSVEIYDRREYARFEKEQQQLNWKQDSNPLYKSAITTTINPRFQEADSPTL (SEQ ID NO: 27)β.sub.7 V4FYRLSFEIYDRREYSRFEKEQQQLNWKQDSNPLYKSAITTTINPRFQEADSPTL (SEQ ID NO: 47)β.sub.7 I6FYRLSVEFYDRREYSRFEKEQQQLNWKQDSNPLYKSAITTTINPRFQEADSPTL (SEQ ID NO: 48)β.sub.7 Y7FYRLSVEIFDRREYSRFEKEQQQLNWKQDSNPLYKSAITTTINPRFQEADSPTL (SEQ ID NO: 49)β.sub.7 D8AYRLSVEIYARREYSRFEKEQQQLNWKQDSNPLYKSAITTTINPRFQEADSPTL (SEQ ID NO: 50)β.sub.7 R10AYRLSVEIYDRAEYSRFEKEQQQLNWKQDSNPLYKSAITTTINPRFQEADSPTL (SEQ ID NO: 51)Oligonucleotides used to generate the various substitutionvariants are set out in SEQ ID NOs: 28 to 31 and 52 to 56, infra.B7S3AGTCATAGATTTCCACCGCGAGCCGGTATCCGAG (SEQ ID NO: 28)B7E5QCCGGCCGTCATAGATTTGCACCGAGAGCCGGTATC (SEQ ID NO: 29)B7R9AGCGACTGTATTCCCGCGCGTCATAGATTTCCAC (SEQ ID NO: 30)B7S13ACTCCTTCTCAAAGCGCGCGTATTCCCGGCGGTC (SEQ ID NO: 31)β.sub.7 V4FGCGGTCATAGATTTCAAACGAGAGCCGGTATCC (SEQ ID NO: 52)β.sub.7 I6FTTCCCGGCGGTCATAGAATTCCACCGAGAGCCG (SEQ ID NO: 53)β.sub.7 Y7FGTATTCCCGGCGGTCAAAGATTTCCACCGAGAG (SEQ ID NO: 54)β.sub.7 D8AACTGTATTCCCGGCGCGCATAGATTTCCACCGA (SEQ ID NO: 55)β.sub.7 R10AAAAGCGACTGTATTCCGCGCGGTCATAGATTTC (SEQ ID NO: 56)
Specific truncation mutants of filamin were generated by PCR amplification of existing clones under conditions described in Example 1. Mutant ABPD1 encoded a region including a portion of repeat 23, the second hinge region and repeat 24 of filamin (amino acid 2487-2647 in SEQ ID NO: 7). Mutant ABPD2 (amino acids 2487-2577 in SEQ ID NO: 7) encoded a truncated form of ABPD1 which lacked the filamin dimerization domain. Mutant ABPD4 (amino acids 2517-2647 in SEQ ID NO: 7) encoded a truncated form of ABPD1 which lacked the twenty-third repeat. Mutant ABPD5 (amino acid 2198-2435 in SEQ ID NO: 7) encoded a truncated form of clone 411 which lacked most of repeat 23, the second hinge region and repeat 24. Mutant ABPD9 (amino acid 2350-2435 in SEQ ID NO:7) encoded a truncated form of ABPD5. Mutant ABPD10 (amino acid 2256-2363 in SEQ ID NO: 7) encoded another truncated form of ABPD5.
Mutant ABPD1 was generated by PCR using primers set out in SEQ ID NO: 32 and 33, and mutant ABPD2 was generated by PCR using primers set out in SEQ ID NO: 32 and 34.
ABP.5x ATATCTCGAGAGTATACCCCCATGGCACCT (SEQ ID NO: 32)ABP.Xho1 ATATCTCGAGTCAGGGCACCACAACGCG (SEQ ID NO: 33)ABP.Xho2 ATATCTCGAGTCAGCTGCTCTTCTGGCCCTAC (SEQ ID NO: 34)
Primers 32-34 were used in a reaction with filamin clone 1271 under the following amplification conditions: an initial incubation at 94° C. for five minutes, followed by thirty cycles of 94° C. for 30 seconds, 50° C. for 30 seconds, and 72° C. for one minute. The resulting PCR product was cut with Xho1 and ligated into vector pACT (described in Example 1) previously digested with Xho1.
Mutants ABPD4, ABPD5, ABPD9 and ABPD10 were generated by PCR. ABPD4 was generated using primers 1271/151 and 1271/3XR and used clone 1271 as the DNA template. ABPD5 was generated using primers B7411/1X and B7411/700X and used clone 411 as the DNA template. ABPD9 was generated using primers B7411/457X and B7411/700X and used clone 411 as the DNA template. ABPD10 was generated using primers B7411/175X and B7411/498X and used clone 411 as the DNA template.
1271/151 CCCGAATTCACAGGCCCCCGTCTCGTC (SEQ ID NO: 57)1271/3XR CCCGAATTCCTCGAGTCAGGGCACCACAACGCGGTAG (SEQ ID NO: 58)B7411/1X CCCCCTCGAGGCTACTGCATCCGCTTTGTTC (SEQ ID NO: 59)B7411/700X CCCCTCGAGTCAGTAAGCAGACACCAAGCC (SEQ ID NO: 60)B7411/457X CCCCTCGAGCCAGCCTCTTTTGCAGTC (SEQ ID NO: 61)B7411/175X CCCCTCGAGCCAGCCGAATTCAGTATC (SEQ ID NO: 62)B7411/498X CCCCTCGAGTCACGCCCCCTTGGCCCCCTTC (SEQ ID NO: 63)
Primers as described were used in PCR reactions with the appropriate templates under amplification conditions outlined in Example 1. The resulting PCR products were cut with XhoI (ABPD5, ABPD9 and ABPD10) or EcoRI (ABPD4) and ligated into vector pACT (ABPD5) or vector pACT2 (ABPD9 and ABPD10) previously digested with XhoI or ligated into vector pGAD10 (ABPD4) previously digested with EcoRI. The resulting subclones were sequenced to rule out PCR derived errors.
An FLP-1 mutant comprised of amino acid sequences 696 to 857 in SEQ ID NO: 1 and showing identity to TABP (the TABP-like analog) was also generated by PCR amplification (under conditions described in Example 1) from a human spleen cDNA library. The FLP-1 mutant was generated by PCR using the primer pair set out in SEQ ID NO: 35 and 36.
TABP.Nde ATATCATATGTACACCCCCATGGCTCCT (SEQ ID NO: 35)TABP.Bam ATAGGATCCTCAGCCCCACAAACAGGC (SEQ ID NO: 36)
Reactions were carried out using 2.5 μg spleen cDNA under the following amplification conditions: an initial incubation at 94° C. for five minutes, followed by thirty cycles of 94° C. for 30 seconds, 50° C. for 30 seconds, and 72° C. for one minute. The resulting PCR products were digested with NdeI and BamHI and cloned into vector pET previously digested with the same enzymes. The resulting TABP/pET vector was then utilized in a secondary PCR with the PCR primer pair set out in SEQ ID NO: 32 and 33, above, under the following conditions: an initial incubation at 94° C. for five minutes, followed by thirty cycles at 94° for one minute, 50° C. for one minute and 72° C. for two minutes. The resulting PCR product was digested with Xho1 and cloned into pACT previously digested with Xho1. The FLP-1 TABP-like truncate represents the same size and region in filamin as represented by mutant ABPD1.
Another FLP-1 mutant, FLP1D3, was generated by PCR. FLPlD3 encoded a truncated form of clone S5 (amino acid 272-483 in SEQ ID NO:11). FLP1D3 represents the carboxy terminal region of S5, which is not encoded by S3. The primers used to generate this mutant were B7S5/814X and B7S5/1475X and clone S5 was used as the DNA template.
B7S5/814X CCCCCTCGAGGCGGCACGGGACTCGAAGGG (SEQ ID NO: 64)B7S5/1475X CCCCTCGAGTTAAGGCACTGTGACATG (SEQ ID NO: 65)
These primers were utilized in PCR reactions under amplification conditions outlined in Example 1. The resulting PCR products were digested with AoI and ligated into the vector pACT previously digested with )aoi. Sequencing of the resulting subclones ruled out PCR derived errors.
Results from the two hybrid assays as shown in Tables 2-4, discussed below, indicate that there are two distinct regions of filamin capable of interacting with the β 7 cytoplasmic tail. The first region is represented by clones 514 and 1271, the second region by deletion mutant ABPD5. In the first binding region of filamin (as represented by clones 514 and 1271) the dimerization domain (amino acids 2578-2647 of SEQ ID NO: 7) (not present in ABPD2) and the region at the 5' end of repeat 23 (not present in ABPD4) appear to be critical for interaction with the β 7 cytoplasmic tail. The results with TABP and FLP1D3 also show that despite a high degree of homology with filamin, there does not appear to be a corresponding region in FLP-1 similar to the "repeat 23-24" region found in filamin clones 514 and 1271 which is capable of interacting with the β 7 cytoplasmic tail. In addition, interaction with ABPD5 indicates a second region of filamin centered around repeat 21 which interacts with the β 7 cytoplasmic tail, corresponding to a region of FLP-1 (amino acid 1-273 of SEQ ID NO: 12), and is most likely to be responsible for the FLP-1 interaction with β 7 cytoplasmic tail.
TABLE 2______________________________________INTERACTION OF FILAMIN (1271)AND FLP-1 (S5) WITH β.sub.7 DELETION ANDSUBSTITUTION ANALOGSFILAMIN ABPD1 ABPD2 FLP-1 TABP______________________________________β.sub.2 - - - - -β.sub.7 + +/- - + -β.sub.7 D1 + + - +/-β.sub.7 D2 + + - +/-β.sub.7 D3 + + - +β.sub.7 D4 + + - +β.sub.7 D5 + + +β.sub.7 S3A + + +β.sub.7 E5Q +/- +/- +β.sub.7 R9A + + +β.sub.7 S13A + + +α.sub.L - - -______________________________________
TABLE 3______________________________________INTERACTION OF β.sub.7 WITH FILAMINAND FLP-1 AND DELETION MUTANTS β.sub.7______________________________________ FILAMIN 1271 + 514 + 411 + ABPD1 +/- ABPD2 - ABPD4 - ABPD5 + ABPD9 - ABPD10 - FLP-1 S3 + S5 + TABP - FLP1D3 -______________________________________
Table 2 and Table 4 below summarize the effect of β 7 deletion mutants and substitution analogs on binding of β 7 to filamin (clone 514), ABPD1, ABPD2, ABPD5, TABP and FLP-1 clones S3 and S5. The binding properties of the first filamin binding site, represented by clones 514 and 1271, is affected by substitutions in the membrane proximal region of the β 7 cytoplasmic tail. Specifically, substitution mutant E5Q greatly weakens the interaction with clones 514 and 1271. Substitution mutant D8A completely disrupts the interaction of β 7 with clones 514 and 1271 (Table 4). The binding of ABPD5 to β 7 (the second region of filamin which interacts with the β 7 cytoplasmic tail) is not affected by substitutions in the membrane proximal region of the β 7 cytoplasmic tail, as shown by substitution mutants E5Q and D8A. However, the binding of ABPD5 to β 7 is decreased in deletion mutants at the carboxy terminus of the β 7 cytoplasmic tail, as shown by deletion mutants β 7 D1 and β 7 D2 (Table 4). FFLP-1 clones S3 and S5 demonstrate a pattern of interaction with the β 7 deletion and substitution mutants that is remarkably similar to ABPD5. Because ABPD5, S3 and S5 were able to interact with deletion mutants smaller than β 7 D1 and β 7 D2, such as β 7 D6, it is possible that this region of filamin or FLP-1 can interact with more than one region of the β 7 cytoplasmic tail.
TABLE 4______________________________________INTERACTION OFFILAMIN (514) WITH β.sub.7 DELETIONAND SUBSTITUTION ON ANALOGS 514 ABPD5 S3 S5______________________________________β.sub.7 + + + +β.sub.7 D1 + +/- +/- +/-β.sub.7 D2 + +/- +/- +/-β.sub.7 D4 + + +β.sub.7 D5 + + +β.sub.7 D6 + + + +/-β.sub.7 D8 +/- + + +β.sub.7 D9 + + + +β.sub.7 S3A + + +β.sub.7 V4F + +β.sub.7 E5Q +/- + + +β.sub.7 I6F + +β.sub.7 Y7F + + +β.sub.7 D8A - + + +β.sub.7 R9A + + +β.sub.7 S13A + +______________________________________
The data presented in this Example demonstrates that there are two distinct regions of filamin which interact with two distinct regions of the β 7 cytoplasmic tail. They also show that the region of FLP-1 which interacts with the β 7 cytoplasmic tail is similar to the ABPD5 region of filamin in its interaction characteristics with the β 7 cytoplasmic tail.
EXAMPLE 6
Applications for Modulators of Filamin/β 7 and FLP-1/β 7 Binding
Two β 7 associated integrins have been identified: α 4 β 7 and α E β 7 . Both are expressed on a subpopulation of peripheral blood lymphocytes and their expression is inducible. Both are expressed on macrophages but not monocytes and both appear to function in homing or localization of lymphocytes to mucosal tissue see review in Jutila, J. Leukocyte Biol. 55:133-140 (1994)!. The homing properties of α 4 β 7 can be attributed to interaction with MadCAM-1 expressed in mucosal nodes, while the retention of α E β 7 + cells in the gut is attributed to interactions with epithelial cells expressing E-cadherin. Thus, binding by one or both β 7 integrins to their respective counter-receptor may contribute to mucosal immune responses as well as inflammatory (e.g., inflammatory bowel disease, IIBD) and autoimmune responses at this site.
Further, it has been suggested that filamin is important in cell locomotion due to the fact that cells expressing low levels of the protein do not form leading lamella structures required for locomotion. The structural homology of FLP-1 to filamin suggests a similar role for this protein. In view of the observation that integrins can be observed clustered in point contacts, which are also important in cell locomotion, the invention contemplates that β 7 interaction with FLP-1 and/or filamin may be crucial to cell movement, and that disruption of the interactions will be useful, for example, in preventing the homing of β 7 + cells which occurs in certain pathological inflammatory responses such as IBD.
In order to identify modulators of β 7 /FLP-1 interaction, it is necessary to clearly define the portions of both proteins which are necessary for binding. Amino acid substitution, through standard mutagenesis techniques will permit identification of the binding regions of the proteins. Deletion analysis, wherein truncated forms of either protein are generated, for example by PCR, is also useful for identification of binding regions if the deletion does not disrupt the tertiary or quaternary structure of the protein to the point that it is no longer recognized buy its counter-receptor.
Identification of the significant protein regions involved in binding permits more accurate and efficient screening of putative modulators of binding activity. The invention contemplates of a high throughput screening assay to analyze large libraries of small molecules or peptides, as well as antibodies immunospecific for either or both binding partners, for the ability to modulate binding of β 7 integrins to FLP-1 or filamin. While two hybrid screening, scintillation proximity assays (SPA) and immunological methodologies, for example, enzyme-linked immunosorbent assays (FLISA), disclosed herein are not HTS methods per se, they are amenable to test many of the compounds listed for an ability to modulate binding. SPA and ELISA are particularly useful in this identification process and can be modified to permit high throughput screening of the test compounds described.
__________________________________________________________________________# SEQUENCE LISTING- (1) GENERAL INFORMATION:- (iii) NUMBER OF SEQUENCES: 65- (2) INFORMATION FOR SEQ ID NO:1:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 2574 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: cDNA- (ix) FEATURE: (A) NAME/KEY: CDS (B) LOCATION: 1..2574- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:- CCT TTT GAC CTG GTC ATT CCG TTT GCT GTC AG - #G AAA GGA GAA ATC ACT 48Pro Phe Asp Leu Val Ile Pro Phe Ala Val Ar - #g Lys Gly Glu Ile Thr# 15- GGA GAG GTC CAC ATG CCT TCT GGG AAG ACA GC - #C ACA CCT GAG ATT GTG 96Gly Glu Val His Met Pro Ser Gly Lys Thr Al - #a Thr Pro Glu Ile Val# 30- GAC AAC AAG GAC GGC ACG GTC ACT GTT AGA TA - #T GCC CCC ACT GAG GTC 144Asp Asn Lys Asp Gly Thr Val Thr Val Arg Ty - #r Ala Pro Thr Glu Val# 45- GGG CTC CAT GAG ATG CAC ATC AAA TAC ATG GG - #C AGC CAC ATC CCT GAG 192Gly Leu His Glu Met His Ile Lys Tyr Met Gl - #y Ser His Ile Pro Glu# 60- AGC CCA CTC CAG TTC TAC GTG AAC TAC CCC AA - #C AGT GGA AGT GTT TCT 240Ser Pro Leu Gln Phe Tyr Val Asn Tyr Pro As - #n Ser Gly Ser Val Ser# 80- GCA TAC GGT CCA GGC CTC GTG TAT GGA GTG GC - #C AAC AAA ACT GCC ACC 288Ala Tyr Gly Pro Gly Leu Val Tyr Gly Val Al - #a Asn Lys Thr Ala Thr# 95- TTC ACC ATC GTC ACA GAG GAT GCA GGA GAA GG - #T GGT CTG GAC TTG GCT 336Phe Thr Ile Val Thr Glu Asp Ala Gly Glu Gl - #y Gly Leu Asp Leu Ala# 110- ATT GAG GGC CCC TCA AAA GCA GAA ATC AGC TG - #C ATT GAC AAT AAA GAT 384Ile Glu Gly Pro Ser Lys Ala Glu Ile Ser Cy - #s Ile Asp Asn Lys Asp# 125- GGG ACA TGC ACA GTG ACC TAC CTG CCG ACT CT - #G CCA GGC GAC TAC AGC 432Gly Thr Cys Thr Val Thr Tyr Leu Pro Thr Le - #u Pro Gly Asp Tyr Ser# 140- ATT CTG GTC AAG TAC AAT GAC AAG CAC ATC CC - #T GGC AGC CCC TTC ACA 480Ile Leu Val Lys Tyr Asn Asp Lys His Ile Pr - #o Gly Ser Pro Phe Thr145 1 - #50 1 - #55 1 -#60- GCC AAG ATC ACA GAT GAC AGC AGG CGG TGC TC - #C CAG GTG AAG TTG GGC 528Ala Lys Ile Thr Asp Asp Ser Arg Arg Cys Se - #r Gln Val Lys Leu Gly# 175- TCA GCC GCT GAC TTC CTG CTC GAC ATC AGT GA - #G ACT GAC CTC AGC AGC 576Ser Ala Ala Asp Phe Leu Leu Asp Ile Ser Gl - #u Thr Asp Leu Ser Ser# 190- CTG ACG GCC AGC ATT AAG GCC CCA TCT GGC CG - #A GAC GAG CCC TGT CTC 624Leu Thr Ala Ser Ile Lys Ala Pro Ser Gly Ar - #g Asp Glu Pro Cys Leu# 205- CTG AAG AGG CTG CCC AAC AAC CAC ATT GGC AT - #C TCC TTC ATC CCC CGG 672Leu Lys Arg Leu Pro Asn Asn His Ile Gly Il - #e Ser Phe Ile Pro Arg# 220- GAA GTG GGC GAA CAT CTG GTC AGC ATC AAG AA - #A AAT GGC AAC CAT GTG 720Glu Val Gly Glu His Leu Val Ser Ile Lys Ly - #s Asn Gly Asn His Val225 2 - #30 2 - #35 2 -#40- GCC AAC AGC CCC GTG TCT ATC ATG GTG GTC CA - #G TCG GAG ATT GGT GAC 768Ala Asn Ser Pro Val Ser Ile Met Val Val Gl - #n Ser Glu Ile Gly Asp# 255- GCC CGC CGA GCC AAA GTC TAT GGC CGC GGC CT - #G TCA GAA GGC CGG ACT 816Ala Arg Arg Ala Lys Val Tyr Gly Arg Gly Le - #u Ser Glu Gly Arg Thr# 270- TTC GAG ATG TCT GAC TTC ATC GTG GAC ACA AG - #G GAT GCA GGT TAT GGT 864Phe Glu Met Ser Asp Phe Ile Val Asp Thr Ar - #g Asp Ala Gly Tyr Gly# 285- GGC ATA TCC TTG GCG GTG GAA GGC CCC AGC AA - #A GTG GAC ATC CAG ACG 912Gly Ile Ser Leu Ala Val Glu Gly Pro Ser Ly - #s Val Asp Ile Gln Thr# 300- GAG GAC CTG GAA GAT GGC ACC TGC AAA GTC TC - #C TAC TTC CCT ACC GTG 960Glu Asp Leu Glu Asp Gly Thr Cys Lys Val Se - #r Tyr Phe Pro Thr Val305 3 - #10 3 - #15 3 -#20- CCT GGG GTT TAT ATC GTC TCC ACC AAA TTC GC - #T GAC GAG CAC GTG CCT1008Pro Gly Val Tyr Ile Val Ser Thr Lys Phe Al - #a Asp Glu His Val Pro# 335- GGG AGC CCA TTT ACC GTG AAG ATC AGT GGG GA - #G GGA AGA GTC AAA GAG1056Gly Ser Pro Phe Thr Val Lys Ile Ser Gly Gl - #u Gly Arg Val Lys Glu# 350- AGC ATC ACC CGC ACC AGT CGG GCC CCG TCC GT - #G GCC ACT GTC GGG AGC1104Ser Ile Thr Arg Thr Ser Arg Ala Pro Ser Va - #l Ala Thr Val Gly Ser# 365- ATT TGT GAC CTG AAC CTG AAA ATC CCA GAA AT - #C AAC AGC AGT GAT ATG1152Ile Cys Asp Leu Asn Leu Lys Ile Pro Glu Il - #e Asn Ser Ser Asp Met# 380- TCG GCC CAC GTC ACC AGC CCC TCT GGC CGT GT - #G ACT GAG GCA GAG ATT1200Ser Ala His Val Thr Ser Pro Ser Gly Arg Va - #l Thr Glu Ala Glu Ile385 3 - #90 3 - #95 4 -#00- GTG CCC ATG GGG AAG AAC TCA CAC TGC GTC CG - #G TTT GTG CCC CAG GAG1248Val Pro Met Gly Lys Asn Ser His Cys Val Ar - #g Phe Val Pro Gln Glu# 415- ATG GGC GTG CAC ACG GTC AGC GTC AAG TAC CG - #T GGG CAG CAC GTC ACC1296Met Gly Val His Thr Val Ser Val Lys Tyr Ar - #g Gly Gln His Val Thr# 430- GGC AGC CCC TTC CAG TTC ACC GTG GGG GCA CT - #T GGT GAA GGA GGC GCC1344Gly Ser Pro Phe Gln Phe Thr Val Gly Ala Le - #u Gly Glu Gly Gly Ala# 445- CAC AAG GTG CGG GCA GGA GGC CCT GGC CTG GA - #G AGA GGA GAA GCG GGA1392His Lys Val Arg Ala Gly Gly Pro Gly Leu Gl - #u Arg Gly Glu Ala Gly# 460- GTC CCA GCT GAG TTC AGC ATT TGG ACC CGG GA - #A GCA GGC GCT GGA GGC1440Val Pro Ala Glu Phe Ser Ile Trp Thr Arg Gl - #u Ala Gly Ala Gly Gly465 4 - #70 4 - #75 4 -#80- CTC TCC ATC GCT GTT GAG GGC CCC AGT AAG GC - #C GAG ATT ACA TTC GAT1488Leu Ser Ile Ala Val Glu Gly Pro Ser Lys Al - #a Glu Ile Thr Phe Asp# 495- GAC CAT AAA AAT GGG TCG TGC GGT GTA TCT TA - #T ATT GCC CAA GAG CCT1536Asp His Lys Asn Gly Ser Cys Gly Val Ser Ty - #r Ile Ala Gln Glu Pro# 510- GGT AAC TAC GAG GTG TCC ATC AAG TTC AAT GA - #T GAG CAC ATC CCG GAA1584Gly Asn Tyr Glu Val Ser Ile Lys Phe Asn As - #p Glu His Ile Pro Glu# 525- AGC CCC TAC CTG GTG CCG GTC ATC GCA CCC TC - #C GAC GAC GCC CGC CGC1632Ser Pro Tyr Leu Val Pro Val Ile Ala Pro Se - #r Asp Asp Ala Arg Arg# 540- CTC ACT GTT ATG AGC CTT CAG GAA TCG GGA TT - #A AAA GTT AAC CAG CCA1680Leu Thr Val Met Ser Leu Gln Glu Ser Gly Le - #u Lys Val Asn Gln Pro545 5 - #50 5 - #55 5 -#60- GCA TCC TTT GCT ATA AGG TTG AAT GGC GCA AA - #A GGC AAG ATT GAT GCA1728Ala Ser Phe Ala Ile Arg Leu Asn Gly Ala Ly - #s Gly Lys Ile Asp Ala# 575- AAG GTG CAC AGC CCC TCT GGA GCC GTG GAG GA - #G TGC CAC GTG TCT GAG1776Lys Val His Ser Pro Ser Gly Ala Val Glu Gl - #u Cys His Val Ser Glu# 590- CTG GAG CCA GAT AAG TAT GCT GTT CGC TTC AT - #C CCT CAT GAG AAT GGT1824Leu Glu Pro Asp Lys Tyr Ala Val Arg Phe Il - #e Pro His Glu Asn Gly# 605- GTC CAC ACC ATC GAT GTC AAG TTC AAT GGG AG - #C CAC GTG GTT GGA AGC1872Val His Thr Ile Asp Val Lys Phe Asn Gly Se - #r His Val Val Gly Ser# 620- CCC TTC AAA GTG CGC GTT GGG GAG CCT GGA CA - #A GCG GGG AAC CCT GCC1920Pro Phe Lys Val Arg Val Gly Glu Pro Gly Gl - #n Ala Gly Asn Pro Ala625 6 - #30 6 - #35 6 -#40- CTG GTG TCC GCC TAT GGC ACG GGA CTC GAA GG - #G GGN ACC ACA GGT ATC1968Leu Val Ser Ala Tyr Gly Thr Gly Leu Glu Gl - #y Xaa Thr Thr Gly Ile# 655- CAG TCG GAA TTC TTT ATT AAC ACC ACC CGA GC - #A GGT CCA GGG ACA TTA2016Gln Ser Glu Phe Phe Ile Asn Thr Thr Arg Al - #a Gly Pro Gly Thr Leu# 670- TCC GTC ACC ATC GAA GGC CCA TCC AAG GTT AA - #A ATG GAT TGC CAG GAA2064Ser Val Thr Ile Glu Gly Pro Ser Lys Val Ly - #s Met Asp Cys Gln Glu# 685- ACA CCT GAA GGG TAC AAA GTC ATG TAC ACC CC - #C ATG GCT CCT GGT AAC2112Thr Pro Glu Gly Tyr Lys Val Met Tyr Thr Pr - #o Met Ala Pro Gly Asn# 700- TAC CTG ATC AGT GTC AAA TAC GGT GGG CCC AA - #C CAC ATC GTG GGC AGT2160Tyr Leu Ile Ser Val Lys Tyr Gly Gly Pro As - #n His Ile Val Gly Ser705 7 - #10 7 - #15 7 -#20- CCC TTC AAG GCC AAG GTG ACT GGC CAG CGT CT - #A GTT AGC CCT GGC TCA2208Pro Phe Lys Ala Lys Val Thr Gly Gln Arg Le - #u Val Ser Pro Gly Ser# 735- GCC AAC GAG ACC TCA TCC ATC CTG GTG GAG TC - #A GTG ACC AGG TCG TCT2256Ala Asn Glu Thr Ser Ser Ile Leu Val Glu Se - #r Val Thr Arg Ser Ser# 750- ACA GAG ACC TGC TAT AGC GCC ATT CCC AAG GC - #A TCC TCG GAC GCC AGC2304Thr Glu Thr Cys Tyr Ser Ala Ile Pro Lys Al - #a Ser Ser Asp Ala Ser# 765- AAG GTG ACC TCT AAG GGG GCA GGG CTC TCA AA - #G GCC TTT GTG GGC CAG2352Lys Val Thr Ser Lys Gly Ala Gly Leu Ser Ly - #s Ala Phe Val Gly Gln# 780- AAG AGT TCC TTC CTG GTG GAC TGC AGC AAA GC - #T GGC TCC AAC ATG CTG2400Lys Ser Ser Phe Leu Val Asp Cys Ser Lys Al - #a Gly Ser Asn Met Leu785 7 - #90 7 - #95 8 -#00- CTG ATC GGG GTC CAT GGG CCC ACC ACC CCC TG - #C GAG GAG GTC TCC ATG2448Leu Ile Gly Val His Gly Pro Thr Thr Pro Cy - #s Glu Glu Val Ser Met# 815- AAG CAT GTA GGC AAC CAG CAA TAC AAC GTC AC - #A TAC GTC GTC AAG GAG2496Lys His Val Gly Asn Gln Gln Tyr Asn Val Th - #r Tyr Val Val Lys Glu# 830- AGG GGC GAT TAT GTG CTG GCT GTG AAG TGG GG - #G GAG GAA CAC ATC CCT2544Arg Gly Asp Tyr Val Leu Ala Val Lys Trp Gl - #y Glu Glu His Ile Pro# 845# 2574 AT GTC ACA GTG CCT TAAGly Ser Pro Phe His Val Thr Val Pro# 855- (2) INFORMATION FOR SEQ ID NO:2:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 857 amino (B) TYPE: amino acid (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: protein- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:2:- Pro Phe Asp Leu Val Ile Pro Phe Ala Val Ar - #g Lys Gly Glu Ile Thr# 15- Gly Glu Val His Met Pro Ser Gly Lys Thr Al - #a Thr Pro Glu Ile Val# 30- Asp Asn Lys Asp Gly Thr Val Thr Val Arg Ty - #r Ala Pro Thr Glu Val# 45- Gly Leu His Glu Met His Ile Lys Tyr Met Gl - #y Ser His Ile Pro Glu# 60- Ser Pro Leu Gln Phe Tyr Val Asn Tyr Pro As - #n Ser Gly Ser Val Ser# 80- Ala Tyr Gly Pro Gly Leu Val Tyr Gly Val Al - #a Asn Lys Thr Ala Thr# 95- Phe Thr Ile Val Thr Glu Asp Ala Gly Glu Gl - #y Gly Leu Asp Leu Ala# 110- Ile Glu Gly Pro Ser Lys Ala Glu Ile Ser Cy - #s Ile Asp Asn Lys Asp# 125- Gly Thr Cys Thr Val Thr Tyr Leu Pro Thr Le - #u Pro Gly Asp Tyr Ser# 140- Ile Leu Val Lys Tyr Asn Asp Lys His Ile Pr - #o Gly Ser Pro Phe Thr145 1 - #50 1 - #55 1 -#60- Ala Lys Ile Thr Asp Asp Ser Arg Arg Cys Se - #r Gln Val Lys Leu Gly# 175- Ser Ala Ala Asp Phe Leu Leu Asp Ile Ser Gl - #u Thr Asp Leu Ser Ser# 190- Leu Thr Ala Ser Ile Lys Ala Pro Ser Gly Ar - #g Asp Glu Pro Cys Leu# 205- Leu Lys Arg Leu Pro Asn Asn His Ile Gly Il - #e Ser Phe Ile Pro Arg# 220- Glu Val Gly Glu His Leu Val Ser Ile Lys Ly - #s Asn Gly Asn His Val225 2 - #30 2 - #35 2 -#40- Ala Asn Ser Pro Val Ser Ile Met Val Val Gl - #n Ser Glu Ile Gly Asp# 255- Ala Arg Arg Ala Lys Val Tyr Gly Arg Gly Le - #u Ser Glu Gly Arg Thr# 270- Phe Glu Met Ser Asp Phe Ile Val Asp Thr Ar - #g Asp Ala Gly Tyr Gly# 285- Gly Ile Ser Leu Ala Val Glu Gly Pro Ser Ly - #s Val Asp Ile Gln Thr# 300- Glu Asp Leu Glu Asp Gly Thr Cys Lys Val Se - #r Tyr Phe Pro Thr Val305 3 - #10 3 - #15 3 -#20- Pro Gly Val Tyr Ile Val Ser Thr Lys Phe Al - #a Asp Glu His Val Pro# 335- Gly Ser Pro Phe Thr Val Lys Ile Ser Gly Gl - #u Gly Arg Val Lys Glu# 350- Ser Ile Thr Arg Thr Ser Arg Ala Pro Ser Va - #l Ala Thr Val Gly Ser# 365- Ile Cys Asp Leu Asn Leu Lys Ile Pro Glu Il - #e Asn Ser Ser Asp Met# 380- Ser Ala His Val Thr Ser Pro Ser Gly Arg Va - #l Thr Glu Ala Glu Ile385 3 - #90 3 - #95 4 -#00- Val Pro Met Gly Lys Asn Ser His Cys Val Ar - #g Phe Val Pro Gln Glu# 415- Met Gly Val His Thr Val Ser Val Lys Tyr Ar - #g Gly Gln His Val Thr# 430- Gly Ser Pro Phe Gln Phe Thr Val Gly Ala Le - #u Gly Glu Gly Gly Ala# 445- His Lys Val Arg Ala Gly Gly Pro Gly Leu Gl - #u Arg Gly Glu Ala Gly# 460- Val Pro Ala Glu Phe Ser Ile Trp Thr Arg Gl - #u Ala Gly Ala Gly Gly465 4 - #70 4 - #75 4 -#80- Leu Ser Ile Ala Val Glu Gly Pro Ser Lys Al - #a Glu Ile Thr Phe Asp# 495- Asp His Lys Asn Gly Ser Cys Gly Val Ser Ty - #r Ile Ala Gln Glu Pro# 510- Gly Asn Tyr Glu Val Ser Ile Lys Phe Asn As - #p Glu His Ile Pro Glu# 525- Ser Pro Tyr Leu Val Pro Val Ile Ala Pro Se - #r Asp Asp Ala Arg Arg# 540- Leu Thr Val Met Ser Leu Gln Glu Ser Gly Le - #u Lys Val Asn Gln Pro545 5 - #50 5 - #55 5 -#60- Ala Ser Phe Ala Ile Arg Leu Asn Gly Ala Ly - #s Gly Lys Ile Asp Ala# 575- Lys Val His Ser Pro Ser Gly Ala Val Glu Gl - #u Cys His Val Ser Glu# 590- Leu Glu Pro Asp Lys Tyr Ala Val Arg Phe Il - #e Pro His Glu Asn Gly# 605- Val His Thr Ile Asp Val Lys Phe Asn Gly Se - #r His Val Val Gly Ser# 620- Pro Phe Lys Val Arg Val Gly Glu Pro Gly Gl - #n Ala Gly Asn Pro Ala625 6 - #30 6 - #35 6 -#40- Leu Val Ser Ala Tyr Gly Thr Gly Leu Glu Gl - #y Xaa Thr Thr Gly Ile# 655- Gln Ser Glu Phe Phe Ile Asn Thr Thr Arg Al - #a Gly Pro Gly Thr Leu# 670- Ser Val Thr Ile Glu Gly Pro Ser Lys Val Ly - #s Met Asp Cys Gln Glu# 685- Thr Pro Glu Gly Tyr Lys Val Met Tyr Thr Pr - #o Met Ala Pro Gly Asn# 700- Tyr Leu Ile Ser Val Lys Tyr Gly Gly Pro As - #n His Ile Val Gly Ser705 7 - #10 7 - #15 7 -#20- Pro Phe Lys Ala Lys Val Thr Gly Gln Arg Le - #u Val Ser Pro Gly Ser# 735- Ala Asn Glu Thr Ser Ser Ile Leu Val Glu Se - #r Val Thr Arg Ser Ser# 750- Thr Glu Thr Cys Tyr Ser Ala Ile Pro Lys Al - #a Ser Ser Asp Ala Ser# 765- Lys Val Thr Ser Lys Gly Ala Gly Leu Ser Ly - #s Ala Phe Val Gly Gln# 780- Lys Ser Ser Phe Leu Val Asp Cys Ser Lys Al - #a Gly Ser Asn Met Leu785 7 - #90 7 - #95 8 -#00- Leu Ile Gly Val His Gly Pro Thr Thr Pro Cy - #s Glu Glu Val Ser Met# 815- Lys His Val Gly Asn Gln Gln Tyr Asn Val Th - #r Tyr Val Val Lys Glu# 830- Arg Gly Asp Tyr Val Leu Ala Val Lys Trp Gl - #y Glu Glu His Ile Pro# 845- Gly Ser Pro Phe His Val Thr Val Pro# 855- (2) INFORMATION FOR SEQ ID NO:3:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 30 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:3:# 30 GGCT CTCGGTGAAG- (2) INFORMATION FOR SEQ ID NO:4:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 30 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:4:# 30 GGGA CTGTCTGCCT- (2) INFORMATION FOR SEQ ID NO:5:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 545 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: cDNA- (ix) FEATURE: (A) NAME/KEY: CDS (B) LOCATION: 1..534- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:5:- AAG GTG AAG ATG GAT TGC CAG GAG TGC CCT GA - #G GGC TAC CGC GTC ACC 48Lys Val Lys Met Asp Cys Gln Glu Cys Pro Gl - #u Gly Tyr Arg Val Thr# 15- TAT ACC CCC ATG GCA CCT GGC AGC TAC CTC AT - #C TCC ATC AAG TAC GGC 96Tyr Thr Pro Met Ala Pro Gly Ser Tyr Leu Il - #e Ser Ile Lys Tyr Gly# 30- GGC CCC TAC CAC ATT GGG GGC AGC CCC TTC AA - #G GCC AAA GTC ACA GGC 144Gly Pro Tyr His Ile Gly Gly Ser Pro Phe Ly - #s Ala Lys Val Thr Gly# 45- CCC CGT CTC GTC AGC AAC CAC AGC CTC CAC GA - #G ACA TCA TCA GTG TTT 192Pro Arg Leu Val Ser Asn His Ser Leu His Gl - #u Thr Ser Ser Val Phe# 60- GTA GAC TCT CTG ACC AAG GCC ACC TGT GCC CC - #C CAG CAT GGG GCC CCG 240Val Asp Ser Leu Thr Lys Ala Thr Cys Ala Pr - #o Gln His Gly Ala Pro# 80- GGT CCT GGG CCT GCT GAC GCC AGC AAG GTG GT - #G GCC AAG GGC CTG GGG 288Gly Pro Gly Pro Ala Asp Ala Ser Lys Val Va - #l Ala Lys Gly Leu Gly# 95- CTG AGC AAG GCC TAC GTA GGC CAG AAG AGC AG - #C TTC ACA GTA GAC TGC 336Leu Ser Lys Ala Tyr Val Gly Gln Lys Ser Se - #r Phe Thr Val Asp Cys# 110- AGC AAA GCA GGC AAC AAC ATG CTG CTG GTG GG - #G GTT CAT GGC CCA AGG 384Ser Lys Ala Gly Asn Asn Met Leu Leu Val Gl - #y Val His Gly Pro Arg# 125- ACC CCC TGC GAG GAG ATC CTG GTG AAG CAC GT - #G GGC AGC CGG CTC TAC 432Thr Pro Cys Glu Glu Ile Leu Val Lys His Va - #l Gly Ser Arg Leu Tyr# 140- AGC GTG TCC TAC CTG CTC AAG GAC AAG GGG GA - #G TAC ACA CTG GTG GTC 480Ser Val Ser Tyr Leu Leu Lys Asp Lys Gly Gl - #u Tyr Thr Leu Val Val145 1 - #50 1 - #55 1 -#60- AAA TGG GGG GAC GAG CAC ATC CCA GGC AGN CC - #C TAC CGN GTT GTG GTG 528Lys Trp Gly Asp Glu His Ile Pro Gly Xaa Pr - #o Tyr Xaa Val Val Val# 175# 545 CCPro- (2) INFORMATION FOR SEQ ID NO:6:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 177 amino (B) TYPE: amino acid (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: protein- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:6:- Lys Val Lys Met Asp Cys Gln Glu Cys Pro Gl - #u Gly Tyr Arg Val Thr# 15- Tyr Thr Pro Met Ala Pro Gly Ser Tyr Leu Il - #e Ser Ile Lys Tyr Gly# 30- Gly Pro Tyr His Ile Gly Gly Ser Pro Phe Ly - #s Ala Lys Val Thr Gly# 45- Pro Arg Leu Val Ser Asn His Ser Leu His Gl - #u Thr Ser Ser Val Phe# 60- Val Asp Ser Leu Thr Lys Ala Thr Cys Ala Pr - #o Gln His Gly Ala Pro# 80- Gly Pro Gly Pro Ala Asp Ala Ser Lys Val Va - #l Ala Lys Gly Leu Gly# 95- Leu Ser Lys Ala Tyr Val Gly Gln Lys Ser Se - #r Phe Thr Val Asp Cys# 110- Ser Lys Ala Gly Asn Asn Met Leu Leu Val Gl - #y Val His Gly Pro Arg# 125- Thr Pro Cys Glu Glu Ile Leu Val Lys His Va - #l Gly Ser Arg Leu Tyr# 140- Ser Val Ser Tyr Leu Leu Lys Asp Lys Gly Gl - #u Tyr Thr Leu Val Val145 1 - #50 1 - #55 1 -#60- Lys Trp Gly Asp Glu His Ile Pro Gly Xaa Pr - #o Tyr Xaa Val Val Val# 175- Pro- (2) INFORMATION FOR SEQ ID NO:7:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 8367 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: cDNA- (ix) FEATURE: (A) NAME/KEY: CDS (B) LOCATION: 172..8115- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:7:- CGATCCGGGC GCCACCCCGC GGTCATCGGT CACCGGTCGC TCTCAGGAAC AG - #CAGCGCAA 60- CCTCTGCTCC CTGCCTCGCC TCCCGCGCGC CTAGGTGCCT GCGACTTTAA TT - #AAAGGGCC 120#ATG AGT 177GGCTGCA GCACCGCCCC CCCGGCTTCT CGCGCCTCAA A# Met Ser# 1- AGC TCC CAC TCT CGG GCG GGC CAG AGC GCA GC - #A GGC GCG GCT CCG GGC 225Ser Ser His Ser Arg Ala Gly Gln Ser Ala Al - #a Gly Ala Ala Pro Gly# 15- GGC GGC GTC GAC ACG CGG GAC GCC GAG ATG CC - #G GCC ACC GAG AAG GAC 273Gly Gly Val Asp Thr Arg Asp Ala Glu Met Pr - #o Ala Thr Glu Lys Asp# 30- CTG GCG GAG GAC GCG CCG TGG AAG AAG ATC CA - #G CAG AAC ACT TTC ACG 321Leu Ala Glu Asp Ala Pro Trp Lys Lys Ile Gl - #n Gln Asn Thr Phe Thr# 50- CGC TGG TGC AAC GAG CAC CTG AAG TGC GTG AG - #C AAG CGC ATC GCC AAC 369Arg Trp Cys Asn Glu His Leu Lys Cys Val Se - #r Lys Arg Ile Ala Asn# 65- CTG CAG ACG GAC CTG AGC GAC GGG CTG CGG CT - #T ATC GCG CTG TTG GAG 417Leu Gln Thr Asp Leu Ser Asp Gly Leu Arg Le - #u Ile Ala Leu Leu Glu# 80- GTG CTC AGC CAG AAG AAG ATG CAC CGC AAG CA - #C AAC CAG CGG CCC ACT 465Val Leu Ser Gln Lys Lys Met His Arg Lys Hi - #s Asn Gln Arg Pro Thr# 95- TTC CGC CAA ATG CAG CTT GAG AAC GTG TCG GT - #G GCG CTC GAG TTC CTG 513Phe Arg Gln Met Gln Leu Glu Asn Val Ser Va - #l Ala Leu Glu Phe Leu# 110- GAC CGC GAG AGC ATC AAA CTG GTG TCC ATC GA - #C AGC AAG GCC ATC GTG 561Asp Arg Glu Ser Ile Lys Leu Val Ser Ile As - #p Ser Lys Ala Ile Val115 1 - #20 1 - #25 1 -#30- GAC GGG AAC CTG AAG CTG ATC CTG GGC CTC AT - #C TGG ACC CTG ATC CTG 609Asp Gly Asn Leu Lys Leu Ile Leu Gly Leu Il - #e Trp Thr Leu Ile Leu# 145- CAC TAC TCC ATC TCC ATG CCC ATG TGG GAC GA - #G GAG GAG GAT GAG GAG 657His Tyr Ser Ile Ser Met Pro Met Trp Asp Gl - #u Glu Glu Asp Glu Glu# 160- GCC AAG AAG CAG ACC CCC AAG CAG AGG CTC CT - #G GGC TGG ATC CAG AAC 705Ala Lys Lys Gln Thr Pro Lys Gln Arg Leu Le - #u Gly Trp Ile Gln Asn# 175- AAG CTG CCG CAG CTG CCC ATC ACC AAC TTC AG - #C CGG GAC TGG CAG AGC 753Lys Leu Pro Gln Leu Pro Ile Thr Asn Phe Se - #r Arg Asp Trp Gln Ser# 190- GGC CGG GCC CTG GGC GCC CTG GTG GAC AGC TG - #T GCC CCG GGC CTG TGT 801Gly Arg Ala Leu Gly Ala Leu Val Asp Ser Cy - #s Ala Pro Gly Leu Cys195 2 - #00 2 - #05 2 -#10- CCT GAC TGG GAC TCT TGG GAC GCC AGC AAG CC - #C GTT ACC AAT GCG CGA 849Pro Asp Trp Asp Ser Trp Asp Ala Ser Lys Pr - #o Val Thr Asn Ala Arg# 225- GAG GCC ATG CAG CAG GCG GAT GAC TGG CTG GG - #C ATC CCC CAG GTG ATC 897Glu Ala Met Gln Gln Ala Asp Asp Trp Leu Gl - #y Ile Pro Gln Val Ile# 240- ACC CCC GAG GAG ATT GTG GAC CCC AAC GTG GA - #C GAG CAC TCT GTC ATG 945Thr Pro Glu Glu Ile Val Asp Pro Asn Val As - #p Glu His Ser Val Met# 255- ACC TAC CTG TCC CAG TTC CCC AAG GCC AAG CT - #G AAG CCA GGG GCT CCC 993Thr Tyr Leu Ser Gln Phe Pro Lys Ala Lys Le - #u Lys Pro Gly Ala Pro# 270- TTG CGC CCC AAA CTG AAC CCG AAG AAA GCC CG - #T GCC TAC GGG CCA GGC1041Leu Arg Pro Lys Leu Asn Pro Lys Lys Ala Ar - #g Ala Tyr Gly Pro Gly275 2 - #80 2 - #85 2 -#90- ATC GAG CCC ACA GGC AAC ATG GTG AAG AAG CG - #G GCA GAG TTC ACT GTG1089Ile Glu Pro Thr Gly Asn Met Val Lys Lys Ar - #g Ala Glu Phe Thr Val# 305- GAG ACC AGA AGT GCT GGC CAG GGA GAG GTG CT - #G GTG TAC GTG GAG GAC1137Glu Thr Arg Ser Ala Gly Gln Gly Glu Val Le - #u Val Tyr Val Glu Asp# 320- CCG GCC GGA CAC CAG GAG GAG GCA AAA GTG AC - #C GCC AAT AAC GAC AAG1185Pro Ala Gly His Gln Glu Glu Ala Lys Val Th - #r Ala Asn Asn Asp Lys# 335- AAC CGC ACC TTC TCC GTC TGG TAC GTC CCC GA - #G GTG ACG GGG ACT CAT1233Asn Arg Thr Phe Ser Val Trp Tyr Val Pro Gl - #u Val Thr Gly Thr His# 350- AAG GTT ACT GTG CTC TTT GCT GGC CAG CAC AT - #C GCC AAG AGC CCC TTC1281Lys Val Thr Val Leu Phe Ala Gly Gln His Il - #e Ala Lys Ser Pro Phe355 3 - #60 3 - #65 3 -#70- GAG GTG TAC GTG GAT AAG TCA CAG GGT GAC GC - #C AGC AAA GTG ACA GCC1329Glu Val Tyr Val Asp Lys Ser Gln Gly Asp Al - #a Ser Lys Val Thr Ala# 385- CAA GGT CCC GGC CTG GAG CCC AGT GGC AAC AT - #C GCC AAC AAG ACC ACC1377Gln Gly Pro Gly Leu Glu Pro Ser Gly Asn Il - #e Ala Asn Lys Thr Thr# 400- TAC TTT GAG ATC TTT ACG GCA GGA GCT GGC AC - #G GGC GAG GTC GAG GTT1425Tyr Phe Glu Ile Phe Thr Ala Gly Ala Gly Th - #r Gly Glu Val Glu Val# 415- GTG ATC CAG GAC CCC ATG GGA CAG AAG GGC AC - #G GTA GAG CCT CAG CTG1473Val Ile Gln Asp Pro Met Gly Gln Lys Gly Th - #r Val Glu Pro Gln Leu# 430- GAG GCC CGG GGC GAC AGC ACA TAC CGC TGC AG - #C TAC CAG CCC ACC ATG1521Glu Ala Arg Gly Asp Ser Thr Tyr Arg Cys Se - #r Tyr Gln Pro Thr Met435 4 - #40 4 - #45 4 -#50- GAG GGC GTC CAC ACC GTG CAC GTC ACG TTT GC - #C GGC GTG CCC ATC CCT1569Glu Gly Val His Thr Val His Val Thr Phe Al - #a Gly Val Pro Ile Pro# 465- CGC AGC CCC TAC ACT GTC ACT GTT GGC CAA GC - #C TGT AAC CCG AGT GCC1617Arg Ser Pro Tyr Thr Val Thr Val Gly Gln Al - #a Cys Asn Pro Ser Ala# 480- TGC CGG GCG GTT GGC CGG GGC CTC CAG CCC AA - #G GGT GTG CGG GTG AAG1665Cys Arg Ala Val Gly Arg Gly Leu Gln Pro Ly - #s Gly Val Arg Val Lys# 495- GAG ACA GCT GAC TTC AAG GTG TAC ACA AAG GG - #C GCT GGC AGT GGG GAG1713Glu Thr Ala Asp Phe Lys Val Tyr Thr Lys Gl - #y Ala Gly Ser Gly Glu# 510- CTG AAG GTC ACC GTG AAG GGC CCC AAG GGA GA - #G GAG CGC GTG AAG CAG1761Leu Lys Val Thr Val Lys Gly Pro Lys Gly Gl - #u Glu Arg Val Lys Gln515 5 - #20 5 - #25 5 -#30- AAG GAC CTG GGG GAT GGC GTG TAT GGC TTC GA - #G TAT TAC CCC ATG GTC1809Lys Asp Leu Gly Asp Gly Val Tyr Gly Phe Gl - #u Tyr Tyr Pro Met Val# 545- CCT GGA ACC TAT ATC GTC ACC ATC ACG TGG GG - #T GGT CAG AAC ATC GGG1857Pro Gly Thr Tyr Ile Val Thr Ile Thr Trp Gl - #y Gly Gln Asn Ile Gly# 560- CGC AGT CCC TTC GAA GTG AAG GTG GGC ACC GA - #G TGT GGC AAT CAG AAG1905Arg Ser Pro Phe Glu Val Lys Val Gly Thr Gl - #u Cys Gly Asn Gln Lys# 575- GTA CGG GCC TGG GGC CCT GGG CTG GAG GGC GG - #C GTC GTT GGC AAG TCA1953Val Arg Ala Trp Gly Pro Gly Leu Glu Gly Gl - #y Val Val Gly Lys Ser# 590- GCA GAC TTT GTG GTG GAG GCT ATC GGG GAC GA - #C GTG GGC ACG CTG GGC2001Ala Asp Phe Val Val Glu Ala Ile Gly Asp As - #p Val Gly Thr Leu Gly595 6 - #00 6 - #05 6 -#10- TTC TCG GTG GAA GGG CCA TCG CAG GCT AAG AT - #C GAA TGT GAC GAC AAG2049Phe Ser Val Glu Gly Pro Ser Gln Ala Lys Il - #e Glu Cys Asp Asp Lys# 625- GGC GAC GGC TCC TGT GAT GTG CGC TAC TGG CC - #G CAG GAG GCT GGC GAG2097Gly Asp Gly Ser Cys Asp Val Arg Tyr Trp Pr - #o Gln Glu Ala Gly Glu# 640- TAT GCC GTT CAC GTG CTG TGC AAC AGC GAA GA - #C ATC CGC CTC AGC CCC2145Tyr Ala Val His Val Leu Cys Asn Ser Glu As - #p Ile Arg Leu Ser Pro# 655- TTC ATG GCT GAC ATC CGT GAC GCG CCC CAG GA - #C TTC CAC CCA GAC AGG2193Phe Met Ala Asp Ile Arg Asp Ala Pro Gln As - #p Phe His Pro Asp Arg# 670- GTG AAG GCA CGT GGG CCT GGA TTG GAG AAG AC - #A GGT GTG GCC GTC AAC2241Val Lys Ala Arg Gly Pro Gly Leu Glu Lys Th - #r Gly Val Ala Val Asn675 6 - #80 6 - #85 6 -#90- AAG CCA GCA GAG TTC ACA GTG GAT GCC AAG CA - #C GGT GGC AAG GCC CCA2289Lys Pro Ala Glu Phe Thr Val Asp Ala Lys Hi - #s Gly Gly Lys Ala Pro# 705- CTT CGG GTC CAA GTC CAG GAC AAT GAA GGC TG - #C CCT GTG GAG GCG TTG2337Leu Arg Val Gln Val Gln Asp Asn Glu Gly Cy - #s Pro Val Glu Ala Leu# 720- GTC AAG GAC AAC GGC AAT GGC ACT TAC AGC TG - #C TCC TAC GTG CCC AGG2385Val Lys Asp Asn Gly Asn Gly Thr Tyr Ser Cy - #s Ser Tyr Val Pro Arg# 735- AAG CCG GTG AAG CAC ACA GCC ATG GTG TCC TG - #G GGA GGC GTC AGC ATC2433Lys Pro Val Lys His Thr Ala Met Val Ser Tr - #p Gly Gly Val Ser Ile# 750- CCC AAC AGC CCC TTC AGG GTG AAT GTG GGA GC - #T GGC AGC CAC CCC AAC2481Pro Asn Ser Pro Phe Arg Val Asn Val Gly Al - #a Gly Ser His Pro Asn755 7 - #60 7 - #65 7 -#70- AAG GTC AAA GTA TAC GGC CCC GGA GTA GCC AA - #G ACA GGG CTC AAG GCC2529Lys Val Lys Val Tyr Gly Pro Gly Val Ala Ly - #s Thr Gly Leu Lys Ala# 785- CAC GAG CCC ACC TAC TTC ACT GTG GAC TGC GC - #C GAG GCT GGC CAG GGG2577His Glu Pro Thr Tyr Phe Thr Val Asp Cys Al - #a Glu Ala Gly Gln Gly# 800- GAC GTC AGC ATC GGC ATC AAG TGT GCC CCT GG - #A GTG GTA GGC CCC GCC2625Asp Val Ser Ile Gly Ile Lys Cys Ala Pro Gl - #y Val Val Gly Pro Ala# 815- GAA GCT GAC ATC GAC TTC GAC ATC ATC CGC AA - #T GAC AAT GAC ACC TTC2673Glu Ala Asp Ile Asp Phe Asp Ile Ile Arg As - #n Asp Asn Asp Thr Phe# 830- ACG GTC AAG TAC ACG CCC CGG GGG GCT GGC AG - #C TAC ACC ATT ATG GTC2721Thr Val Lys Tyr Thr Pro Arg Gly Ala Gly Se - #r Tyr Thr Ile Met Val835 8 - #40 8 - #45 8 -#50- CTC TTT GCT GAC CAG GCC ACG CCC ACC AGC CC - #C ATC CGA GTC AAG GTG2769Leu Phe Ala Asp Gln Ala Thr Pro Thr Ser Pr - #o Ile Arg Val Lys Val# 865- GAG CCC TCT CAT GAC GCC AGT AAG GTG AAG GC - #C GAG GGC CCT GGC CTC2817Glu Pro Ser His Asp Ala Ser Lys Val Lys Al - #a Glu Gly Pro Gly Leu# 880- AGT CGC ACT GGT GTC GAG CTT GGC AAG CCC AC - #C CAC TTC ACA GTA AAT2865Ser Arg Thr Gly Val Glu Leu Gly Lys Pro Th - #r His Phe Thr Val Asn# 895- GCC AAA GCT GCT GGC AAA GGC AAG CTG GAC GT - #C CAG TTC TCA GGA CTC2913Ala Lys Ala Ala Gly Lys Gly Lys Leu Asp Va - #l Gln Phe Ser Gly Leu# 910- ACC AAG GGG GAT GCA GTG CGA GAT GTG GAC AT - #C ATC GAC CAC CAT GAC2961Thr Lys Gly Asp Ala Val Arg Asp Val Asp Il - #e Ile Asp His His Asp915 9 - #20 9 - #25 9 -#30- AAC ACC TAC ACA GTC AAG TAC ACG CCT GTC CA - #G CAG GGT CCA GTA GGC3009Asn Thr Tyr Thr Val Lys Tyr Thr Pro Val Gl - #n Gln Gly Pro Val Gly# 945- GTC AAT GTC ACT TAT GGA GGG GAT CCC ATC CC - #T AAG AGC CCT TTC TCA3057Val Asn Val Thr Tyr Gly Gly Asp Pro Ile Pr - #o Lys Ser Pro Phe Ser# 960- GTG GCA GTA TCT CCA AGC CTG GAC CTC AGC AA - #G ATC AAG GTG TCT GGC3105Val Ala Val Ser Pro Ser Leu Asp Leu Ser Ly - #s Ile Lys Val Ser Gly# 975- CTG GGA GAG AAG GTG GAC GTT GGC AAA GAC CA - #G GAG TTC ACA GTC AAA3153Leu Gly Glu Lys Val Asp Val Gly Lys Asp Gl - #n Glu Phe Thr Val Lys# 990- TCA AAG GGT GCT GGT GGT CAA GGC AAA GTG GC - #A TCC AAG ATT GTG GGC3201Ser Lys Gly Ala Gly Gly Gln Gly Lys Val Al - #a Ser Lys Ile Val Gly995 1 - #000 1005 - # 1010- CCC TCG GGT GCA GCG GTG CCC TGC AAG GTG GA - #G CCA GGC CTG GGG GCT3249Pro Ser Gly Ala Ala Val Pro Cys Lys Val Gl - #u Pro Gly Leu Gly Ala# 10250- GAC AAC AGT GTG GTG CGC TTC CTG CCC CGT GA - #G GAA GGG CCC TAT GAG3297Asp Asn Ser Val Val Arg Phe Leu Pro Arg Gl - #u Glu Gly Pro Tyr Glu# 10405- GTG GAG GTG ACC TAT GAC GGC GTG CCC GTG CC - #T GGC AGC CCC TTT CCT3345Val Glu Val Thr Tyr Asp Gly Val Pro Val Pr - #o Gly Ser Pro Phe Pro# 10550- CTG GAA GCT GTG GCC CCC ACC AAG CCT AGC AA - #G GTG AAG GCG TTT GGG3393Leu Glu Ala Val Ala Pro Thr Lys Pro Ser Ly - #s Val Lys Ala Phe Gly# 10705- CCG GGG CTG CAG GGA GGC AGT GCG GGC TCC CC - #C GCC CGC TTC ACC ATC3441Pro Gly Leu Gln Gly Gly Ser Ala Gly Ser Pr - #o Ala Arg Phe Thr Ile# 10901080 - # 1085- GAC ACC AAG GGC GCC GGC ACA GGT GGC CTG GG - #C CTG ACG GTG GAG GGC3489Asp Thr Lys Gly Ala Gly Thr Gly Gly Leu Gl - #y Leu Thr Val Glu Gly# 11050- CCC TGT GAG GCG CAG CTC GAG TGC TTG GAC AA - #T GGG GAT GGC ACA TGT3537Pro Cys Glu Ala Gln Leu Glu Cys Leu Asp As - #n Gly Asp Gly Thr Cys# 11205- TCC GTG TCC TAC GTG CCC ACC GAG CCC GGG GA - #C TAC AAC ATC AAC ATC3585Ser Val Ser Tyr Val Pro Thr Glu Pro Gly As - #p Tyr Asn Ile Asn Ile# 11350- CTC TTC GCT GAC ACC CAC ATC CCT GGC TCC CC - #A TTC AAG GCC CAC GTG3633Leu Phe Ala Asp Thr His Ile Pro Gly Ser Pr - #o Phe Lys Ala His Val# 11505- GTT CCC TGC TTT GAC GCA TCC AAA GTC AAG TG - #C TCA GGC CCC GGG CTG3681Val Pro Cys Phe Asp Ala Ser Lys Val Lys Cy - #s Ser Gly Pro Gly Leu# 11701160 - # 1165- GAG CGG GCC ACC GCT GGG GAG GTG GGC CAA TT - #C CAA GTG GAC TGC TCG3729Glu Arg Ala Thr Ala Gly Glu Val Gly Gln Ph - #e Gln Val Asp Cys Ser# 11850- AGC GCG GGC AGC GCG GAG CTG ACC ATT GAG AT - #C TGC TCG GAG GCG GGG3777Ser Ala Gly Ser Ala Glu Leu Thr Ile Glu Il - #e Cys Ser Glu Ala Gly# 12005- CTT CCG GCC GAG GTG TAC ATC CAG GAC CAC GG - #T GAT GGC ACG CAC ACC3825Leu Pro Ala Glu Val Tyr Ile Gln Asp His Gl - #y Asp Gly Thr His Thr# 12150- ATT ACC TAC ATT CCC CTC TGC CCC GGG GCC TA - #C ACC GTC ACC ATC AAG3873Ile Thr Tyr Ile Pro Leu Cys Pro Gly Ala Ty - #r Thr Val Thr Ile Lys# 12305- TAC GGC GGC CAG CCC GTG CCC AAC TTC CCC AG - #C AAG CTG CAG GTG GAA3921Tyr Gly Gly Gln Pro Val Pro Asn Phe Pro Se - #r Lys Leu Gln Val Glu# 12501240 - # 1245- CCT GCG GTG GAC ACT TCC GGT GTC CAG TGC TA - #T GGG CCT GGT ATT GAG3969Pro Ala Val Asp Thr Ser Gly Val Gln Cys Ty - #r Gly Pro Gly Ile Glu# 12650- GGC CAG GGT GTC TTC CGT GAG GCC ACC ACT GA - #G TTC AGT GTG GAC GCC4017Gly Gln Gly Val Phe Arg Glu Ala Thr Thr Gl - #u Phe Ser Val Asp Ala# 12805- CGG GCT CTG ACA CAG ACC GGA GGG CCG CAC GT - #C AAG GCC CGT GTG GCC4065Arg Ala Leu Thr Gln Thr Gly Gly Pro His Va - #l Lys Ala Arg Val Ala# 12950- AAC CCC TCA GGC AAC CTG ACG GAG ACC TAC GT - #T CAG GAC CGT GGC GAT4113Asn Pro Ser Gly Asn Leu Thr Glu Thr Tyr Va - #l Gln Asp Arg Gly Asp# 13105- GGC ATG TAC AAA GTG GAG TAC ACG CCT TAC GA - #G GAG GGA CTG CAC TCC4161Gly Met Tyr Lys Val Glu Tyr Thr Pro Tyr Gl - #u Glu Gly Leu His Ser# 13301320 - # 1325- GTG GAC GTG ACC TAT GAC GGC AGT CCC GTG CC - #C AGC AGC CCC TTC CAG4209Val Asp Val Thr Tyr Asp Gly Ser Pro Val Pr - #o Ser Ser Pro Phe Gln# 13450- GTG CCC GTG ACC GAG GGC TGC GAC CCC TCC CG - #G GTG CGT GTC CAC GGG4257Val Pro Val Thr Glu Gly Cys Asp Pro Ser Ar - #g Val Arg Val His Gly# 13605- CCA GGC ATC CAA AGT GGC ACC ACC AAC AAG CC - #C AAC AAG TTC ACT GTG4305Pro Gly Ile Gln Ser Gly Thr Thr Asn Lys Pr - #o Asn Lys Phe Thr Val# 13750- GAG ACC AGG GGA GCT GGC ACG GGC GGC CTG GG - #C CTG GCT GTA GAG GGC4353Glu Thr Arg Gly Ala Gly Thr Gly Gly Leu Gl - #y Leu Ala Val Glu Gly# 13905- CCC TCC GAG GCC AAG ATG TCC TGC ATG GAT AA - #C AAG GAC GGC AGC TGC4401Pro Ser Glu Ala Lys Met Ser Cys Met Asp As - #n Lys Asp Gly Ser Cys# 14101400 - # 1405- TCG GTC GAG TAC ATC CCT TAT GAG GCT GGC AC - #C TAC AGC CTC AAC GTC4449Ser Val Glu Tyr Ile Pro Tyr Glu Ala Gly Th - #r Tyr Ser Leu Asn Val# 14250- ACC TAT GGT GGC CAT CAA GTG CCA GGC AGT CC - #T TTC AAG GTC CCT GTG4497Thr Tyr Gly Gly His Gln Val Pro Gly Ser Pr - #o Phe Lys Val Pro Val# 14405- CAT GAT GTG ACA GAT GCG TCC AAG GTC AAG TG - #C TCT GGG CCC GGC CTG4545His Asp Val Thr Asp Ala Ser Lys Val Lys Cy - #s Ser Gly Pro Gly Leu# 14550- AGC CCA GGC ATG GTT CGT GCC AAC CTC CCT CA - #G TCC TTC CAG GTG GAC4593Ser Pro Gly Met Val Arg Ala Asn Leu Pro Gl - #n Ser Phe Gln Val Asp# 14705- ACA AGC AAG GCT GGT GTG GCC CCA TTG CAG GT - #C AAA GTG CAA GGG CCC4641Thr Ser Lys Ala Gly Val Ala Pro Leu Gln Va - #l Lys Val Gln Gly Pro# 14901480 - # 1485- AAA GGC CTG GTG GAG CCA GTG GAC GTG GTA GA - #C AAC GCT GAT GGC ACC4689Lys Gly Leu Val Glu Pro Val Asp Val Val As - #p Asn Ala Asp Gly Thr# 15050- CAG ACC GTC AAT TAT GTG CCC AGC CGA GAA GG - #G CCC TAC AGC ATC TCA4737Gln Thr Val Asn Tyr Val Pro Ser Arg Glu Gl - #y Pro Tyr Ser Ile Ser# 15205- GTA CTG TAT GGA GAT GAA GAG GTA CCC CGG AG - #C CCC TTC AAG GTC AAG4785Val Leu Tyr Gly Asp Glu Glu Val Pro Arg Se - #r Pro Phe Lys Val Lys# 15350- GTG CTG CCT ACT CAT GAT GCC AGC AAG GTG AA - #G GCC AGT GGC CCC GGG4833Val Leu Pro Thr His Asp Ala Ser Lys Val Ly - #s Ala Ser Gly Pro Gly# 15505- CTC AAC ACC ACT GGC GTG CCT GCC AGC CTG CC - #C GTG GAG TTC ACC ATC4881Leu Asn Thr Thr Gly Val Pro Ala Ser Leu Pr - #o Val Glu Phe Thr Ile# 15701560 - # 1565- GAT GCA AAG GAC GCC GGG GAG GGC CTG CTG GC - #T GTC CAG ATC ACG GAT4929Asp Ala Lys Asp Ala Gly Glu Gly Leu Leu Al - #a Val Gln Ile Thr Asp# 15850- CCC GAA GGC AAG CCG AAG AAG ACA CAC ATC CA - #A GAC AAC CAT GAC GGC4977Pro Glu Gly Lys Pro Lys Lys Thr His Ile Gl - #n Asp Asn His Asp Gly# 16005- ACG TAT ACA GTG GCC TAC GTG CCA GAC GTG AC - #A GGT CGC TAC ACC ATC5025Thr Tyr Thr Val Ala Tyr Val Pro Asp Val Th - #r Gly Arg Tyr Thr Ile# 16150- CTC ATC AAG TAC GGT GGT GAC GAG ATC CCC TT - #C TCC CCG TAC CGC GTG5073Leu Ile Lys Tyr Gly Gly Asp Glu Ile Pro Ph - #e Ser Pro Tyr Arg Val# 16305- CGT GCC GTG CCC ACC GGG GAC GCC AGC AAG TG - #C ACT GTC ACA GTG TCA5121Arg Ala Val Pro Thr Gly Asp Ala Ser Lys Cy - #s Thr Val Thr Val Ser# 16501640 - # 1645- ATC GGA GGT CAC GGG CTA GGT GCT GGC ATC GG - #C CCC ACC ATT CAG ATT5169Ile Gly Gly His Gly Leu Gly Ala Gly Ile Gl - #y Pro Thr Ile Gln Ile# 16650- GGG GAG GAG ACG GTG ATC ACT GTG GAC ACT AA - #G GCG GCA GGC AAA GGC5217Gly Glu Glu Thr Val Ile Thr Val Asp Thr Ly - #s Ala Ala Gly Lys Gly# 16805- AAA GTG ACG TGC ACC GTG TGC ACG CCT GAT GG - #C TCA GAG GTG GAT GTG5265Lys Val Thr Cys Thr Val Cys Thr Pro Asp Gl - #y Ser Glu Val Asp Val# 16950- GAC GTG GTG GAG AAT GAG GAC GGC ACT TTC GA - #C ATC TTC TAC ACG GCC5313Asp Val Val Glu Asn Glu Asp Gly Thr Phe As - #p Ile Phe Tyr Thr Ala# 17105- CCC CAG CCG GGC AAA TAC GTC ATC TGT GTG CG - #C TTT GGT GGC GAG CAC5361Pro Gln Pro Gly Lys Tyr Val Ile Cys Val Ar - #g Phe Gly Gly Glu His# 17301720 - # 1725- GTG CCC AAC AGC CCC TTC CAA GTG ACG GCT CT - #G GCT GGG GAC CAG CCC5409Val Pro Asn Ser Pro Phe Gln Val Thr Ala Le - #u Ala Gly Asp Gln Pro# 17450- TCG GTG CAG CCC CCT CTA CGG TCT CAG CAG CT - #G GCC CCA CAG TAC ACC5457Ser Val Gln Pro Pro Leu Arg Ser Gln Gln Le - #u Ala Pro Gln Tyr Thr# 17605- TAC GCC CAG GGC GGC CAG CAG ACT TGG GCC CC - #G GAG AGG CCC CTG GTG5505Tyr Ala Gln Gly Gly Gln Gln Thr Trp Ala Pr - #o Glu Arg Pro Leu Val# 17750- GGT GTC AAT GGG CTG GAT GTG ACC AGC CTG AG - #G CCC TTT GAC CTT GTC5553Gly Val Asn Gly Leu Asp Val Thr Ser Leu Ar - #g Pro Phe Asp Leu Val# 17905- ATC CCC TTC ACC ATC AAG AAG GGC GAG ATC AC - #A GGG GAG GTT CGG ATG5601Ile Pro Phe Thr Ile Lys Lys Gly Glu Ile Th - #r Gly Glu Val Arg Met# 18101800 - # 1805- CCC TCA GGC AAG GTG GCG CAG CCC ACC ATC AC - #T GAC AAC AAA GAC GGC5649Pro Ser Gly Lys Val Ala Gln Pro Thr Ile Th - #r Asp Asn Lys Asp Gly# 18250- ACC GTG ACC GTG CGG TAT GCA CCC AGC GAG GC - #T GGC CTG CAC GAG ATG5697Thr Val Thr Val Arg Tyr Ala Pro Ser Glu Al - #a Gly Leu His Glu Met# 18405- GAC ATC CGC TAT GAC AAC ATG CAC ATC CCA GG - #A AGC CCC TTG CAG TTC5745Asp Ile Arg Tyr Asp Asn Met His Ile Pro Gl - #y Ser Pro Leu Gln Phe# 18550- TAT GTG GAT TAC GTC AAC TGT GGC CAT GTC AC - #T GCC TAT GGG CCT GGC5793Tyr Val Asp Tyr Val Asn Cys Gly His Val Th - #r Ala Tyr Gly Pro Gly# 18705- CTC ACC CAT GGA GTA GTG AAC AAG CCT GCC AC - #C TTC ACC GTC AAC ACC5841Leu Thr His Gly Val Val Asn Lys Pro Ala Th - #r Phe Thr Val Asn Thr# 18901880 - # 1885- AAG GAT GCA GGA GAG GGG GGC CTG TCT CTG GC - #C ATT GAG GGC CCG TCC5889Lys Asp Ala Gly Glu Gly Gly Leu Ser Leu Al - #a Ile Glu Gly Pro Ser# 19050- AAA GCA GAA ATC AGC TGC ACT GAC AAC CAG GA - #T GGG ACA TGC AGC GTG5937Lys Ala Glu Ile Ser Cys Thr Asp Asn Gln As - #p Gly Thr Cys Ser Val# 19205- TCC TAC CTG CCT GTG CTG CCG GGG GAC TAC AG - #C ATT CTA GTC AAG TAC5985Ser Tyr Leu Pro Val Leu Pro Gly Asp Tyr Se - #r Ile Leu Val Lys Tyr# 19350- AAT GAA CAG CAC GTC CCA GGC AGC CCC TTC AC - #T GCT CGG GTC ACA GGT6033Asn Glu Gln His Val Pro Gly Ser Pro Phe Th - #r Ala Arg Val Thr Gly# 19505- GAC GAC TCC ATG CGT ATG TCC CAC CTA AAG GT - #C GGC TCT GCT GCC GAC6081Asp Asp Ser Met Arg Met Ser His Leu Lys Va - #l Gly Ser Ala Ala Asp# 19701960 - # 1965- ATC CCC ATC AAC ATC TCA GAG ACG GAT CTC AG - #C CTG CTG ACG GCC ACT6129Ile Pro Ile Asn Ile Ser Glu Thr Asp Leu Se - #r Leu Leu Thr Ala Thr# 19850- GTG GTC CCG CCC TCG GGC CGG GAG GAG CCC TG - #T TTG CTG AAG CGG CTG6177Val Val Pro Pro Ser Gly Arg Glu Glu Pro Cy - #s Leu Leu Lys Arg Leu# 20005- CGT AAT GGC CAC GTG GGG ATT TCA TTC GTG CC - #C AAG GAG ACG GGG GAG6225Arg Asn Gly His Val Gly Ile Ser Phe Val Pr - #o Lys Glu Thr Gly Glu# 20150- CAC CTG GTG CAT GTG AAG AAA AAT GGC CAG CA - #C GTG GCC AGC AGC CCC6273His Leu Val His Val Lys Lys Asn Gly Gln Hi - #s Val Ala Ser Ser Pro# 20305- ATC CCG GTG GTG ATC AGC CAG TCG GAA ATT GG - #G GAT GCC AGT CGT GTT6321Ile Pro Val Val Ile Ser Gln Ser Glu Ile Gl - #y Asp Ala Ser Arg Val# 20502040 - # 2045- CGG GTC TCT GGT CAG GGC CTT CAC GAA GGC CA - #C ACC TTT GAG CCT GCA6369Arg Val Ser Gly Gln Gly Leu His Glu Gly Hi - #s Thr Phe Glu Pro Ala# 20650- GAG TTT ATC ATT GAT ACC CGC GAT GCA GGC TA - #T GGT GGG CTC AGC CTG6417Glu Phe Ile Ile Asp Thr Arg Asp Ala Gly Ty - #r Gly Gly Leu Ser Leu# 20805- TCC ATT GAG GGC CCC AGC AAG GTG GAC ATC AA - #C ACA GAG GAC CTG GAG6465Ser Ile Glu Gly Pro Ser Lys Val Asp Ile As - #n Thr Glu Asp Leu Glu# 20950- GAC GGG ACG TGC AGG GTC ACC TAC TGC CCC AC - #A GAG CCA GGC AAC TAC6513Asp Gly Thr Cys Arg Val Thr Tyr Cys Pro Th - #r Glu Pro Gly Asn Tyr# 21105- ATC ATC AAC ATC AAG TTT GCC GAC CAG CAC GT - #G CCT GGC AGC CCC TTC6561Ile Ile Asn Ile Lys Phe Ala Asp Gln His Va - #l Pro Gly Ser Pro Phe# 21302120 - # 2125- TCT GTG AAG GTG ACA GGC GAG GGC CGG GTG AA - #A GAG AGC ATC ACC CGC6609Ser Val Lys Val Thr Gly Glu Gly Arg Val Ly - #s Glu Ser Ile Thr Arg# 21450- AGG CGT CGG GCT CCT TCA GTG GCC AAC GTT GG - #T AGT CAT TGT GAC CTC6657Arg Arg Arg Ala Pro Ser Val Ala Asn Val Gl - #y Ser His Cys Asp Leu# 21605- AGC CTG AAA ATC CCT GAA ATT AGC ATC CAG GA - #T ATG ACA GCC CAG GTG6705Ser Leu Lys Ile Pro Glu Ile Ser Ile Gln As - #p Met Thr Ala Gln Val# 21750- ACC AGC CCA TCG GGC AAG ACC CAT GAG GCC GA - #G ATC GTG GAA GGG GAG6753Thr Ser Pro Ser Gly Lys Thr His Glu Ala Gl - #u Ile Val Glu Gly Glu# 21905- AAC CAC ACC TAC TGC ATC CGC TTT GTT CCC GC - #T GAG ATG GGC ACA CAC6801Asn His Thr Tyr Cys Ile Arg Phe Val Pro Al - #a Glu Met Gly Thr His# 22102200 - # 2205- ACA GTC AGC GTC AAG TAC AAG GGC CAG CAC GT - #G CCT GGG AGC CCC TTC6849Thr Val Ser Val Lys Tyr Lys Gly Gln His Va - #l Pro Gly Ser Pro Phe# 22250- CAG TTC ACC GTG GGG CCC CTA GGG GAA GGG GG - #A GCC CAC AAG GTC CGA6897Gln Phe Thr Val Gly Pro Leu Gly Glu Gly Gl - #y Ala His Lys Val Arg# 22405- GCT GGG GGC CCT GGC CTG GAG AGA GCT GAA GC - #T GGA GTG CCA GCC GAA6945Ala Gly Gly Pro Gly Leu Glu Arg Ala Glu Al - #a Gly Val Pro Ala Glu# 22550- TTC AGT ATC TGG ACC CGG GAA GCT GGT GCT GG - #A GGC CTG GCC ATT GCT6993Phe Ser Ile Trp Thr Arg Glu Ala Gly Ala Gl - #y Gly Leu Ala Ile Ala# 22705- GTC GAG GGC CCC AGC AAG GCT GAG ATC TCT TT - #T GAG GAC CGC AAG GAC7041Val Glu Gly Pro Ser Lys Ala Glu Ile Ser Ph - #e Glu Asp Arg Lys Asp# 22902280 - # 2285- GGC TCC TGT GGT GTG GCT TAT GTG GTC CAG GA - #G CCA GGT GAC TAC GAA7089Gly Ser Cys Gly Val Ala Tyr Val Val Gln Gl - #u Pro Gly Asp Tyr Glu# 23050- GTC TCA GTC AAG TTC AAC GAG GAA CAC ATT CC - #C GAC AGC CCC TTC GTG7137Val Ser Val Lys Phe Asn Glu Glu His Ile Pr - #o Asp Ser Pro Phe Val# 23205- GTG CCT GTG GCT TCT CCG TCT GGC GAC GCC CG - #C CGC CTC ACT GTT TCT7185Val Pro Val Ala Ser Pro Ser Gly Asp Ala Ar - #g Arg Leu Thr Val Ser# 23350- AGC CTT CAG GAG TCA GGG CTA AAG GTC AAC CA - #G CCA GCC TCT TTT GCA7233Ser Leu Gln Glu Ser Gly Leu Lys Val Asn Gl - #n Pro Ala Ser Phe Ala# 23505- GTC AGC CTG AAC GGG GCC AAG GGG GCG ATC GA - #T GCC AAG GTG CAC AGC7281Val Ser Leu Asn Gly Ala Lys Gly Ala Ile As - #p Ala Lys Val His Ser# 23702360 - # 2365- CCC TCA GGA GCC CTG GAG GAG TGC TAT GTC AC - #A GAA ATT GAC CAA GAT7329Pro Ser Gly Ala Leu Glu Glu Cys Tyr Val Th - #r Glu Ile Asp Gln Asp# 23850- AAG TAT GCT GTG CGC TTC ATC CCT CGG GAG AA - #T GGC GTT TAC CTG ATT7377Lys Tyr Ala Val Arg Phe Ile Pro Arg Glu As - #n Gly Val Tyr Leu Ile# 24005- GAC GTC AAG TTC AAC GGT ACC CAC ATC CCT GG - #A AGC CCC TTC AAG ATC7425Asp Val Lys Phe Asn Gly Thr His Ile Pro Gl - #y Ser Pro Phe Lys Ile# 24150- CGA GTT GGG GAG CCT GGG CAT GGA GGG GAC CC - #A GGC TTG GTG TCT GCT7473Arg Val Gly Glu Pro Gly His Gly Gly Asp Pr - #o Gly Leu Val Ser Ala# 24305- TAC GGA GCA GGT CTG GAA GGC GGT GTC ACA GG - #G AAC CCA GCT GAG TTC7521Tyr Gly Ala Gly Leu Glu Gly Gly Val Thr Gl - #y Asn Pro Ala Glu Phe# 24502440 - # 2445- GTC GTG AAC ACG AGC AAT GCG GGA GCT GGT GC - #C CTG TCG GTG ACC ATT7569Val Val Asn Thr Ser Asn Ala Gly Ala Gly Al - #a Leu Ser Val Thr Ile# 24650- GAC GGC CCC TCC AAG GTG AAG ATG GAT TGC CA - #G GAG TGC CCT GAG GGC7617Asp Gly Pro Ser Lys Val Lys Met Asp Cys Gl - #n Glu Cys Pro Glu Gly# 24805- TAC CGC GTC ACC TAT ACC CCC ATG GCA CCT GG - #C AGC TAC CTC ATC TCC7665Tyr Arg Val Thr Tyr Thr Pro Met Ala Pro Gl - #y Ser Tyr Leu Ile Ser# 24950- ATC AAG TAC GGC GGC CCC TAC CAC ATT GGG GG - #C AGC CCC TTC AAG GCC7713Ile Lys Tyr Gly Gly Pro Tyr His Ile Gly Gl - #y Ser Pro Phe Lys Ala# 25105- AAA GTC ACA GGC CCC CGT CTC GTC AGC AAC CA - #C AGC CTC CAC GAG ACA7761Lys Val Thr Gly Pro Arg Leu Val Ser Asn Hi - #s Ser Leu His Glu Thr# 25302520 - # 2525- TCA TCA GTG TTT GTA GAC TCT CTG ACC AAG GC - #C ACC TGT GCC CCC CAG7809Ser Ser Val Phe Val Asp Ser Leu Thr Lys Al - #a Thr Cys Ala Pro Gln# 25450- CAT GGG GCC CCG GGT CCT GGG CCT GCT GAC GC - #C AGC AAG GTG GTG GCC7857His Gly Ala Pro Gly Pro Gly Pro Ala Asp Al - #a Ser Lys Val Val Ala# 25605- AAG GGC CTG GGG CTG AGC AAG GCC TAC GTA GG - #C CAG AAG AGC AGC TTC7905Lys Gly Leu Gly Leu Ser Lys Ala Tyr Val Gl - #y Gln Lys Ser Ser Phe# 25750- ACA GTA GAC TGC AGC AAA GCA GGC AAC AAC AT - #G CTG CTG GTG GGG GTT7953Thr Val Asp Cys Ser Lys Ala Gly Asn Asn Me - #t Leu Leu Val Gly Val# 25905- CAT GGC CCA AGG ACC CCC TGC GAG GAG ATC CT - #G GTG AAG CAC GTG GGC8001His Gly Pro Arg Thr Pro Cys Glu Glu Ile Le - #u Val Lys His Val Gly# 26102600 - # 2605- AGC CGG CTC TAC AGC GTG TCC TAC CTG CTC AA - #G GAC AAG GGG GAG TAC8049Ser Arg Leu Tyr Ser Val Ser Tyr Leu Leu Ly - #s Asp Lys Gly Glu Tyr# 26250- ACA CTG GTG GTC AAA TGG GGG CAC GAG CAC AT - #C CCA GGC AGC CCC TAC8097Thr Leu Val Val Lys Trp Gly His Glu His Il - #e Pro Gly Ser Pro Tyr# 26405- CGC GTT GTG GTG CCC TGAGTCTGGG GCCCGTGCCA GCCGGCAGC - #C CCCAAGCCTG8152Arg Val Val Val Pro 2645- CCCCGCTACC CAAGCAGCCC CGCCCTCTTC CCCTCAACCC CGGCCCAGGC CG - #CCCTGGCC8212- GCCCGCCTGT CACTGCAGCT GCCCCTGCCC TGTGCCGTGC TGCGCTCACC TG - #CCTCCCCA8272- GCCAGCCGCT GACCTCTCGG CTTTCACTTG GGCAGAGGGA GCCATTTGGT GG - #CGCTGCTT8332# 8367 GGAG GGGTGAGGGA TGGGG- (2) INFORMATION FOR SEQ ID NO:8:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 2647 amino (B) TYPE: amino acid (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: protein- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:8:- Met Ser Ser Ser His Ser Arg Ala Gly Gln Se - #r Ala Ala Gly Ala Ala# 15- Pro Gly Gly Gly Val Asp Thr Arg Asp Ala Gl - #u Met Pro Ala Thr Glu# 30- Lys Asp Leu Ala Glu Asp Ala Pro Trp Lys Ly - #s Ile Gln Gln Asn Thr# 45- Phe Thr Arg Trp Cys Asn Glu His Leu Lys Cy - #s Val Ser Lys Arg Ile# 60- Ala Asn Leu Gln Thr Asp Leu Ser Asp Gly Le - #u Arg Leu Ile Ala Leu# 80- Leu Glu Val Leu Ser Gln Lys Lys Met His Ar - #g Lys His Asn Gln Arg# 95- Pro Thr Phe Arg Gln Met Gln Leu Glu Asn Va - #l Ser Val Ala Leu Glu# 110- Phe Leu Asp Arg Glu Ser Ile Lys Leu Val Se - #r Ile Asp Ser Lys Ala# 125- Ile Val Asp Gly Asn Leu Lys Leu Ile Leu Gl - #y Leu Ile Trp Thr Leu# 140- Ile Leu His Tyr Ser Ile Ser Met Pro Met Tr - #p Asp Glu Glu Glu Asp145 1 - #50 1 - #55 1 -#60- Glu Glu Ala Lys Lys Gln Thr Pro Lys Gln Ar - #g Leu Leu Gly Trp Ile# 175- Gln Asn Lys Leu Pro Gln Leu Pro Ile Thr As - #n Phe Ser Arg Asp Trp# 190- Gln Ser Gly Arg Ala Leu Gly Ala Leu Val As - #p Ser Cys Ala Pro Gly# 205- Leu Cys Pro Asp Trp Asp Ser Trp Asp Ala Se - #r Lys Pro Val Thr Asn# 220- Ala Arg Glu Ala Met Gln Gln Ala Asp Asp Tr - #p Leu Gly Ile Pro Gln225 2 - #30 2 - #35 2 -#40- Val Ile Thr Pro Glu Glu Ile Val Asp Pro As - #n Val Asp Glu His Ser# 255- Val Met Thr Tyr Leu Ser Gln Phe Pro Lys Al - #a Lys Leu Lys Pro Gly# 270- Ala Pro Leu Arg Pro Lys Leu Asn Pro Lys Ly - #s Ala Arg Ala Tyr Gly# 285- Pro Gly Ile Glu Pro Thr Gly Asn Met Val Ly - #s Lys Arg Ala Glu Phe# 300- Thr Val Glu Thr Arg Ser Ala Gly Gln Gly Gl - #u Val Leu Val Tyr Val305 3 - #10 3 - #15 3 -#20- Glu Asp Pro Ala Gly His Gln Glu Glu Ala Ly - #s Val Thr Ala Asn Asn# 335- Asp Lys Asn Arg Thr Phe Ser Val Trp Tyr Va - #l Pro Glu Val Thr Gly# 350- Thr His Lys Val Thr Val Leu Phe Ala Gly Gl - #n His Ile Ala Lys Ser# 365- Pro Phe Glu Val Tyr Val Asp Lys Ser Gln Gl - #y Asp Ala Ser Lys Val# 380- Thr Ala Gln Gly Pro Gly Leu Glu Pro Ser Gl - #y Asn Ile Ala Asn Lys385 3 - #90 3 - #95 4 -#00- Thr Thr Tyr Phe Glu Ile Phe Thr Ala Gly Al - #a Gly Thr Gly Glu Val# 415- Glu Val Val Ile Gln Asp Pro Met Gly Gln Ly - #s Gly Thr Val Glu Pro# 430- Gln Leu Glu Ala Arg Gly Asp Ser Thr Tyr Ar - #g Cys Ser Tyr Gln Pro# 445- Thr Met Glu Gly Val His Thr Val His Val Th - #r Phe Ala Gly Val Pro# 460- Ile Pro Arg Ser Pro Tyr Thr Val Thr Val Gl - #y Gln Ala Cys Asn Pro465 4 - #70 4 - #75 4 -#80- Ser Ala Cys Arg Ala Val Gly Arg Gly Leu Gl - #n Pro Lys Gly Val Arg# 495- Val Lys Glu Thr Ala Asp Phe Lys Val Tyr Th - #r Lys Gly Ala Gly Ser# 510- Gly Glu Leu Lys Val Thr Val Lys Gly Pro Ly - #s Gly Glu Glu Arg Val# 525- Lys Gln Lys Asp Leu Gly Asp Gly Val Tyr Gl - #y Phe Glu Tyr Tyr Pro# 540- Met Val Pro Gly Thr Tyr Ile Val Thr Ile Th - #r Trp Gly Gly Gln Asn545 5 - #50 5 - #55 5 -#60- Ile Gly Arg Ser Pro Phe Glu Val Lys Val Gl - #y Thr Glu Cys Gly Asn# 575- Gln Lys Val Arg Ala Trp Gly Pro Gly Leu Gl - #u Gly Gly Val Val Gly# 590- Lys Ser Ala Asp Phe Val Val Glu Ala Ile Gl - #y Asp Asp Val Gly Thr# 605- Leu Gly Phe Ser Val Glu Gly Pro Ser Gln Al - #a Lys Ile Glu Cys Asp# 620- Asp Lys Gly Asp Gly Ser Cys Asp Val Arg Ty - #r Trp Pro Gln Glu Ala625 6 - #30 6 - #35 6 -#40- Gly Glu Tyr Ala Val His Val Leu Cys Asn Se - #r Glu Asp Ile Arg Leu# 655- Ser Pro Phe Met Ala Asp Ile Arg Asp Ala Pr - #o Gln Asp Phe His Pro# 670- Asp Arg Val Lys Ala Arg Gly Pro Gly Leu Gl - #u Lys Thr Gly Val Ala# 685- Val Asn Lys Pro Ala Glu Phe Thr Val Asp Al - #a Lys His Gly Gly Lys# 700- Ala Pro Leu Arg Val Gln Val Gln Asp Asn Gl - #u Gly Cys Pro Val Glu705 7 - #10 7 - #15 7 -#20- Ala Leu Val Lys Asp Asn Gly Asn Gly Thr Ty - #r Ser Cys Ser Tyr Val# 735- Pro Arg Lys Pro Val Lys His Thr Ala Met Va - #l Ser Trp Gly Gly Val# 750- Ser Ile Pro Asn Ser Pro Phe Arg Val Asn Va - #l Gly Ala Gly Ser His# 765- Pro Asn Lys Val Lys Val Tyr Gly Pro Gly Va - #l Ala Lys Thr Gly Leu# 780- Lys Ala His Glu Pro Thr Tyr Phe Thr Val As - #p Cys Ala Glu Ala Gly785 7 - #90 7 - #95 8 -#00- Gln Gly Asp Val Ser Ile Gly Ile Lys Cys Al - #a Pro Gly Val Val Gly# 815- Pro Ala Glu Ala Asp Ile Asp Phe Asp Ile Il - #e Arg Asn Asp Asn Asp# 830- Thr Phe Thr Val Lys Tyr Thr Pro Arg Gly Al - #a Gly Ser Tyr Thr Ile# 845- Met Val Leu Phe Ala Asp Gln Ala Thr Pro Th - #r Ser Pro Ile Arg Val# 860- Lys Val Glu Pro Ser His Asp Ala Ser Lys Va - #l Lys Ala Glu Gly Pro865 8 - #70 8 - #75 8 -#80- Gly Leu Ser Arg Thr Gly Val Glu Leu Gly Ly - #s Pro Thr His Phe Thr# 895- Val Asn Ala Lys Ala Ala Gly Lys Gly Lys Le - #u Asp Val Gln Phe Ser# 910- Gly Leu Thr Lys Gly Asp Ala Val Arg Asp Va - #l Asp Ile Ile Asp His# 925- His Asp Asn Thr Tyr Thr Val Lys Tyr Thr Pr - #o Val Gln Gln Gly Pro# 940- Val Gly Val Asn Val Thr Tyr Gly Gly Asp Pr - #o Ile Pro Lys Ser Pro945 9 - #50 9 - #55 9 -#60- Phe Ser Val Ala Val Ser Pro Ser Leu Asp Le - #u Ser Lys Ile Lys Val# 975- Ser Gly Leu Gly Glu Lys Val Asp Val Gly Ly - #s Asp Gln Glu Phe Thr# 990- Val Lys Ser Lys Gly Ala Gly Gly Gln Gly Ly - #s Val Ala Ser Lys Ile# 10050- Val Gly Pro Ser Gly Ala Ala Val Pro Cys Ly - #s Val Glu Pro Gly Leu# 10205- Gly Ala Asp Asn Ser Val Val Arg Phe Leu Pr - #o Arg Glu Glu Gly Pro# 10401030 - # 1035- Tyr Glu Val Glu Val Thr Tyr Asp Gly Val Pr - #o Val Pro Gly Ser Pro# 10550- Phe Pro Leu Glu Ala Val Ala Pro Thr Lys Pr - #o Ser Lys Val Lys Ala# 10705- Phe Gly Pro Gly Leu Gln Gly Gly Ser Ala Gl - #y Ser Pro Ala Arg Phe# 10850- Thr Ile Asp Thr Lys Gly Ala Gly Thr Gly Gl - #y Leu Gly Leu Thr Val# 11005- Glu Gly Pro Cys Glu Ala Gln Leu Glu Cys Le - #u Asp Asn Gly Asp Gly# 11201110 - # 1115- Thr Cys Ser Val Ser Tyr Val Pro Thr Glu Pr - #o Gly Asp Tyr Asn Ile# 11350- Asn Ile Leu Phe Ala Asp Thr His Ile Pro Gl - #y Ser Pro Phe Lys Ala# 11505- His Val Val Pro Cys Phe Asp Ala Ser Lys Va - #l Lys Cys Ser Gly Pro# 11650- Gly Leu Glu Arg Ala Thr Ala Gly Glu Val Gl - #y Gln Phe Gln Val Asp# 11805- Cys Ser Ser Ala Gly Ser Ala Glu Leu Thr Il - #e Glu Ile Cys Ser Glu# 12001190 - # 1195- Ala Gly Leu Pro Ala Glu Val Tyr Ile Gln As - #p His Gly Asp Gly Thr# 12150- His Thr Ile Thr Tyr Ile Pro Leu Cys Pro Gl - #y Ala Tyr Thr Val Thr# 12305- Ile Lys Tyr Gly Gly Gln Pro Val Pro Asn Ph - #e Pro Ser Lys Leu Gln# 12450- Val Glu Pro Ala Val Asp Thr Ser Gly Val Gl - #n Cys Tyr Gly Pro Gly# 12605- Ile Glu Gly Gln Gly Val Phe Arg Glu Ala Th - #r Thr Glu Phe Ser Val# 12801270 - # 1275- Asp Ala Arg Ala Leu Thr Gln Thr Gly Gly Pr - #o His Val Lys Ala Arg# 12950- Val Ala Asn Pro Ser Gly Asn Leu Thr Glu Th - #r Tyr Val Gln Asp Arg# 13105- Gly Asp Gly Met Tyr Lys Val Glu Tyr Thr Pr - #o Tyr Glu Glu Gly Leu# 13250- His Ser Val Asp Val Thr Tyr Asp Gly Ser Pr - #o Val Pro Ser Ser Pro# 13405- Phe Gln Val Pro Val Thr Glu Gly Cys Asp Pr - #o Ser Arg Val Arg Val# 13601350 - # 1355- His Gly Pro Gly Ile Gln Ser Gly Thr Thr As - #n Lys Pro Asn Lys Phe# 13750- Thr Val Glu Thr Arg Gly Ala Gly Thr Gly Gl - #y Leu Gly Leu Ala Val# 13905- Glu Gly Pro Ser Glu Ala Lys Met Ser Cys Me - #t Asp Asn Lys Asp Gly# 14050- Ser Cys Ser Val Glu Tyr Ile Pro Tyr Glu Al - #a Gly Thr Tyr Ser Leu# 14205- Asn Val Thr Tyr Gly Gly His Gln Val Pro Gl - #y Ser Pro Phe Lys Val# 14401430 - # 1435- Pro Val His Asp Val Thr Asp Ala Ser Lys Va - #l Lys Cys Ser Gly Pro# 14550- Gly Leu Ser Pro Gly Met Val Arg Ala Asn Le - #u Pro Gln Ser Phe Gln# 14705- Val Asp Thr Ser Lys Ala Gly Val Ala Pro Le - #u Gln Val Lys Val Gln# 14850- Gly Pro Lys Gly Leu Val Glu Pro Val Asp Va - #l Val Asp Asn Ala Asp# 15005- Gly Thr Gln Thr Val Asn Tyr Val Pro Ser Ar - #g Glu Gly Pro Tyr Ser# 15201510 - # 1515- Ile Ser Val Leu Tyr Gly Asp Glu Glu Val Pr - #o Arg Ser Pro Phe Lys# 15350- Val Lys Val Leu Pro Thr His Asp Ala Ser Ly - #s Val Lys Ala Ser Gly# 15505- Pro Gly Leu Asn Thr Thr Gly Val Pro Ala Se - #r Leu Pro Val Glu Phe# 15650- Thr Ile Asp Ala Lys Asp Ala Gly Glu Gly Le - #u Leu Ala Val Gln Ile# 15805- Thr Asp Pro Glu Gly Lys Pro Lys Lys Thr Hi - #s Ile Gln Asp Asn His# 16001590 - # 1595- Asp Gly Thr Tyr Thr Val Ala Tyr Val Pro As - #p Val Thr Gly Arg Tyr# 16150- Thr Ile Leu Ile Lys Tyr Gly Gly Asp Glu Il - #e Pro Phe Ser Pro Tyr# 16305- Arg Val Arg Ala Val Pro Thr Gly Asp Ala Se - #r Lys Cys Thr Val Thr# 16450- Val Ser Ile Gly Gly His Gly Leu Gly Ala Gl - #y Ile Gly Pro Thr Ile# 16605- Gln Ile Gly Glu Glu Thr Val Ile Thr Val As - #p Thr Lys Ala Ala Gly# 16801670 - # 1675- Lys Gly Lys Val Thr Cys Thr Val Cys Thr Pr - #o Asp Gly Ser Glu Val# 16950- Asp Val Asp Val Val Glu Asn Glu Asp Gly Th - #r Phe Asp Ile Phe Tyr# 17105- Thr Ala Pro Gln Pro Gly Lys Tyr Val Ile Cy - #s Val Arg Phe Gly Gly# 17250- Glu His Val Pro Asn Ser Pro Phe Gln Val Th - #r Ala Leu Ala Gly Asp# 17405- Gln Pro Ser Val Gln Pro Pro Leu Arg Ser Gl - #n Gln Leu Ala Pro Gln# 17601750 - # 1755- Tyr Thr Tyr Ala Gln Gly Gly Gln Gln Thr Tr - #p Ala Pro Glu Arg Pro# 17750- Leu Val Gly Val Asn Gly Leu Asp Val Thr Se - #r Leu Arg Pro Phe Asp# 17905- Leu Val Ile Pro Phe Thr Ile Lys Lys Gly Gl - #u Ile Thr Gly Glu Val# 18050- Arg Met Pro Ser Gly Lys Val Ala Gln Pro Th - #r Ile Thr Asp Asn Lys# 18205- Asp Gly Thr Val Thr Val Arg Tyr Ala Pro Se - #r Glu Ala Gly Leu His# 18401830 - # 1835- Glu Met Asp Ile Arg Tyr Asp Asn Met His Il - #e Pro Gly Ser Pro Leu# 18550- Gln Phe Tyr Val Asp Tyr Val Asn Cys Gly Hi - #s Val Thr Ala Tyr Gly# 18705- Pro Gly Leu Thr His Gly Val Val Asn Lys Pr - #o Ala Thr Phe Thr Val# 18850- Asn Thr Lys Asp Ala Gly Glu Gly Gly Leu Se - #r Leu Ala Ile Glu Gly# 19005- Pro Ser Lys Ala Glu Ile Ser Cys Thr Asp As - #n Gln Asp Gly Thr Cys# 19201910 - # 1915- Ser Val Ser Tyr Leu Pro Val Leu Pro Gly As - #p Tyr Ser Ile Leu Val# 19350- Lys Tyr Asn Glu Gln His Val Pro Gly Ser Pr - #o Phe Thr Ala Arg Val# 19505- Thr Gly Asp Asp Ser Met Arg Met Ser His Le - #u Lys Val Gly Ser Ala# 19650- Ala Asp Ile Pro Ile Asn Ile Ser Glu Thr As - #p Leu Ser Leu Leu Thr# 19805- Ala Thr Val Val Pro Pro Ser Gly Arg Glu Gl - #u Pro Cys Leu Leu Lys# 20001990 - # 1995- Arg Leu Arg Asn Gly His Val Gly Ile Ser Ph - #e Val Pro Lys Glu Thr# 20150- Gly Glu His Leu Val His Val Lys Lys Asn Gl - #y Gln His Val Ala Ser# 20305- Ser Pro Ile Pro Val Val Ile Ser Gln Ser Gl - #u Ile Gly Asp Ala Ser# 20450- Arg Val Arg Val Ser Gly Gln Gly Leu His Gl - #u Gly His Thr Phe Glu# 20605- Pro Ala Glu Phe Ile Ile Asp Thr Arg Asp Al - #a Gly Tyr Gly Gly Leu# 20802070 - # 2075- Ser Leu Ser Ile Glu Gly Pro Ser Lys Val As - #p Ile Asn Thr Glu Asp# 20950- Leu Glu Asp Gly Thr Cys Arg Val Thr Tyr Cy - #s Pro Thr Glu Pro Gly# 21105- Asn Tyr Ile Ile Asn Ile Lys Phe Ala Asp Gl - #n His Val Pro Gly Ser# 21250- Pro Phe Ser Val Lys Val Thr Gly Glu Gly Ar - #g Val Lys Glu Ser Ile# 21405- Thr Arg Arg Arg Arg Ala Pro Ser Val Ala As - #n Val Gly Ser His Cys# 21602150 - # 2155- Asp Leu Ser Leu Lys Ile Pro Glu Ile Ser Il - #e Gln Asp Met Thr Ala# 21750- Gln Val Thr Ser Pro Ser Gly Lys Thr His Gl - #u Ala Glu Ile Val Glu# 21905- Gly Glu Asn His Thr Tyr Cys Ile Arg Phe Va - #l Pro Ala Glu Met Gly# 22050- Thr His Thr Val Ser Val Lys Tyr Lys Gly Gl - #n His Val Pro Gly Ser# 22205- Pro Phe Gln Phe Thr Val Gly Pro Leu Gly Gl - #u Gly Gly Ala His Lys# 22402230 - # 2235- Val Arg Ala Gly Gly Pro Gly Leu Glu Arg Al - #a Glu Ala Gly Val Pro# 22550- Ala Glu Phe Ser Ile Trp Thr Arg Glu Ala Gl - #y Ala Gly Gly Leu Ala# 22705- Ile Ala Val Glu Gly Pro Ser Lys Ala Glu Il - #e Ser Phe Glu Asp Arg# 22850- Lys Asp Gly Ser Cys Gly Val Ala Tyr Val Va - #l Gln Glu Pro Gly Asp# 23005- Tyr Glu Val Ser Val Lys Phe Asn Glu Glu Hi - #s Ile Pro Asp Ser Pro# 23202310 - # 2315- Phe Val Val Pro Val Ala Ser Pro Ser Gly As - #p Ala Arg Arg Leu Thr# 23350- Val Ser Ser Leu Gln Glu Ser Gly Leu Lys Va - #l Asn Gln Pro Ala Ser# 23505- Phe Ala Val Ser Leu Asn Gly Ala Lys Gly Al - #a Ile Asp Ala Lys Val# 23650- His Ser Pro Ser Gly Ala Leu Glu Glu Cys Ty - #r Val Thr Glu Ile Asp# 23805- Gln Asp Lys Tyr Ala Val Arg Phe Ile Pro Ar - #g Glu Asn Gly Val Tyr# 24002390 - # 2395- Leu Ile Asp Val Lys Phe Asn Gly Thr His Il - #e Pro Gly Ser Pro Phe# 24150- Lys Ile Arg Val Gly Glu Pro Gly His Gly Gl - #y Asp Pro Gly Leu Val# 24305- Ser Ala Tyr Gly Ala Gly Leu Glu Gly Gly Va - #l Thr Gly Asn Pro Ala# 24450- Glu Phe Val Val Asn Thr Ser Asn Ala Gly Al - #a Gly Ala Leu Ser Val# 24605- Thr Ile Asp Gly Pro Ser Lys Val Lys Met As - #p Cys Gln Glu Cys Pro# 24802470 - # 2475- Glu Gly Tyr Arg Val Thr Tyr Thr Pro Met Al - #a Pro Gly Ser Tyr Leu# 24950- Ile Ser Ile Lys Tyr Gly Gly Pro Tyr His Il - #e Gly Gly Ser Pro Phe# 25105- Lys Ala Lys Val Thr Gly Pro Arg Leu Val Se - #r Asn His Ser Leu His# 25250- Glu Thr Ser Ser Val Phe Val Asp Ser Leu Th - #r Lys Ala Thr Cys Ala# 25405- Pro Gln His Gly Ala Pro Gly Pro Gly Pro Al - #a Asp Ala Ser Lys Val# 25602550 - # 2555- Val Ala Lys Gly Leu Gly Leu Ser Lys Ala Ty - #r Val Gly Gln Lys Ser# 25750- Ser Phe Thr Val Asp Cys Ser Lys Ala Gly As - #n Asn Met Leu Leu Val# 25905- Gly Val His Gly Pro Arg Thr Pro Cys Glu Gl - #u Ile Leu Val Lys His# 26050- Val Gly Ser Arg Leu Tyr Ser Val Ser Tyr Le - #u Leu Lys Asp Lys Gly# 26205- Glu Tyr Thr Leu Val Val Lys Trp Gly His Gl - #u His Ile Pro Gly Ser# 26402630 - # 2635- Pro Tyr Arg Val Val Val Pro 2645- (2) INFORMATION FOR SEQ ID NO:9:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 1125 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: cDNA- (ix) FEATURE: (A) NAME/KEY: CDS (B) LOCATION: 1..1125- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:9:- TTC GAG ATG TCT GAC TTC ATC GTG GAC ACA AG - #G GAT GCA GGT TAT GGT 48Phe Glu Met Ser Asp Phe Ile Val Asp Thr Ar - #g Asp Ala Gly Tyr Gly# 15- GGC ATA TCC TTG GCG GTG GAA GGC CCC AGC AA - #A GTG GAC ATC CAG ACG 96Gly Ile Ser Leu Ala Val Glu Gly Pro Ser Ly - #s Val Asp Ile Gln Thr# 30- GAG GAC CTG GAA GAT GGC ACC TGC AAA GTC TC - #C TAC TTC CCT ACC GTG 144Glu Asp Leu Glu Asp Gly Thr Cys Lys Val Se - #r Tyr Phe Pro Thr Val# 45- CCT GGG GTT TAT ATC GTC TCC ACC AAA TTC GC - #T GAC GAG CAC GTG CCT 192Pro Gly Val Tyr Ile Val Ser Thr Lys Phe Al - #a Asp Glu His Val Pro# 60- GGG AGC CCA TTT ACC GTG AAG ATC AGT GGG GA - #G GGA AGA GTC AAA GAG 240Gly Ser Pro Phe Thr Val Lys Ile Ser Gly Gl - #u Gly Arg Val Lys Glu# 80- AGC ATC ACC CGC ACC AGT CGG GCC CCG TCC GT - #G GCC ACT GTC GGG AGC 288Ser Ile Thr Arg Thr Ser Arg Ala Pro Ser Va - #l Ala Thr Val Gly Ser# 95- ATT TGT GAC CTG AAC CTC AAA ATC CCA GAA AT - #C AAC AGC AGT GAT ATG 336Ile Cys Asp Leu Asn Leu Lys Ile Pro Glu Il - #e Asn Ser Ser Asp Met# 110- TCG GCC CAC GTC ACC AGC CCC TCT GGC CGT GT - #G ACT GAG GCA GAG ATT 384Ser Ala His Val Thr Ser Pro Ser Gly Arg Va - #l Thr Glu Ala Glu Ile# 125- GTG CCC ATG GGG AAG AAC TCA CAC TGC GTC CG - #G TTT GTG CCC CAG GAG 432Val Pro Met Gly Lys Asn Ser His Cys Val Ar - #g Phe Val Pro Gln Glu# 140- ATG GGC GTG CAC ACG GTC AGC GTC AAG TAC CG - #T GGG CAG CAC GTC ACC 480Met Gly Val His Thr Val Ser Val Lys Tyr Ar - #g Gly Gln His Val Thr145 1 - #50 1 - #55 1 -#60- GGC AGC CCC TTC CAG TTC ACC GTG GGG GCA CT - #T GGT GAA GGA GGC GCC 528Gly Ser Pro Phe Gln Phe Thr Val Gly Ala Le - #u Gly Glu Gly Gly Ala# 175- CAC AAG GTG CGG GCA GGA GGC CCT GGC CTG GA - #G AGA GGA GAA GCG GGA 576His Lys Val Arg Ala Gly Gly Pro Gly Leu Gl - #u Arg Gly Glu Ala Gly# 190- GTC CCA GCT GAG TTC AGC ATT TGG ACC CGG GA - #A GCA GGC GCT GGA GGC 624Val Pro Ala Glu Phe Ser Ile Trp Thr Arg Gl - #u Ala Gly Ala Gly Gly# 205- CTC TCC ATC GCT GTT GAG GGC CCC AGT AAG GC - #C GAG ATT ACA TTC GAT 672Leu Ser Ile Ala Val Glu Gly Pro Ser Lys Al - #a Glu Ile Thr Phe Asp# 220- GAC CAT AAA AAT GGG TCG TGC GGT GTA TCT TA - #T ATT GCC CAA GAG CCT 720Asp His Lys Asn Gly Ser Cys Gly Val Ser Ty - #r Ile Ala Gln Glu Pro225 2 - #30 2 - #35 2 -#40- GGT AAC TAC GAG GTG TCC ATC AAG TTC AAT GA - #T GAG CAC ATC CCG GAA 768Gly Asn Tyr Glu Val Ser Ile Lys Phe Asn As - #p Glu His Ile Pro Glu# 255- AGC CCC TAC CTG GTG CCG GTC ATC GCA CCC TC - #C GAC GAC GCC CGC CGC 816Ser Pro Tyr Leu Val Pro Val Ile Ala Pro Se - #r Asp Asp Ala Arg Arg# 270- CTC ACT GTT ATG AGC CTT CAG GAA TCG GGA TT - #A AAA GTT AAC CAG CCA 864Leu Thr Val Met Ser Leu Gln Glu Ser Gly Le - #u Lys Val Asn Gln Pro# 285- GCA TCC TTT GCT ATA AGG TTG AAT GGC GCA AA - #A GGC AAG ATT GAT GCA 912Ala Ser Phe Ala Ile Arg Leu Asn Gly Ala Ly - #s Gly Lys Ile Asp Ala# 300- AAG GTG CAC AGC CCC TCT GGA GCC GTG GAG GA - #G TGC CAC GTG TCT GAG 960Lys Val His Ser Pro Ser Gly Ala Val Glu Gl - #u Cys His Val Ser Glu305 3 - #10 3 - #15 3 -#20- CTG GAG CCA GAT AAG TAT GCT GTT CGC TTC AT - #C CCT CAT GAG AAT GGT1008Leu Glu Pro Asp Lys Tyr Ala Val Arg Phe Il - #e Pro His Glu Asn Gly# 335- GTC CAC ACC ATC GAT GTC AAG TTC AAT GGG AG - #C CAC GTG GTT GGA AGC1056Val His Thr Ile Asp Val Lys Phe Asn Gly Se - #r His Val Val Gly Ser# 350- CCC TTC AAA GTG CGC GTT GGG GAG CCT GGA CA - #A GCG GGG AAC CCT GCC1104Pro Phe Lys Val Arg Val Gly Glu Pro Gly Gl - #n Ala Gly Asn Pro Ala# 365# 1125 GGC ACGLeu Val Ser Ala Tyr Gly Thr# 375- (2) INFORMATION FOR SEQ ID NO:10:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 375 amino (B) TYPE: amino acid (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: protein- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:10:- Phe Glu Met Ser Asp Phe Ile Val Asp Thr Ar - #g Asp Ala Gly Tyr Gly# 15- Gly Ile Ser Leu Ala Val Glu Gly Pro Ser Ly - #s Val Asp Ile Gln Thr# 30- Glu Asp Leu Glu Asp Gly Thr Cys Lys Val Se - #r Tyr Phe Pro Thr Val# 45- Pro Gly Val Tyr Ile Val Ser Thr Lys Phe Al - #a Asp Glu His Val Pro# 60- Gly Ser Pro Phe Thr Val Lys Ile Ser Gly Gl - #u Gly Arg Val Lys Glu# 80- Ser Ile Thr Arg Thr Ser Arg Ala Pro Ser Va - #l Ala Thr Val Gly Ser# 95- Ile Cys Asp Leu Asn Leu Lys Ile Pro Glu Il - #e Asn Ser Ser Asp Met# 110- Ser Ala His Val Thr Ser Pro Ser Gly Arg Va - #l Thr Glu Ala Glu Ile# 125- Val Pro Met Gly Lys Asn Ser His Cys Val Ar - #g Phe Val Pro Gln Glu# 140- Met Gly Val His Thr Val Ser Val Lys Tyr Ar - #g Gly Gln His Val Thr145 1 - #50 1 - #55 1 -#60- Gly Ser Pro Phe Gln Phe Thr Val Gly Ala Le - #u Gly Glu Gly Gly Ala# 175- His Lys Val Arg Ala Gly Gly Pro Gly Leu Gl - #u Arg Gly Glu Ala Gly# 190- Val Pro Ala Glu Phe Ser Ile Trp Thr Arg Gl - #u Ala Gly Ala Gly Gly# 205- Leu Ser Ile Ala Val Glu Gly Pro Ser Lys Al - #a Glu Ile Thr Phe Asp# 220- Asp His Lys Asn Gly Ser Cys Gly Val Ser Ty - #r Ile Ala Gln Glu Pro225 2 - #30 2 - #35 2 -#40- Gly Asn Tyr Glu Val Ser Ile Lys Phe Asn As - #p Glu His Ile Pro Glu# 255- Ser Pro Tyr Leu Val Pro Val Ile Ala Pro Se - #r Asp Asp Ala Arg Arg# 270- Leu Thr Val Met Ser Leu Gln Glu Ser Gly Le - #u Lys Val Asn Gln Pro# 285- Ala Ser Phe Ala Ile Arg Leu Asn Gly Ala Ly - #s Gly Lys Ile Asp Ala# 300- Lys Val His Ser Pro Ser Gly Ala Val Glu Gl - #u Cys His Val Ser Glu305 3 - #10 3 - #15 3 -#20- Leu Glu Pro Asp Lys Tyr Ala Val Arg Phe Il - #e Pro His Glu Asn Gly# 335- Val His Thr Ile Asp Val Lys Phe Asn Gly Se - #r His Val Val Gly Ser# 350- Pro Phe Lys Val Arg Val Gly Glu Pro Gly Gl - #n Ala Gly Asn Pro Ala# 365- Leu Val Ser Ala Tyr Gly Thr# 375- (2) INFORMATION FOR SEQ ID NO:11:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 1494 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: cDNA- (ix) FEATURE: (A) NAME/KEY: CDS (B) LOCATION: 1..1449- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:11:- AAA ATC CCA GAA ATC AAC AGC AGT GAT ATG TC - #G GCC CAC GTC ACC AGC 48Lys Ile Pro Glu Ile Asn Ser Ser Asp Met Se - #r Ala His Val Thr Ser# 15- CCC TCT GGC CGT GTG ACT GAG GCA GAG ATT GT - #G CCC ATG GGG AAG AAC 96Pro Ser Gly Arg Val Thr Glu Ala Glu Ile Va - #l Pro Met Gly Lys Asn# 30- TCA CAC TGC GTC CGG TTT GTG CCC CAG GAG AT - #G GGC GTG CAC ACG GTC 144Ser His Cys Val Arg Phe Val Pro Gln Glu Me - #t Gly Val His Thr Val# 45- AGC GTC AAG TAC CGT GGG CAG CAC GTC ACC GG - #C AGC CCC TTC CAG TTC 192Ser Val Lys Tyr Arg Gly Gln His Val Thr Gl - #y Ser Pro Phe Gln Phe# 60- ACC GTG GGG GCA CTT GGT GAA GGA GGC GCC CA - #C AAG GTG CGG GCA GGA 240Thr Val Gly Ala Leu Gly Glu Gly Gly Ala Hi - #s Lys Val Arg Ala Gly# 80- GGC CCT GGC CTG GAG AGA GGA GAA GCG GGA GT - #C CCA GCT GAG TTC AGC 288Gly Pro Gly Leu Glu Arg Gly Glu Ala Gly Va - #l Pro Ala Glu Phe Ser# 95- ATT TGG ACC CGG GAA GCA GGC GCT GGA GGC CT - #C TCC ATC GCT GTT GAG 336Ile Trp Thr Arg Glu Ala Gly Ala Gly Gly Le - #u Ser Ile Ala Val Glu# 110- GGC CCC AGT AAG GCC GAG ATT ACA TTC GAT GA - #C CAT AAA AAT GGG TCG 384Gly Pro Ser Lys Ala Glu Ile Thr Phe Asp As - #p His Lys Asn Gly Ser# 125- TGC GGT GTA TCT TAT ATT GCC CAA GAG CCT GG - #T AAC TAC GAG GTG TCC 432Cys Gly Val Ser Tyr Ile Ala Gln Glu Pro Gl - #y Asn Tyr Glu Val Ser# 140- ATC AAG TTC AAT GAT GAG CAC ATC CCG GAA AG - #C CCC TAC CTG GTG CCG 480Ile Lys Phe Asn Asp Glu His Ile Pro Glu Se - #r Pro Tyr Leu Val Pro145 1 - #50 1 - #55 1 -#60- GTC ATC GCA CCC TCC GAC GAC GCC CGC CGC CT - #C ACT GTT ATG AGC CTT 528Val Ile Ala Pro Ser Asp Asp Ala Arg Arg Le - #u Thr Val Met Ser Leu# 175- CAG GAA TCG GGA TTA AAA GTT AAC CAG CCA GC - #A TCC TTT GCT ATA AGG 576Gln Glu Ser Gly Leu Lys Val Asn Gln Pro Al - #a Ser Phe Ala Ile Arg# 190- TTG AAT GGC GCA AAA GGC AAG ATT GAT GCA AA - #G GTG CAC AGC CCC TCT 624Leu Asn Gly Ala Lys Gly Lys Ile Asp Ala Ly - #s Val His Ser Pro Ser# 205- GGA GCC GTG GAG GAG TGC CAC GTG TCT GAG CT - #G GAG CCA GAT AAG TAT 672Gly Ala Val Glu Glu Cys His Val Ser Glu Le - #u Glu Pro Asp Lys Tyr# 220- GCT GTT CGC TTC ATC CCT CAT GAG AAT GGT GT - #C CAC ACC ATC GAT GTC 720Ala Val Arg Phe Ile Pro His Glu Asn Gly Va - #l His Thr Ile Asp Val225 2 - #30 2 - #35 2 -#40- AAG TTC AAT GGG AGC CAC GTG GTT GGA AGC CC - #C TTC AAA GTG CGC GTT 768Lys Phe Asn Gly Ser His Val Val Gly Ser Pr - #o Phe Lys Val Arg Val# 255- GGG GAG CCT GGA CAA GCG GGG AAC CCT GCC CT - #G GTG TCC GCC TAT GGC 816Gly Glu Pro Gly Gln Ala Gly Asn Pro Ala Le - #u Val Ser Ala Tyr Gly# 270- ACG GGA CTC GAA GGG GGN ACC ACA GGT ATC CA - #G TCG GAA TTC TTT ATT 864Thr Gly Leu Glu Gly Xaa Thr Thr Gly Ile Gl - #n Ser Glu Phe Phe Ile# 285- AAC ACC ACC CGA GCA GGT CCA GGG ACA TTA TC - #C GTC ACC ATC GAA GGC 912Asn Thr Thr Arg Ala Gly Pro Gly Thr Leu Se - #r Val Thr Ile Glu Gly# 300- CCA TCC AAG GTT AAA ATG GAT TGC CAG GAA AC - #A CCT GAA GGG TAC AAA 960Pro Ser Lys Val Lys Met Asp Cys Gln Glu Th - #r Pro Glu Gly Tyr Lys305 3 - #10 3 - #15 3 -#20- GTC ATG TAC ACC CCC ATG GCT CCT GGT AAC TA - #C CTG ATC AGT GTC AAA1008Val Met Tyr Thr Pro Met Ala Pro Gly Asn Ty - #r Leu Ile Ser Val Lys# 335- TAC GGT GGG CCC AAC CAC ATC GTG GGC AGT CC - #C TTC AAG GCC AAG GTG1056Tyr Gly Gly Pro Asn His Ile Val Gly Ser Pr - #o Phe Lys Ala Lys Val# 350- ACT GGC CAG CGT CTA GTT AGC CCT GGC TCA GC - #C AAC GAG ACC TCA TCC1104Thr Gly Gln Arg Leu Val Ser Pro Gly Ser Al - #a Asn Glu Thr Ser Ser# 365- ATC CTG GTG GAG TCA GTG ACC AGG TCG TCT AC - #A GAG ACC TGC TAT AGC1152Ile Leu Val Glu Ser Val Thr Arg Ser Ser Th - #r Glu Thr Cys Tyr Ser# 380- GCC ATT CCC AAG GCA TCC TCG GAC GCC AGC AA - #G GTG ACC TCT AAG GGG1200Ala Ile Pro Lys Ala Ser Ser Asp Ala Ser Ly - #s Val Thr Ser Lys Gly385 3 - #90 3 - #95 4 -#00- GCA GGG CTC TCA AAG GCC TTT GTG GGC CAG AA - #G AGT TCC TTC CTG GTG1248Ala Gly Leu Ser Lys Ala Phe Val Gly Gln Ly - #s Ser Ser Phe Leu Val# 415- GAC TGC AGC AAA GCT GGC TCC AAC ATG CTG CT - #G ATC GGG GTC CAT GGG1296Asp Cys Ser Lys Ala Gly Ser Asn Met Leu Le - #u Ile Gly Val His Gly# 430- CCC ACC ACC CCC TGC GAG GAG GTC TCC ATG AA - #G CAT GTA GGC AAC CAG1344Pro Thr Thr Pro Cys Glu Glu Val Ser Met Ly - #s His Val Gly Asn Gln# 445- CAA TAC AAC GTC ACA TAC GTC GTC AAG GAG AG - #G GGC GAT TAT GTG CTG1392Gln Tyr Asn Val Thr Tyr Val Val Lys Glu Ar - #g Gly Asp Tyr Val Leu# 460- GCT GTG AAG TGG GGG GAG GAA CAC ATC CCT GG - #C AGC CCT TTT CAT GTC1440Ala Val Lys Trp Gly Glu Glu His Ile Pro Gl - #y Ser Pro Phe His Val465 4 - #70 4 - #75 4 -#80- ACA GTG CCT TAAAACAGTT TTCTCAAATC CTGGAAAAAA AAAAAAAAA - #A AAAAA1494Thr Val Pro- (2) INFORMATION FOR SEQ ID NO:12:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 483 amino (B) TYPE: amino acid (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: protein- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:12:- Lys Ile Pro Glu Ile Asn Ser Ser Asp Met Se - #r Ala His Val Thr Ser# 15- Pro Ser Gly Arg Val Thr Glu Ala Glu Ile Va - #l Pro Met Gly Lys Asn# 30- Ser His Cys Val Arg Phe Val Pro Gln Glu Me - #t Gly Val His Thr Val# 45- Ser Val Lys Tyr Arg Gly Gln His Val Thr Gl - #y Ser Pro Phe Gln Phe# 60- Thr Val Gly Ala Leu Gly Glu Gly Gly Ala Hi - #s Lys Val Arg Ala Gly# 80- Gly Pro Gly Leu Glu Arg Gly Glu Ala Gly Va - #l Pro Ala Glu Phe Ser# 95- Ile Trp Thr Arg Glu Ala Gly Ala Gly Gly Le - #u Ser Ile Ala Val Glu# 110- Gly Pro Ser Lys Ala Glu Ile Thr Phe Asp As - #p His Lys Asn Gly Ser# 125- Cys Gly Val Ser Tyr Ile Ala Gln Glu Pro Gl - #y Asn Tyr Glu Val Ser# 140- Ile Lys Phe Asn Asp Glu His Ile Pro Glu Se - #r Pro Tyr Leu Val Pro145 1 - #50 1 - #55 1 -#60- Val Ile Ala Pro Ser Asp Asp Ala Arg Arg Le - #u Thr Val Met Ser Leu# 175- Gln Glu Ser Gly Leu Lys Val Asn Gln Pro Al - #a Ser Phe Ala Ile Arg# 190- Leu Asn Gly Ala Lys Gly Lys Ile Asp Ala Ly - #s Val His Ser Pro Ser# 205- Gly Ala Val Glu Glu Cys His Val Ser Glu Le - #u Glu Pro Asp Lys Tyr# 220- Ala Val Arg Phe Ile Pro His Glu Asn Gly Va - #l His Thr Ile Asp Val225 2 - #30 2 - #35 2 -#40- Lys Phe Asn Gly Ser His Val Val Gly Ser Pr - #o Phe Lys Val Arg Val# 255- Gly Glu Pro Gly Gln Ala Gly Asn Pro Ala Le - #u Val Ser Ala Tyr Gly# 270- Thr Gly Leu Glu Gly Xaa Thr Thr Gly Ile Gl - #n Ser Glu Phe Phe Ile# 285- Asn Thr Thr Arg Ala Gly Pro Gly Thr Leu Se - #r Val Thr Ile Glu Gly# 300- Pro Ser Lys Val Lys Met Asp Cys Gln Glu Th - #r Pro Glu Gly Tyr Lys305 3 - #10 3 - #15 3 -#20- Val Met Tyr Thr Pro Met Ala Pro Gly Asn Ty - #r Leu Ile Ser Val Lys# 335- Tyr Gly Gly Pro Asn His Ile Val Gly Ser Pr - #o Phe Lys Ala Lys Val# 350- Thr Gly Gln Arg Leu Val Ser Pro Gly Ser Al - #a Asn Glu Thr Ser Ser# 365- Ile Leu Val Glu Ser Val Thr Arg Ser Ser Th - #r Glu Thr Cys Tyr Ser# 380- Ala Ile Pro Lys Ala Ser Ser Asp Ala Ser Ly - #s Val Thr Ser Lys Gly385 3 - #90 3 - #95 4 -#00- Ala Gly Leu Ser Lys Ala Phe Val Gly Gln Ly - #s Ser Ser Phe Leu Val# 415- Asp Cys Ser Lys Ala Gly Ser Asn Met Leu Le - #u Ile Gly Val His Gly# 430- Pro Thr Thr Pro Cys Glu Glu Val Ser Met Ly - #s His Val Gly Asn Gln# 445- Gln Tyr Asn Val Thr Tyr Val Val Lys Glu Ar - #g Gly Asp Tyr Val Leu# 460- Ala Val Lys Trp Gly Glu Glu His Ile Pro Gl - #y Ser Pro Phe His Val465 4 - #70 4 - #75 4 -#80- Thr Val Pro- (2) INFORMATION FOR SEQ ID NO:13:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 53 amino (B) TYPE: amino acid (C) STRANDEDNESS: Not R - #elevant (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: peptide- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:13:- Tyr Arg Leu Ser Val Glu Ile Tyr Asp Arg Ar - #g Glu Tyr Ser Arg Phe# 15- Glu Lys Glu Gln Gln Gln Leu Asn Trp Lys Gl - #n Asp Ser Asn Pro Leu# 30- Tyr Lys Ser Ala Ile Thr Thr Thr Ile Asn Pr - #o Arg Phe Gln Glu Ala# 45- Asp Ser Pro Thr Leu 50- (2) INFORMATION FOR SEQ ID NO:14:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 31 amino (B) TYPE: amino acid (C) STRANDEDNESS: Not R - #elevant (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: peptide- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:14:- Tyr Arg Leu Ser Val Glu Ile Tyr Asp Arg Ar - #g Glu Tyr Ser Arg Phe# 15- Glu Lys Glu Gln Gln Gln Leu Asn Trp Lys Gl - #n Asp Ser Asn Pro# 30- (2) INFORMATION FOR SEQ ID NO:15:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 36 amino (B) TYPE: amino acid (C) STRANDEDNESS: Not R - #elevant (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: peptide- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:15:- Tyr Arg Leu Ser Val Glu Ile Tyr Asp Arg Ar - #g Glu Tyr Ser Arg Phe# 15- Glu Lys Glu Gln Gln Gln Leu Asn Trp Lys Gl - #n Asp Ser Asn Pro Leu# 30Tyr Lys Ser Ala 35- (2) INFORMATION FOR SEQ ID NO:16:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 43 amino (B) TYPE: amino acid (C) STRANDEDNESS: Not R - #elevant (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: peptide- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:16:- Tyr Arg Leu Ser Val Glu Ile Tyr Asp Arg Ar - #g Glu Tyr Ser Arg Phe# 15- Glu Lys Glu Gln Gln Gln Leu Asn Trp Lys Gl - #n Asp Ser Asn Pro Leu# 30- Tyr Lys Ser Ala Ile Thr Thr Thr Ile Asn Pr - #o# 40- (2) INFORMATION FOR SEQ ID NO:17:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 19 amino (B) TYPE: amino acid (C) STRANDEDNESS: Not R - #elevant (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: peptide- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:17:- Tyr Arg Leu Ser Val Glu Ile Tyr Asp Arg Ar - #g Glu Tyr Ser Arg Phe# 15- Glu Lys Glu- (2) INFORMATION FOR SEQ ID NO:18:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 15 amino (B) TYPE: amino acid (C) STRANDEDNESS: Not R - #elevant (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: peptide- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:18:- Tyr Arg Leu Ser Val Glu Ile Tyr Asp Arg Ar - #g Glu Tyr Ser Arg# 15- (2) INFORMATION FOR SEQ ID NO:19:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 33 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:19:# 33 TAAG GATTACTGTC CTG- (2) INFORMATION FOR SEQ ID NO:20:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 33 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:20:# 33 TAGG CACTTTTGTA GAG- (2) INFORMATION FOR SEQ ID NO:21:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 33 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:21:# 33 TAAG GATTGATGGT GGT- (2) INFORMATION FOR SEQ ID NO:22:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 33 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:22:# 33 TACT CCTTCTCAAA GCG- (2) INFORMATION FOR SEQ ID NO:23:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 34 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:23:# 34 CTAG CGACTGTATT CCCG- (2) INFORMATION FOR SEQ ID NO:24:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 53 amino (B) TYPE: amino acid (C) STRANDEDNESS: Not R - #elevant (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: peptide- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:24:- Tyr Arg Leu Ala Val Glu Ile Tyr Asp Arg Ar - #g Glu Tyr Ser Arg PheGlu# 15- Lys Glu Gln Gln Gln Leu Asn Trp Lys Gln As - #p Ser Asn Pro Leu Tyr# 30- Lys Ser Ala Ile Thr Thr Thr Ile Asn Pro Ar - #g Phe Gln Glu Ala Asp# 45- Ser Pro Thr Leu50- (2) INFORMATION FOR SEQ ID NO:25:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 53 amino (B) TYPE: amino acid (C) STRANDEDNESS: Not R - #elevant (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: peptide- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:25:- Tyr Arg Leu Ser Val Gln Ile Tyr Asp Arg Ar - #g Glu Tyr Ser Arg PheGlu# 15- Lys Glu Gln Gln Gln Leu Asn Trp Lys Gln As - #p Ser Asn Pro Leu Tyr# 30- Lys Ser Ala Ile Thr Thr Thr Ile Asn Pro Ar - #g Phe Gln Glu Ala Asp# 45- Ser Pro Thr Leu50- (2) INFORMATION FOR SEQ ID NO:26:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 53 amino (B) TYPE: amino acid (C) STRANDEDNESS: Not R - #elevant (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: peptide- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:26:- Tyr Arg Leu Ser Val Glu Ile Tyr Asp Ala Ar - #g Glu Tyr Ser Arg PheGlu# 15- Lys Glu Gln Gln Gln Leu Asn Trp Lys Gln As - #p Ser Asn Pro Leu Tyr# 30- Lys Ser Ala Ile Thr Thr Thr Ile Asn Pro Ar - #g Phe Gln Glu Ala Asp# 45- Ser Pro Thr Leu50- (2) INFORMATION FOR SEQ ID NO:27:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 53 amino (B) TYPE: amino acid (C) STRANDEDNESS: Not R - #elevant (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: peptide- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:27:- Tyr Arg Leu Ser Val Glu Ile Tyr Asp Arg Ar - #g Glu Tyr Ala Arg PheGlu# 15- Lys Glu Gln Gln Gln Leu Asn Trp Lys Gln As - #p Ser Asn Pro Leu Tyr# 30- Lys Ser Ala Ile Thr Thr Thr Ile Asn Pro Ar - #g Phe Gln Glu Ala Asp# 45- Ser Pro Thr Leu50- (2) INFORMATION FOR SEQ ID NO:28:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 33 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:28:# 33 GCGA GCCGGTATCC GAG- (2) INFORMATION FOR SEQ ID NO:29:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 35 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:29:# 35 TGCA CCGAGAGCCG GTATC- (2) INFORMATION FOR SEQ ID NO:30:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 33 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:30:# 33 GCGT CATAGATTTC CAC- (2) INFORMATION FOR SEQ ID NO:31:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 33 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:31:# 33 GCGT ATTCCCGGCG GTC- (2) INFORMATION FOR SEQ ID NO:32:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 30 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:32:# 30 CCCC CATGGCACCT- (2) INFORMATION FOR SEQ ID NO:33:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 28 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucelic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:33:# 28 CACC ACAACGCG- (2) INFORMATION FOR SEQ ID NO:34:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 32 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:34:# 32 GCTC TTCTGGCCCT AC- (2) INFORMATION FOR SEQ ID NO:35:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 28 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:35:# 28 CCCA TGGCTCCT- (2) INFORMATION FOR SEQ ID NO:36:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 27 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:36:# 27 CACA AACAGGC- (2) INFORMATION FOR SEQ ID NO:37:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 30 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:37:# 30 GAGT CTACAAACAC- (2) INFORMATION FOR SEQ ID NO:38:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 30 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:38:# 30 TCTG TAGACGACCT- (2) INFORMATION FOR SEQ ID NO:39:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 11 amino (B) TYPE: amino acid (C) STRANDEDNESS: Not R - #elevant (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: peptide- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:39:- Tyr Arg Leu Ser Val Glu Ile Tyr Asp Arg Ar - #g# 10- (2) INFORMATION FOR SEQ ID NO:40:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 49 amino (B) TYPE: amino acid (C) STRANDEDNESS: Not R - #elevant (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: peptide- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:40:- Tyr Arg Leu Ser Val Glu Ile Tyr Asp Arg Ar - #g Glu Tyr Ser Arg Phe# 15- Glu Lys Glu Gln Gln Gln Leu Asn Trp Lys Gl - #n Asp Ser Asn Pro Leu# 30- Tyr Lys Ser Ala Ile Thr Thr Thr Ile Asn Pr - #o Arg Phe Gln Glu Ala# 45- Asp- (2) INFORMATION FOR SEQ ID NO:41:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 45 amino (B) TYPE: amino acid (C) STRANDEDNESS: Not R - #elevant (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: peptide- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:41:- Tyr Arg Leu Ser Val Glu Ile Tyr Asp Arg Ar - #g Glu Tyr Ser Arg Phe# 15- Glu Lys Glu Gln Gln Gln Leu Asn Trp Lys Gl - #n Asp Ser Asn Pro Leu# 30- Tyr Lys Ser Ala Ile Thr Thr Thr Ile Asn Pr - #o Arg Phe# 45- (2) INFORMATION FOR SEQ ID NO:42:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 36 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:42:# 36 TACC GGCGGTCATA GATTTC- (2) INFORMATION FOR SEQ ID NO:43:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 34 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:43:# 34 TGAC CCACTCTCTG AGGA- (2) INFORMATION FOR SEQ ID NO:44:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 34 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:44:# 34 CAGT CTGCCTCTTG AAAG- (2) INFORMATION FOR SEQ ID NO:45:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 34 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid- (xi) SEQUENCE DESCRIPTION: SEQ ID NO:45:# 34 TGAG AGGCAGACAG TCCC- (2) INFORMATION FOR SEQ ID NO:46:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 34 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#ID NO:46:(xi) SEQUENCE DESCRIPTION: SEQ# 34 CAAA AGCGAGGATT GATC- (2) INFORMATION FOR SEQ ID NO:47:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 53 amino (B) TYPE: amino acid (C) STRANDEDNESS: Not R - #elevant (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: peptide#ID NO:47:(xi) SEQUENCE DESCRIPTION: SEQ- Tyr Arg Leu Ser Phe Glu Ile Tyr - # Asp Arg Arg Glu Tyr Ser ArgPhe# 15- Glu Lys Glu Gln Gln Gln Leu Asn - # Trp Lys Gln Asp Ser Asn ProLeu# 30- Tyr Lys Ser Ala Ile Thr Thr Thr - # Ile Asn Pro Arg Phe Gln GluAla# 45- Asp Ser Pro Thr Leu 50- (2) INFORMATION FOR SEQ ID NO:48:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 53 amino (B) TYPE: amino acid (C) STRANDEDNESS: Not R - #elevant (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: peptide#ID NO:48:(xi) SEQUENCE DESCRIPTION: SEQ- Tyr Arg Leu Ser Val Glu Phe Tyr - # Asp Arg Arg Glu Tyr Ser ArgPhe# 15- Glu Lys Glu Gln Gln Gln Leu Asn - # Trp Lys Gln Asp Ser Asn ProLeu# 30- Tyr Lys Ser Ala Ile Thr Thr Thr - # Ile Asn Pro Arg Phe Gln GluAla# 45- Asp Ser Pro Thr Leu 50- (2) INFORMATION FOR SEQ ID NO:49:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 53 amino (B) TYPE: amino acid (C) STRANDEDNESS: Not R - #elevant (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: peptide#ID NO:49:(xi) SEQUENCE DESCRIPTION: SEQ- Tyr Arg Leu Ser Val Glu Ile Phe - # Asp Arg Arg Glu Tyr Ser ArgPhe# 15- Glu Lys Glu Gln Gln Gln Leu Asn - # Trp Lys Gln Asp Ser Asn ProLeu# 30- Tyr Lys Ser Ala Ile Thr Thr Thr - # Ile Asn Pro Arg Phe Gln GluAla# 45- Asp Ser Pro Thr Leu 50- (2) INFORMATION FOR SEQ ID NO:50:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 53 amino (B) TYPE: amino acid (C) STRANDEDNESS: Not R - #elevant (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: peptide#ID NO:50:(xi) SEQUENCE DESCRIPTION: SEQ- Tyr Arg Leu Ser Val Glu Ile Tyr - # Ala Arg Arg Glu Tyr Ser ArgPhe# 15- Glu Lys Glu Gln Gln Gln Leu Asn - # Trp Lys Gln Asp Ser Asn ProLeu# 30- Tyr Lys Ser Ala Ile Thr Thr Thr - # Ile Asn Pro Arg Phe Gln GluAla# 45- Asp Ser Pro Thr Leu 50- (2) INFORMATION FOR SEQ ID NO:51:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 53 amino (B) TYPE: amino acid (C) STRANDEDNESS: Not R - #elevant (D) TOPOLOGY: Not Relev - #ant- (ii) MOLECULE TYPE: peptide#ID NO:51:(xi) SEQUENCE DESCRIPTION: SEQ- Tyr Arg Leu Ser Val Glu Ile Tyr - # Asp Arg Ala Glu Tyr Ser ArgPhe# 15- Glu Lys Glu Gln Gln Gln Leu Asn - # Trp Lys Gln Asp Ser Asn ProLeu# 30- Tyr Lys Ser Ala Ile Thr Thr Thr - # Ile Asn Pro Arg Phe Gln GluAla# 45- Asp Ser Pro Thr Leu 50- (2) INFORMATION FOR SEQ ID NO:52:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 33 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#ID NO:52:(xi) SEQUENCE DESCRIPTION: SEQ# 33 AACG AGAGCCGGTA TCC- (2) INFORMATION FOR SEQ ID NO:53:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 33 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#ID NO:53:(xi) SEQUENCE DESCRIPTION: SEQ# 33 AATT CCACCGAGAG CCG- (2) INFORMATION FOR SEQ ID NO:54:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 33 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#ID NO:54:(xi) SEQUENCE DESCRIPTION: SEQ# 33 AAGA TTTCCACCGA GAG- (2) INFORMATION FOR SEQ ID NO:55:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 33 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#ID NO:55:(xi) SEQUENCE DESCRIPTION: SEQ# 33 GCAT AGATTTCCAC CGA- (2) INFORMATION FOR SEQ ID NO:56:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 33 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#ID NO:56:(xi) SEQUENCE DESCRIPTION: SEQ# 33 GCGC GGTCATAGAT TTC- (2) INFORMATION FOR SEQ ID NO:57:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 27 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#ID NO:57:(xi) SEQUENCE DESCRIPTION: SEQ# 27 CCCG TCTCGTC- (2) INFORMATION FOR SEQ ID NO:58:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 37 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#ID NO:58:(xi) SEQUENCE DESCRIPTION: SEQ# 37 CAGG GCACCACAAC GCGGTAG- (2) INFORMATION FOR SEQ ID NO:59:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 31 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#ID NO:59:(xi) SEQUENCE DESCRIPTION: SEQ# 31 GCAT CCGCTTTGTT C- (2) INFORMATION FOR SEQ ID NO:60:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 30 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#ID NO:60:(xi) SEQUENCE DESCRIPTION: SEQ# 30 GCAG ACACCAAGCC- (2) INFORMATION FOR SEQ ID NO:61:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 27 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#SEQ ID NO:61:) SEQUENCE DESCRIPTION:# 27 CTTT TGCAGTC- (2) INFORMATION FOR SEQ ID NO:62:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 27 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#ID NO:62:(xi) SEQUENCE DESCRIPTION: SEQ# 27 AATT CAGTATC- (2) INFORMATION FOR SEQ ID NO:63:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 31 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#ID NO:63:(xi) SEQUENCE DESCRIPTION: SEQ# 31 CCCT TGGCCCCCTT C- (2) INFORMATION FOR SEQ ID NO:64:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 30 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#ID NO:64:(xi) SEQUENCE DESCRIPTION: SEQ# 30 CGGG ACTCGAAGGG- (2) INFORMATION FOR SEQ ID NO:65:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 27 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: other nucleic acid#ID NO:65:(xi) SEQUENCE DESCRIPTION: SEQ# 27 ACTG TGACATG__________________________________________________________________________
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The present invention relates to purified and isolated polynucleotides encoding a polypeptide which specifically bind to a cytoplasmic portion of an integrin. Specifically, the invention provides a FLP-1-encoding polynucleotide and the polypeptide product of the gene. Expression vectors comprising the polynucleotide, antibodies which recognize the polypeptide, hybridomas which secrete the antibodies, and method to identify modulators of interaction of the polypeptide with β 7 subunits sequences are also provided.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of PCT application PCT/US99/16798, filed Jul. 22, 1999, and published in English as WO 00/05197 on Feb. 3, 2000. PCT/US99/16798 claimed the priority of U.S. application Ser. No. 09/121,262, filed Jul. 23, 1998. The entire disclosures of both are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to the synthesis of chemical compounds, and more particularly, to the solid phase synthesis of combinatorial libraries of chemical compounds.
BACKGROUND OF THE INVENTION
[0003] Combinatorial organic synthesis is becoming an important tool in drug discovery. Methods for the synthesis of large numbers of diverse compounds have been described (Ellman et al., Chem. Rev. 96, 555-600 (1996)), as have methods for tagging systems (Ohlmeyer et al., Proc. Natl. Acad. Sci. USA 90, 10922-10926 (1993)). The growing importance of combinatorial synthesis has created a need for new resins and linkers having chemical and physical properties that accommodate a wide range of conditions. Success in combinatorial synthesis on solid phase supports depends on the ability to synthesize diverse sets of molecules and to then cleave those molecules from the supports cleanly and in good yield.
[0004] Linkers are molecules that are attached to a solid support and to which the desired members of a library of chemical compounds may in turn be attached. When the construction of the library is complete, the linker allows clean separation of the target compounds from the solid support without harm to the compounds and preferably without damage to the support. Several linkers have been described in the literature. Their value is constrained by the need to have sufficient stability which allows the steps of combinatorial synthesis under conditions that will not cleave the linker. An additional constraint is the need to have a fairly high lability under at least one set of conditions that is not employed in the chemical synthesis.
[0005] For example, if an acid labile linker is employed, then the combinatorial synthesis must be restricted to reactions that do not require the presence of an acid of sufficient strength to endanger the integrity of the linker. Likewise, when a photocleavable linker is employed, conditions that exclude light are necessary to avoid untimely cleavage of the compound from the resin. This sort of balancing act often imposes serious constraints on the reactions that are chosen for preparation of the library.
[0006] The 4-[4-(hydroxymethyl)-3-methoxyphenoxy]butyryl residue is a known linker, which is attached to a solid support having amino groups by forming an amide with the carboxyl of the butyric acid chain. N-Protected amino acids are attached to the hydroxyl of the 4-hydroxymethyl group via their carboxyl to form 2,4-dialkoxybenzyl esters, which can be readily cleaved in acid media when the synthesis is complete (Riniker et al., Tetrahedron 49, 9307-9312 (1993)). The drawback to such 2,4-dialkoxybenzyl esters is their instability with many of the reagents that are available for use in combinatorial synthesis resulting in cleavage of the ester.
[0007] A somewhat more stable ester is formed from 4-[4-(hydroxymethyl)phenoxy]butyric acid, described in European published application EP 445915. In this case, the ester was cleaved with a 90:5:5 mixture of trifluoroacetic acid, dimethyl sulfide and thioanisole.
[0008] When the desired product is a peptide amide, the 4-[4-(formyl)-3,5-dimethoxyphenoxy]butyryl residue has been employed as a linker. This particular linker is attached to a solid phase substrate via the carboxyl of the butyric acid chain, and the 4-formyl group is reductively aminated. N-Protected amino acids are then reacted with the alkylamine via their carboxyl to form 2,4,6-trialkoxybenzylamides. These may be cleaved by 1:1 trifluoroacetic acid in dichloromethane (PCT application WO97/23508).
[0009] If a photocleavable linker is used to attach chemical compounds to the main support, milder photolytic conditions of cleavage can be used which complement traditional acidic or basic cleavage techniques. A wider range of combinatorial synthetic conditions will be tolerated by photocleavable linkers (Gallop et al., J. Med. Chem. 37, 1233-1251 (1994); Gordon et al., J. Med. Chem. 37, 1385-1401 (1994)).
[0010] A phenacyl based linking group that is photocleavable has been described (Wang et al., J. Org. Chem. 41, 3258 (1976)). The 4-bromomethyl-3-nitrobenzoyl residue has been widely employed as a photocleavable linker for both peptide acids and amides (Rich et al., J. Am. Chem. Soc. 97, 1575-1579 (1975); Hammer et al., Int. J. Peptide Protein Res. 36, 31-45 (1990)). This linker suffers from unduly slow cleavage rates, with typical photolysis times in organic solvents ranging from 12 to 24 hours. Moreover, photolytic cleavage of the linker generates a reactive and chromogenic nitrosoaldehyde on the resin support which can trap liberated compounds (Patchnornik et al., J. Am. Chem. Soc. 92, 6333-6335 (1970)). An α-methyl-2-nitrobenzyl linker was designed to obviate formation of the nitroso-aldehyde, but inefficient release of pentapeptides resulted due to swelling of the resin support (Ajajaghosh et al., Tetrahedron 44, 6661-6666 (1988)). Photocleavable linkers such as the 3-bromomethyl-4-nitro-6-methoxyphenoxyacetyl residue are stable to acidic or basic conditions yet, are rapidly cleavable under mild conditions and do not generate highly reactive byproducts (U.S. Pat. No. 5,739,386, issued Apr. 14, 1998).
[0011] It would be useful to have a linker-resin combination that would withstand a wider range of reaction conditions in combinatorial synthesis, but that could be readily and cleanly cleaved following completion of the solid phase synthesis.
SUMMARY OF THE INVENTION
[0012] The present invention relates to a linker-resin combination that demonstrates the ability to withstand many common reaction conditions and yet is cleavable under relatively mild conditions. In the following disclosure, the variables are defined when introduced and retain that definition throughout.
[0013] In one aspect, the invention relates to a substrate for solid phase synthesis comprising a solid phase-linker combination of the formula I:
[0014] wherein:
[0015] represents the residue of a solid support having a plurality of amino groups and the remainder constitutes the linker;
[0016] R 1 is —NO 2 or —CHO;
[0017] R 2 is —OCH 3 , —CHO or —H; and
[0018] n=1 or 3-12.
[0019] Preferred solid phase supports are aminomethylated poly(styrene-co-divinylbenzene) and divinylbenzene-cross-linked resin, polyethyleneglycol-grafted polystyrene functionalized with amino groups.
[0020] In another aspect, the invention relates to a chemical intermediate of the formula II:
[0021] wherein:
[0022] R 1 is —NO 2 or —CHO;
[0023] R 2 is —OCH 3 , —CHO or —H;
[0024] R 3 is chosen from the group consisting of hydroxyl, the residue of a solid support having a plurality of amino groups, and the residue of an ester; and n=1 or 3-12. A preferred ester residue is t-butoxy.
[0025] In a further aspect, the invention relates to processes for preparing the foregoing substrate for solid phase synthesis. One process comprises combining in a suitable solvent, a coupling agent, a solid support having a plurality of amino groups, and a compound of formula II:
[0026] wherein R 3 is hydroxyl. A preferred process is combining in a suitable solvent, a coupling agent, a solid support having a plurality of amino groups, and a compound of formula II wherein R 1 is —NO 2 , R 2 is —CHO and R 3 is hydroxyl. In another preferred process, R 1 is —CHO and R 2 is —OCH 3 . In yet another preferred process, R 1 is —CHO and R 2 is —H.
[0027] In yet another aspect, the invention relates to a process for solid phase synthesis comprising:
[0028] a) reacting a substrate for solid phase synthesis of the formula I:
[0029] wherein:
[0030] represents the residue of a solid support having a plurality of amino groups and the remainder constitutes the linker;
[0031] R 1 is —NO 2 or —CHO;
[0032] R 2 is —OCH 3 , —CHO or —H; and
[0033] n=1 or 3-12,
[0034] with a reagent capable of reacting with an aldehyde to provide a support-linked synthon;
[0035] b) carrying out a plurality of chemical transformations on said support-linked synthon to provide a support-linked product; and
[0036] c) treating said support-linked product with a condition of ultraviolet light or acid to cleave the product from the support and linker. When R 1 =—NO 2 and R 2 =—CHO, the support-linked product is cleaved with ultraviolet light. When R 1 =—CHO and R 2 =—OCH 3 , the support-linked product is cleaved by mild acid. When R 1 =—CHO and R 2 =—H, the support-linked product is cleaved by a stronger concentration of acid. Trifluoroacetic acid is a preferred acid for cleavage.
[0037] In another aspect, the invention relates to a process for preparing a substrate for solid phase synthesis comprising:
[0038] combining in a suitable solvent, a coupling reagent, a solid support having a plurality of amino groups, a compound of the formula:
[0039] and
[0040] a compound of the formula:
[0041] to produce said substrate of formula III:
[0042] wherein:
[0043] represents the residue of a solid support having a plurality of amino groups and the remainder constitutes the linker; R 2 =—OCH 3 or —H; and n=1 or 3-12.
[0044] In yet a further aspect, the invention relates to a process for solid phase synthesis comprising:
[0045] a) reacting a substrate for solid phase synthesis of the formula III:
[0046] wherein:
[0047] represents the residue of a solid support having a plurality of amino groups and the remainder constitutes a linker; R 2 =—OCH 3 or —H; and n=1 or 3-12, with a reagent capable of reacting with an aldehyde to provide a support-linked synthon;
[0048] b) carrying out a plurality of chemical transformations on said support-linked synthon to provide a support-linked product;
[0049] c) treating said support-linked product with ultraviolet light to cleave the photocleavable support-linked product from the support and linker; and
[0050] d) treating said support-linked product with trifluoroacetic acid to cleave the acid cleavable support-linked product from the support and linker.
[0051] When R 2 —OCH 3 , trifluoroacetic acid (2-25%)in CH 2 Cl 2 cleaves the support-linked product. When R 2 =—H, trifluoroacetic acid (50-100%) in CH 2 Cl 2 cleaves the support-linked product.
DETAILED DESCRIPTION OF THE INVENTION
[0052] Abbreviations and Definitions
[0053] The following abbreviations and terms have the indicated meanings throughout:
Ac = acetyl BH 3 = borane BNB = 4-bromomethyl-3-nitrobenzoic acid Boc = t-butyloxy carbonyl Bu = butyl c- = cyclo- CH 2 Cl 2 = dichloromethane = methylene chloride DBU = diazabicyclo[5.4.0]undec-7-ene DCM = dichloromethane = methylene chloride = CH 2 Cl 2 DEAD = diethyl azodicarboxylate DIC = diisopropylcarbodiimide DIEA = N,N-diisopropylethyl amine DMAP = 4-N,N-dimethylaminopyridine DMF = N,N-dimethylformamide DMSO = dimethyl sulfoxide DVB = 1,4-divinylbenzene EEDQ = 2-ethoxy-1-ethoxycarbonyl-1,2-dihydroquinoline EtOAc = ethyl acetate Fmoc = 9-fluorenylmethoxycarbonyl GC = gas chromatography h = hour HATU = O-(7-Azabenzotriazol-1-yl)-1,1,3,3-tetramethyluronium hexafluorophosphate HBr = hydrobromic acid = hydrogen bromide HCl = hydrochloric acid = hydrogen chloride HOAc = acetic acid HOBt = hydroxybenzotriazole in vacuo = under vacuum L = liter MCPBA = meta-chloroperbenzoic acid Me = methyl mesyl = methanesulfonyl MgSO 4 = magnesium sulfate mL = milliliter NaOH = sodium hydroxide NMO = N-methylmorpholine oxide PEG = polyethylene glycol Ph = phenyl PhOH = phenol PfP = pentafluorophenol PyBroP = bromo-tris-pyrrolidino-phosphonium hexafluorophosphate rt = room temperature sat'd = saturated s- = secondary sat. = saturated t- = tertiary TBDMS = t-butyldimethylsilyl TFA = trifluoroacetic acid THF = tetrahydrofuran TLC = thin layer chromatography TMOF = trimethyl orthoformate TMS = trimethylsilyl tosyl = p-toluenesulfonyl Trt = triphenylmethyl
[0054] “Alkyl” is intended to include linear or branched hydrocarbon structures and combinations thereof of 1 to 20 carbons. “Lower alkyl” means alkyl groups of from 1 to 6 carbon atoms. Examples of lower alkyl groups include methyl, ethyl, propyl, isopropyl, butyl, s-and t-butyl, pentyl, hexyl, and the like.
[0055] “Cycloalkyl” refers to saturated hydrocarbons of from 3 to 12 carbon atoms having one or more rings. Examples of “cycloalkyl” groups include c-propyl, c-butyl, c-pentyl, c-hekyl, 2-methylcyclopropyl, cyclopropylmethyl, cyclopentylmethyl, norbornyl, adamantyl, myrtanyl, and the like. “Lower cycloalkyl” refers to cycloalkyl of 3 to 6 carbons.
[0056] C 1 to C 20 hydrocarbon includes alkyl, cycloalkyl, alkenyl, alkynyl, aryl and combinations thereof. Examples include phenethyl, cyclohexylmethyl, and naphthylethyl.
[0057] “Alkoxy” means alkoxy groups of from 1 to 8 carbon atoms of a straight, branched, cyclic configuration and combinations thereof. Examples of alkoxy groups include methoxy, ethoxy, propoxy, isopropoxy, cyclopropyloxy, cyclohexyloxy, and the like. “Lower alkoxy” means alkoxy having 1-4 carbon atoms.
[0058] “Halo” means halogen. Examples include F, Cl, Br, and I.
[0059] “Fluoroalkyl” refers to an alkyl residue in which one or more hydrogen atoms are replaced with F, for example: trifluoromethyl, difluoromethyl, and pentafluoroethyl.
[0060] “Arylalkyl” denotes a residue comprising an alkyl attached to an aromatic or heteroaromatic ring. Examples include benzyl, phenethyl, 4-chlorobenzyl, and the like.
[0061] “Aryl” means an aromatic hydrocarbon radical of 4 to about 16 carbon atoms, preferably 6 to about 12 carbon atoms, more preferably 6 to about 10 carbon atoms. Examples of suitable aromatic hydrocarbon radicals include phenyl and naphthyl.
[0062] For the purpose of the present invention, the term “combinatorial library” means a collection of molecules based on logical design and involving the selective combination of building blocks by means of simultaneous chemical reactions. Each species of molecule in the library is referred to as a member of the library.
[0063] As will be understood by the person of skill in the art, the linkers of the invention could be used in combinatorial synthesis to attach tags as well as to attach the moiety of putative chemical or pharmacological interest. Tags are chemical entities which possess several properties: 1) they are detachable from the solid supports, preferably by means orthogonal to those employed for releasing the compound of pharmacological interest; 2) they are stable under the synthetic conditions; and 3) they are capable of being detected in very small quantities, e.g., 10 −18 to 10 −9 mole. Suitable tags and methods for their employment are described in Still et al., U.S. Pat. No. 5,565,324, the entire disclosure of which is incorporated herein by reference.
[0064] The materials upon which combinatorial syntheses are performed are referred to as solid supports, beads, and resins. These terms are intended to include:
[0065] (a) beads, pellets, disks, fibers, gels, or particles such as cellulose beads, pore-glass beads, silica gels, polystyrene beads optionally cross-linked with divinylbenzene and optionally grafted with polyethylene glycol, poly-acrylamide beads, latex beads, dimethylacrylamide beads optionally cross-linked with N,N′-bis-acryloyl ethylene diamine, glass particles coated with hydrophobic polymer, etc., i.e., material having a rigid or semi-rigid surface; and (b) soluble supports such as polyethylene glycol or low molecular weight, non-cross-linked polystyrene. The solid supports may, and usually do, have functional groups such as amino, hydroxy, carboxy, or halo groups; where amino groups are the most common. Tentagel™ NH 2 (available from Rapp Polymere, Tubingen, Germany) is a preferred amine functionalized polyethylene glycol—grafted polystyrene resin. Techniques for functionalizing the surface of solid phases are well known in the art. Attachment of lysine to the amino groups on a bead (to increase the number of available sites) and subsequent attachment of linkers as well as further steps in a typical combinatorial synthesis are described, for example, in PCT application WO95/30642, the disclosure of which is incorporated herein by reference. In the synthesis described in WO95/30642, the linker is a photolytically cleavable linker, but the general principles of the use of a linker are well illustrated.
[0066] The invention relates to a substrate for solid phase synthesis comprising a solid phase-linker combination of the formula I:
[0067] wherein:
[0068] represents the residue of a solid support having a plurality of amino groups and the remainder constitutes the linker;
[0069] R 1 is —NO 2 or —CHO;
[0070] R 2 is —OCH 3 , —CHO or —H; and
[0071] n=1 or 3-12.
[0072] In these solid phase-linker combinations, the solid phase-linker combination is reacted with a reagent capable of reacting with an aldehyde to provide a support-linked synthon. A plurality of chemical transformations can be carried out on said support-linked synthon to provide a support-linked product. This support-linked product is known as the combinatorial library member. When R 1 is NO 2 and R 2 is CHO, the support-linked product can be treated under conditions of ultraviolet light to cleave the product from the support and linker. When R 1 is CHO and R 2 is OCH 3 , the support-linked product can be treated under conditions of mild acid to cleave the product from the support and linker. Usually trifluoroacetic acid (2-25%) in CH 2 Cl 2 completes the cleavage. Likewise, when R 1 is CHO and R 2 is H, the support-linked product can be treated under acidic conditions to cleave the product from the support and linker. Cleavage conditions are usually trifluoroacetic acid (50-100%) in CH 2 Cl 2 .
[0073] Additionally, this invention relates to a substrate for solid phase synthesis comprising a solid phase-linker combination of the formula III:
[0074] wherein:
[0075] represents the residue of a solid support having a plurality of amino groups and the remainder constitutes the linker;
[0076] R 2 is OCH 3 or —H; and
[0077] n=1 or 3-12.
[0078] In a process for solid phase synthesis, the solid phase-linker combination III is treated with a reagent capable of reacting with an aldehyde to provide a support-linked synthon. A plurality of chemical transformations can be carried out on said support-linked synthon to provide a support-linked product. The support-linked product can be treated with ultraviolet light to cleave the photocleavable support-linked product from the support and linker. The cleaved product is then tested for biological activity. The remaining solid support-linked product is then treated with trifluoroacetic acid to cleave the acid cleavable support-linked product from the support and linker. When R 2 =—OCH 3 , milder acid conditions (2-25% TFA/CH 2 Cl 2 ) are used to cleave the product. When R 2 =—H, more concentrated acid (50-100% TFA/CH 2 Cl 2 ) cleaves the product from the support. Again, the cleaved product is tested for biological activity. Cleaved products can also be tested for analytical properties (e.g., mass spectra, infrared, nuclear magnetic spectra, elemental analysis) and compound characteristics (e.g., solubility, stability, crystal structure) by methods known to those skilled in the art. In another mode, solid support-linked products can be tested for biological activity while on solid support and then cleaved at a later time. Typical examples of suitable biological assays are described in Baldwin et al., PCT application WO97/273 15, the disclosure of which is incorporated herein by reference.
[0079] The solid phase-linker combinations were prepared by the following routes:
[0080] Commercially available, 5-hydroxyisophthalic acid 1 in THF was reduced with borane-THF to provide the triol 2. Treatment of the triol 2 with gaseous bromine afforded the dibromide 3. The dibromide 3 was treated with t-butyl bromoacetate (n =1) and potassium carbonate in DMF to provide the ester 4. As an alternative, t-butyl propionate (n=3) provided the ester 4 where n=3. Other esters (n=4-12) may be prepared by reacting the appropriate ω-haloester as above. The linker in which n=2 is unstable in the presence of bases, and therefore not of general applicability to combinatorial synthesis, since it would only be practical in synthetic sequences that did not include base in any step. The linkers in which n is one or three are preferred because they are most readily accessible synthetically.
[0081] The photocleavable linker 5 and both the acid cleavable linkers, 6 and 7, were prepared from ester 4 as follows:
[0082] The ester 4 was treated with commercially available 5-hydroxy-2-nitrobenzaldehyde and potassium carbonate in DMF followed by treatment with 25% TFA in CH 2 Cl 2 to afford the photocleavable linker 5. To afford the acid cleavable linker 6, ester 4 was treated with commercially available 4-hydroxy-2-methoxybenzaldehyde and potassium carbonate in DMF followed by treatment with 25% TFA in CH 2 Cl 2 . Treatment of ester 4 with 4-hydroxybenzaldehyde and potassium carbonate in DMF followed by 25% TFA in CH 2 Cl 2 afforded the acid cleavable linker 7. These solid phase-linker combinations are “double loaded” on the di-(hydroxymethyl)phenoxy template which can be attached to the solid phase support. The ability to load increased amounts of compound on the “double load” solid phase-linker combinations is advantageous in solid phase combinatorial synthesis.
[0083] Condensation of the carboxylic acid portion of the linker with the solid phase support containing an amino functionality is completed by methods well known to those skilled in the art of the synthesis of combinatorial libraries on solid phase support. Coupling reagents include carbodiimides of various sorts, mixed anhydrides, EEDQ, HATU, and the like. The carboxylic acid portion of the linker may be treated with leaving groups capable of forming “activated esters.” Activated esters describe esters that are capable of undergoing a substitution reaction with primary or secondary amines to form an amide. Activated esters include esters “activated” by neighboring electron withdrawing substituents. Examples include esters of phenols, particularly electronegative substituted phenol esters such as pentafluorophenol esters; O-esters of isourea, such as arise from interaction with carbodiimides; O-esters of N-hydroxyimides and N-hydroxy heterocycles; specific examples include S-t-butyl esters, S-phenyl esters, S-2-pyridyl esters, N-hydroxypiperidine esters, N-hydroxysuccinimide esters, N-hydroxyphthalimide esters, and N-hydroxybenzotriazole esters. Solvents that are inert to the conditions of the condensation are “suitable solvents.” These include, for example, THF, DMF, DCM, and the like.
[0084] Coupling of the photocleavable linker to the resin support to provide the photocleavable solid phase-linker combination is shown:
[0085] Coupling of the acid cleavable linker to the resin support to provide the acid cleavable solid phase-linker combination is shown:
[0086] Coupling of the additional acid cleavable linker to the resin support to provide the more rigorous acid cleavable solid phase-linker combination is shown:
[0087] To improve the methods for making combinatorial libraries and the procedures for testing and analyzing the resulting library members, a solid phase-linker combination was synthesized which provided better control of the release of a support-linked product from the solid phase support. The dual solid phase-linker combination of formula III containing both the photocleavable solid phase-linker and the acid cleavable solid phase-linker allowed reliable cleavage of the support-linked products. A two stage, orthogonal release of a compound was achieved and based primarily upon the preloaded 1:1 ratio of the photocleavable/acid cleavable linker combinations. Photolytic cleavage permitted release of one half the total amount of support-linked product. Later, the remaining product was cleaved reliably under acid conditions in good overall yield. The advantage of employing such dual solid phase-linker combinations over the current linker technology is that this system reliably achieved the release of the product over a two-stage sequence in approximately 1:1 ratio. The orthogonal cleavage mechanisms of this dual solid phase-linker combination avoided the unnecessary development of a complicated kinetic cleavage profile.
[0088] A dual solid phase-linker combination of formula III (R 2 =—OCH 3 ) was prepared by coupling a 1:1 mixture of the photocleavable linker 5 and the acid cleavable linker 6 with the chosen aminomethylated resin support under known conditions. Later, a two-stage cleavage of attached compounds was achieved using photolysis followed by mild acid conditions.
[0089] To develop a solid phase-linker combination that provides a linker with greater stability under more acidic synthetic conditions, a dual solid phase-linker combination of formula III (R 2 =—H) was prepared by coupling a 1:1 mixture of the photocleavable linker 5 and the acid cleavable linker 7 with the chosen aminomethylated resin support under known conditions. Demonstrated release of attached compounds from the dual solid phase-linker combination was provided by photolysis and then treatment with acid conditions.
[0090] Methods of Synthesis
[0091] 3,5-di-(hadroxvmethyl)phenol (2)
[0092] To a solution of 5-hydroxyisophthalic acid 1 (30 g, 0.17 mol) in THF (1 L) at room temperature was added slowly a solution of BH 3 (800 mL, 1 M in THF). The resulting heterogeneous mixture was warmed to reflux overnight. The reaction mixture was cooled to room temperature whereupon 0.8 L of 1M HCl was carefully added. The resulting homogenous solution was concentrated in vacuo and the residues were treated with NaOH (42 g, 1.05 mol). Water was removed from the solution via concentration in vacuo and the residues were extracted with EtOAc (3×350 mL). The combined organic layers were dried (MgSO 4 ), filtered and concentrated in vacuo to give 28 g (93%) of triol 2 as thick colorless oil.
[0093] 3,5-di-(bromomethyl)phenol (3)
[0094] Triol 2 (55 g, 0.37 mmol) in chloroform (500 mL) at room temperature was bubbled with HBr gas for 2 h. The reaction vessel was capped and the resulting light brown solution continued to stir at room temperature until complete disappearance of triol 2 (TLC). The solvent was removed and the residues were washed with sat. aqueous NaHCO 3 . The aqueous layer was extracted with EtOAc (3×150 mL) and the combined organic layers were dried (MgSO 4 ), filtered and concentrated in vacuo to provide 83.4 g (91% based on acid 1) of dibromide 3 as a light brown solid.
[0095] t-butyl 3,5-di-(bromomethyl)phenoxyacetate (4, n=1)
[0096] Dibromide 3 (30 g, 0.11 mol) in DMF (750 mL) at room temperature was treated with potassium carbonate (45 g, 0.32 mol) and t-butyl bromoacetate (48 ml, 0.32 mol) was added dropwise to the solution. The resulting mixture was stirred at room temperature for overnight. Water (300 mL) and EtOAc (500 mL) were added and the layers were separated. The aqueous layer was extracted with EtOAc (3×100 mL) and the combined organic layers were dried (MgSO 4 ), filtered and concentrated in vacuo to afford ester 4 which was purified on silica gel (30:1-hexane:EtOAc). Further purification was accomplished by recrystallization with a mixture of hexane and diethyl ether (10:1) to give the ester 4 as white solid.
[0097] Photocleavable Linker (5)
[0098] The mixture of ester 4 (9.5 g, 24 mmol), potassium carbonate(13.3 g, 96.4 mmol) and 5-hydroxy-2-nitrobenzaldehyde (8.1 g, 48.2 mmol) in DMF (250 mL) was stirred at room temperature for 18 h. Water (200 mL) and EtOAc (200 mL) were added and the layers were separated. The aqueous layer was extracted with EtOAc (3×100 mL) and the combined organic layers were dried (MgSO 4 ), filtered and concentrated in vacuo. The residues were treated with 25% TFA in CH 2 Cl 2 (150 mL) and stirred at room temperature for 2 h. After removing the solvent, the residues were washed with Et 2 O (2×50 mL) and the resulting acid 5 was dried in vacuo to afford yellow solids.
[0099] Acid Cleavable Linker (6)
[0100] The mixture of ester 4 (3.0 g, 7.6 mmol), potassium carbonate (4.2 g, 30 mmol) and 4-hydroxy-2-methoxybenzaldehyde (2.3 g, 15 mmol) in DMF (75 mL) was stirred at room temperature for 18 h. Water (100 mL) and EtOAc (100 mL) were added and the layers were separated. The aqueous layer was extracted with EtOAc (3×50 mL) and the combined organic layers were dried (MgSO 4 ), filtered and concentrated in vacuo. The residues were treated with 25% TFA in CH 2 Cl 2 (100 mL) and stirred at room temperature for 2 h. After removing the solvent, the residues were washed with Et2O (2×50 mL) and dried in vacuo to provide the resulting acid 6 as white solids.
[0101] Acid Cleavable Linker (7)
[0102] The mixture of ester 4 (3.0 g, 7.6 mmol), potassium carbonate (4.2 g, 30 mmol) and 4-hydroxybenzaldehyde (1.8 g, 15 mmol) in DMF (75 mL) was stirred at room temperature for 18 h. Water (100 mL) and EtOAc (100 mL) were added and the layers were separated. The aqueous layer is extracted with EtOAc (3×50 mL) and the combined organic layers were dried (MgSO 4 ), filtered and concentrated in vacuo. The residues were treated with 25% TFA in CH 2 Cl 2 (100 mL) and stirred at room temperature for 2 h. After removing the solvent, the residues were washed with Et2O (2×50 mL) and dried in vacuo to afford the acid 7 as white solids.
[0103] Attachment of Linker to Resin:
[0104] Photocleavable Solid Phase-Linker (5) Combination
[0105] TentaGel™ resin (S—NH 2 , 10 g, 0.3 mmol/g, 3.0 mmol, 180-220 μm) was suspended in a solution of acid 5 (3.1 g, 6.0 mmol) and HOBT (0.81 g, 6.0 mmol) in DMF (35 mL), then treated with DIC (1.9 mL, 12 mmol). The suspension was shaken for 15 h, then the resin was washed with DMF (3×50 mL) and CH 2 Cl 2 (3×50 mL).
[0106] Acid Cleavable Solid Phase-Linker (6) Combination
[0107] TentaGel™ resin (S—NH 2 , 10.0 g, 0.33 mmol/g, 3.3 mmol, 180-220 μm) was suspended in a solution of acid 6 (3.2 g, 6.6 mmol) and HOBT (0.89 g, 6.6 mmol) in DMF (40 mL), then treated with DIC (2.1 mL, 13.2 mmol). The suspension was shaken for 15 h, then the resin was washed with DMF (3×50 mL) and CH 2 Cl 2 (3×50 mL).
[0108] Acid Cleavable Solid Phase-Linker (7) Combination
[0109] TentaGel™ resin (S—NH 2 , 10.0 g, 0.33 mmol/g, 3.3 mmol, 180-220 μm) was suspended in a solution of acid 7 (2.8 g, 6.6 mmol) and HOBT (0.89 g, 6.6 mmol) in DMF (40 mL), then treated with DIC (2.1 mL, 13.2 mmol). The suspension was shaken for 15 h, then the resin was washed with DMF (3×50 mL) and CH 2 Cl 2 (3×50 mL).
[0110] Attachment of 1:1/Photocleavable Linker (5): Acid Cleavable Linker (6) to Resin (III)
[0111] TentaGel™ resin (S—NH 2 , 630 mg, 0.33 mmol/g, 0.21 mmol, 180-220 μm) was suspended in a solution of acid 5 (106 mg, 0.21 mmol), acid 6 (100 mg, 0.21 mmol) and HOBT (56 mg, 0.42 mmol) in DMF (6 mL), then treated with DIC (129 μL, 0.83 mmol). The suspension was shaken for 15 h, then the resin was washed with DMF (3×20 mL) and CH 2 Cl 2 (3×20 mL).
[0112] Attachment of 1:1/Photocleavable Linker (5): Acid Cleavable Linker (7) to Resin (III)
[0113] TentaGel™ resin (S—NH 2 , 630 mg, 0.33 mmol/g, 0.21 mmol, 180-220 μm) was suspended in a solution of acid 5 (106 mg, 0.21 mmol), acid 7 (88 mg, 0.21 mmol) and HOBT (56 mg, 0.42 mmol) in DMF (6 mL), then treated with DIC (129 μL, 0.83 mmol). The suspension was shaken for 15 h, then the resin was washed with DMF (3×20 mL) and CH 2 Cl 2 (3×20 mL).
[0114] For combinatorial synthesis, either the photocleavable or acid cleavable solid phase-linker combination (formula I) or the dual solid phase-linker combination (formula III) is reacted with a primary or secondary amine or any compound known to react with an aldehyde. The choice of reagent is immaterial to the present invention and is determined by the nature of the combinatorial library sought to be synthesized. The number and nature of further reactions of the support-linked synthon is similarly dictated by the needs of the library. When the combinatorial synthesis is complete, the photocleavable linker is cleaved from the resin by photolysis in methanol. When the combinatorial synthesis is completed using an acid cleavable linker, the linker is cleaved from the resin by treatment with acid, preferably trifluoroacetic acid in dichloromethane, or HCl in diethyl ether or dioxane. When the combinatorial library is synthesized upon the dual solid phase-linker combination, the library product can be cleaved in approximately 50% yield with ultraviolet light. Complete cleavage of the remaining product is carried out under appropriate acidic conditions.
[0115] The above discussion of this invention is directed primarily to the preferred embodiments and practices thereof. It will be understood to those skilled in the art that further changes and modifications in the actual implementation of the teachings described herein could be made without departing from the spirit and the scope of the invention as defined in the following claims.
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A substrate for solid phase synthesis comprising a solid phase-linker combination of the formula I is disclosed. Also disclosed are processes for preparing the substrate and chemical intermediates useful therein. Among the novel intermediates are compounds of the formula II wherein R 1 is —NO 2 or —CHO; R 2 is —OCH 3 , —CHO or —H; R 3 is chosen from the group consisting of hydroxyl, the residue of a solid support having a plurality of amino groups, and the residue of an ester, and n=1 or 3-12.
A substrate of solid phase synthesis of the formula III is also disclosed.
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BACKGROUND OF THE INVENTION
The present invention relates to a new and improved apparatus for monitoring the weft thread in a weaving machine or the like.
In its more specific aspects the invention relates to a new and improved apparatus for monitoring the weft thread in a weaving machine, especially in a pneumatically operated weaving machine, which includes a sensing or scanning head comprising a transmitter and a receiver and sensing the weft thread. The monitoring apparatus further includes a signal processing and evaluating circuit connected to the sensing head.
An apparatus of this kind as known, for example, from German Patent Publication No. 2,513,356 comprises a transmitter section including at least one source of radiation and a receiving section including an even number of radiation detectors. The radiation sources and the radiation detectors are arranged at the internal circumference of a ring through which passes an insertion medium. Each radiation detector receives the radiation emanating from only one radiation source. The transmitter and the receiver are connected to a differential amplifier and a processing and evaluating device for the signals which are formed by the differential amplifier during a monitoring time interval, and such transmitter and receiver are also connected to switching means for cutting off the weaving machine. A comparator circuit in the processing and evaluating device is periodically placed into an operationally preparatory state by a switching device for predetermined monitoring intervals. The comparator circuit compares the signals with a reference or set value.
In another state-of-the-art apparatus as known, for example, from German Patent Publication No. 2,105,559, a ring-shaped weft-thread conveying fork is provided at each end thereof with a photoelectric transmitter and receiver which furnish a signal when the weft thread passes therethrough after the same has been inserted and beaten-up at the existent woven material, and which also furnish signals in the event that the weft thread is absent.
A known weft-thread monitoring device in a pneumatic weaving machine including a transport channel formed integrally with the reed comprises a transmitter and a receiver at the end of the reed on the catch side thereof. In case of different weaving widths different reeds of varying and corresponding widths have to be employed in order that there can be used the weft-thread monitoring apparatus.
In a further known weft-thread monitor there is required in the signal processing and evaluating means or circuit a sensitivity adjustment which has to be manually performed a number of times per day, depending upon the degree of contamination or soiling, so that the weft thread may be detected by a sensing beam of rays extending between an oscillator-supplied transmitter and a receiver. A selective amplifier, a rectifier, and a smoothing member are series connected to each other and to the receiver; to the smoothing member there is connected a comparator for comparison of the signal with a reference voltage supplied by a potentiometer, and a light-emitting diode is connected such as to indicate a weft thread which has been detected by the sensing beam of rays. In such an arrangement the weaving machine and the adjustment thereof must be continuously manually monitored.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind, it is a primary object of the present invention to provide a new and improved apparatus for monitoring the weft thread in a weaving machine, which monitoring apparatus can be simply mounted to and dismantled from the reed at different locations in correspondence to the width of the woven material without requiring any modifications, so that different width materials can be woven using one reed including the weft thread monitoring apparatus.
Another important object of the present invention is directed to the provision of a new and improved construction of an apparatus for monitoring the weft thread in a weaving machine which permits automatic adaptation of the intensity of the sensing beam to extraneous effects so as to obtain reliable thread recognition or detection in case of, for example, unavoidable contamination of the equipment.
Still a further significant object of the present invention is directed to a new and improved apparatus for monitoring the weft thread in a weaving machine which can be effectively used throughout a range of operating speeds of the weaving machine.
Another important object of the present invention is directed to a new and improved construction of an apparatus for monitoring the weft thread in a weaving machine by means of which the orderly function of the weaving machine can be effectively monitored and controlled.
Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the monitoring apparatus of the present development is manifested by the features that, the processing and evaluating circuit comprises a detecting circuit for deriving a thread signal which has been rendered independent of extraneous effects and a monitoring and control circuit connected to the detecting circuit for linking the thread signal to operating cycle intervals of the weaving machine in order to monitor and control the function thereof.
According to an advantageous further development of the monitoring apparatus according to the invention, the sensing head is structured so as to be releasably mounted at any desired location of a reed of the weaving machine, and at least sections or portions of the path of the sensing beam of rays emitted from the transmitter to the receiver extend between lamellae of the reed along the depth extension thereof and intersect the path of the inserted weft thread.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a side view of the sensing or scanning head in a first embodiment of weft-thread monitoring apparatus constructed according to the present invention;
FIG. 2 is a front view of the sensing head shown in FIG. 1;
FIG. 3 is a schematic block circuit diagram of a signal processing and evaluating circuit of the monitoring apparatus shown in FIG. 1;
FIG. 4 is a pulse diagram showing the pulses which occur in the presence of the weft thread at different locations of the signal processing and evaluating circuit shown in FIG. 3;
FIG. 5 is a pulse diagram showing the pulses which occur in the absence of the weft thread in the signal processing and evaluating circuit shown in FIG. 3;
FIG. 6 is a schematic block circuit diagram of a signal processing and evaluating circuit in a second embodiment of the weft-thread monitoring apparatus according to the invention;
FIG. 7 is a schematic block circuit diagram of a signal processing and evaluating circuit in a third embodiment of the weft-thread monitoring apparatus according to the invention;
FIGS. 8a and 8b are pulse diagrams showing the pulses which occur at different locations of the signal processing and evaluating circuit shown in FIG. 6 during the operating or run interval and during the stop interval of the weaving machine, respectively;
FIG. 9 is a pulse diagram showing the pulses which occur at different locations of the signal processing and evaluating circuit shown in FIG. 7;
FIG. 10 is a schematic block circuit diagram of a control circuit in a detecting circuit according to a fourth embodiment of the weft-thread monitoring apparatus according to the invention;
FIG. 11 is a schematic block circuit diagram of a control circuit in a detecting circuit according to a fifth embodiment of the weft-thread monitoring apparatus according to the invention;
FIG. 12 is a schematic illustration depicting the path of the sensing beam of rays in a sixth embodiment of the weft-thread monitoring apparatus according to the invention; and
FIG. 13 is a schematic illustration depicting the path of the the sensing beam of rays in a seventh embodiment of the weft-thread monitoring apparatus according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, it is to be understood that only enough of the construction of the weft-thread monitoring apparatus has been shown as needed for those skilled in the art to readily understand the underlying principles and concepts of the present development, while simplifying the showing of the drawings. Turning attention now specifically to the first embodiment of monitoring apparatus illustrated in FIGS. 1 to 5, the sensing or scanning head 1 of the weft-thread monitoring apparatus has arms or arm members 4 which extend between two respective adjacent lamellae 3 of a reed 2 when the sensing or scanning head 1 is mounted at the reed 2. In this arrangement the component or part 1a of the sensing head 1 containing the receiver 11 is releasably fixed on one side of the reed 2 to the arms 4 of the component or part 1b supporting the transmitter 10. Preferably the receiver 11 is placed on the one side of the transport or conveying channel 5 for the weft thread 6 and which transport channel 5 is integrated with the reed 2. The transmitter-carrying component 1b is arranged on the other side of the reed 2 facing away from the transport channel 5. In the present arrangement the transmitter 10 and the receiver 11 are placed in substantially rectilinear opposition to each other. The axis defined by the transmitter 10 and by the receiver 11 forms the axis of a sensing beam of rays or sensing beam 7. When assembling or mounting the sensing or scanning head 1 the axis of the sensing beam 7 is adjusted such that it generally intersects the flight or insertion path of the weft thread 6.
The transmitter 10 and the receiver 11 are connected via a connector 9 or equivalent structure to an electronic signal processing and evaluating circuit 15. This evaluation or evaluation circuit 15 comprises a detecting or detection circuit 16 and a monitoring and control circuit 17 operatively connected therewith. The detecting circuit 16 controls the intensity of the sensing or scanning beam of rays 7 as a function of extraneous effects such as contamination or soiling, outside light, aging and so forth, in order to obtain a system-dependent and essentially constant intensity of the sensing or scanning beam of rays 7, and thus, reliable thread recognition or detection signals. Additionally, the detecting or detection circuit 16 supplies the thread recognition signals and suppresses spurious signals which are caused, for example, by fluff or other thread parts or by outside or ambient light. The monitoring and control or controlling circuit 17 differentiates between the thread signals, which correctly arrive in respect of the operating cycle of the weaving machine or loom WM, and signals caused by malfunction and controls the weaving machine WM in correspondence thereto or cuts-off the same. The latter occurs particularly in the case of thread or yarn rupture.
The detecting circuit 16 comprises a control or regulating circuit 20 and a thread recognition circuit 40 which is operatively connected thereto. The detecting circuit 16 is connected to the monitoring and control circuit 17 of the signal processing and evaluating circuit 15. The detecting circuit 16 also contains electric components or sections 21 and 26 associated with transmitter 10 and the receiver 11, respectively; for abbreviation purposes, these components are also conveniently termed transmitter 21 and receiver 26 in the following description. In the detecting circuit 16 the transmitter 21 is connected to the output side 22a of a controllable current source 22, the input side 22b of which is connected to a suitable controllable control member 23 which, for example, may comprise a conventional sample-and-hold member or circuit composed of a switch and a capacitor. The controllable control member 23 comprises two inputs 30, 31 and an output 32. The first input 30 of the controllable control member 23 is connected to the output 14 of a comparator 24 to be described more fully hereinafter, and the second input 31 of the controllable control member 23 is connected to the monitoring and control circuit 17 also to be described more fully hereinafter. The output 32 is connected to the input side 22b of the controllable current source 22. The comparator 24 of the detecting circuit 20 has two inputs 12 and 13. The first input 12 is connected to the receiver 26 and the second input 13 is connected to the output side 25a of a reference voltage generator 25 which supplies an adjustable reference voltage to the comparator 24.
The receiver 26 is furthermore connected to the thread recognition circuit 40 and specifically to the input 36 of a first comparator 41 thereof. Series connected thereto is an integrator 42 and a second comparator 43 having an output 37. By appropriately selecting the threshold values of the first and second comparators 41 and 43 as well as the rise and fall times of the integrator 42, true thread signals can be reliably differentiated from spurious thread signals. The output 37 of the second comparator 43 is connected to the monitoring and control circuit 17.
This monitoring and control circuit 17 comprises a pulse generator or transmitter 50, for example a trigger, which is controlled by the weaving machine WM. The pulse generator 50 supplies a starting pulse of a control interval at a predetermined moment of time within the operating cycle of the weaving machine WM, for example, at an angle of 220° and, at a subsequent moment of time, for example at an angle of 310°, a stop pulse for limiting the control interval. The control interval may have the same length as a monitoring interval for establishing the correct insertion of the weft thread 6. However, the monitoring interval may also form a true sub-interval within the control interval. Only when the thread signal occurs within the monitoring interval, not only has the weft thread been inserted or introduced, but also has been inserted at the correct moment of time. On its output side 50a the pulse generator 50 is connected to a clock pulse generator 60. The clock pulse generator 60 is feed-back connected to define the start of the monitoring interval.
The clock pulse generator 60, as shown in FIG. 3, comprises a first AND-gate 61 having two inputs 38, 39 and an output 87 and further comprises a third AND-gate 65 having two inputs 51, 52 and an output 53. The first inputs 38 and 51 of the first and third AND-gates 61 and 65, respectively, are connected to the pulse generator 50. The output 87 of the first AND-gate 61 is connected, firstly, to an adjustable monostable or one-shot multivibrator 62 which acts as a timing element and, secondly, to the second input 101 of a counter 83 in a counting and indicating unit or circuit 80 which also forms part of the monitoring and control circuit 17.
In the clock pulse generator 60 there is further provided a first monostable or one-shot multivibrator 63 having two inputs 44, 45 and an output 46. The first input 44 or R-input is connected to the output 53 of the third AND-gate 65 and the second input 45 is connected to the output side 62a of the adjustable monostable multivibrator 62. The output 46 of the first monostable multivibrator 63 is firstly connected to the second input 31 of the controllable control member 23 in the detecting circuit 20 and, secondly, to the second input 48 of a second AND-gate 64, the first input 47 of which is connected to the output side 62a of the adjustable monostable multivibrator 62 and the output 49 of which is connected to the second input 52 of the third AND-gate 65. The output 49 of the second AND-gate 64 is also connected to the second input 39 of the first AND-gate 61 and to a counting pulse unit or circuit 70.
The counting pulse unit 70 which also forms part of the monitoring and control circuit 17 comprises a fourth AND-gate 71 having two inputs 73, 74 and an output 75. The first input 73 of the fourth AND-gate 71 is connected to the output 49 of the second AND-gate 64 in the clock pulse generator 60 and the second input 74 of the fourth AND-gate 71 is connected to a counting and indicating unit 80 as well as to a control unit 90, to be described more fully hereinbelow. The output 75 of the fourth AND-gate 71 is connected to the input of a counting pulse generator 72 having an output 77 which is connected to a third input 102 of the counter 83 in the counting and indicating unit or circuit 80. The counting pulse generator 72 may particularly comprise an astable multivibrator.
The counting and indicating unit or circuit 80 comprises a storage member 81, an indicator 82 and a five-stage forward counter 83. The storage member 81 has a first input 84 which is connected to the output 46 of the first monostable or one-shot multivibrator 63 in the clock pulse generator 60 and a second input 85 which is connected to the output 37 of the second comparator 43 in the thread recognition circuit 40 of the detecting circuit 16. The output 86 of the storage member 81 is connected to the indicator 82 and to a fourth input 103 of the counter 83. The first input 100 of the counter 83 is connected to the indicator 82, the second input 101 is connected to the output 87 of the first AND-gate 61 in the clock pulse generator 60, the third input 102 of the counter 83 is connected to the output 77 of the counting pulse generator 72 in the counting pulse unit or circuit 70, and the output 104 of the counter 83 is connected to the output or output side 105 of the counting and indicating unit 80. This output 105 is firstly connected to the second input 74 of the fourth AND-gate 71 in the counting pulse unit 70 and, secondly, to the control unit 90 which also forms part of the monitoring and control circuit 17. The control unit or circuit 90 comprises a fifth AND-gate 91 having two inputs 96, 97 and an output 98. The first input 96 is connected to the output 105 of the counting and indicating unit 80, while the second input 97 is connected to the output 53 of the third AND-gate 65 in the clock pulse generator 60. The output 98 is connected to a second monostable or one-shot multivibrator 92 and the output 92a thereof is connected to a relay 93 of the weaving machine or loom WM.
When the sensing or scanning beam of rays or sensing beam 7 is interrupted by a thread 6, the detecting circuit 16 supplies a signal to the monitoring and control circuit 17 which establishes whether the thread signal has been generated at the correct moment of time with respect to the operating cycle of the weaving machine or loom WM. When this is not the case, a signal is generated for cutting off the weaving machine WM which is then supplied to the shutdown relay 93 thereof.
The control circuit 20 in the detecting circuit 16 automatically controls or regulates the intensity of the sensing or scanning beam of rays 7. This control or regulation is performed when no signal is present at the second input 31 of the controllable control member 23. Under these conditions the switch contained in the controllable control member 23 is closed and the capacitor therein is charged. The receiver 26 supplies a d.c.-voltage which is compared in the comparator 24 with the reference or set voltage generated by the reference or set voltage generator 25. During normal operation the difference between the two voltages is equal to zero. If the difference is not equal to zero, then the current source 22 is controlled and the intensity of the sensing or scanning beam of rays 7 is varied until there is again set a voltage difference amounting to zero. This control or regulation operation occurs within a fraction of the operating cycle of the weaving machine or loom WM, which cycle, for example, is governed by the interval between the insertion of the weft thread and that of the next following weft thread. For the time period during which the control operation is carried out the weaving machine WM assumes an operational range or state which does not require control of the insertion of the weft thread. The time interval for the intensity control and the control interval, and thus, also the monitoring interval, do not overlap. However, it would also be possible to carry out the intensity control operation more slowly than for a fraction of the operating cycle of the weaving machine WM. Still, a rapid intensity control operation has proven to be more advantageous, i.e. an intensity control interval which is smaller than the operating cycle of the weaving machine.
A part of the operating cycle of the weaving machine or loom WM is defined as a monitoring interval (hold operation) for recognizing or detecting the weft thread 6. Within this monitoring interval there is established, firstly, whether a thread signal occurs and, secondly, whether it occurs at the correct moment of time.
The operation of the weft-thread monitoring apparatus described hereinafter will now be explained in detail with reference to FIGS. 4 and 5, wherein FIG. 4 relates to the case of a present weft thread and FIG. 5 to the case of an absent weft thread.
The pulse generator or trigger 50 which is controlled by the weaving machine or loom WM supplies a starting pulse and at some later moment of time a stop pulse, for example, at loom shaft angles of 220° and 310°, respectively, during the operating cycle. The control interval is established by these pulses. By means of the starting pulse, on the one hand, the intensity control of the sensing beam of rays 7 is terminated in the intensity control circuit 20. This is effected by opening the switch contained in the controllable control member 23 i.e. the sample-and-hold circuit. Since the capacitor therein is charged, such capacitor controls the controllable current source 22 which supplies the current for the sensing or scanning beam of rays 7 in accordance with the last intensity value which was present prior to the end of the intensity control interval.
The monitoring interval, for example, is constituted by a sub-interval of the control interval and is established by the feed-back connected clock pulse generator 60 in combination with the counting and indicating unit or circuit 80. When a weft thread 6 intersects the sensing or scanning beam of rays 7 within the monitoring interval, then a voltage surge or jump occurs in the receiver 26 and such arrives at the first comparator 41 of the thread recognition circuit 40. When the pulse possesses a sufficient length or duration then the voltage in the integrator 42 rises within the contemplated rise time, which is matched to the actual conditions, to a value which corresponds to the threshold value of the series connected second comparator 43. A thread pulse then is supplied to the storage member 81 in the counting and indicating unit 80.
The starting pulse of the pulse generator 50, on the other hand, places the monitoring and control circuit 17 into a state, corresponding to the monitoring interval, in which a thread signal from the receiver 26 can be accepted. Accordingly, the adjustable monostable or one-shot multivibrator 62 and the first monostable or one-shot multivibrator 63 are set to a first state. The moment of time at which the adjustable monostable multivibrator 62 is reset is adjustable, and thus, there is triggered the course or run of counting pulses at the counting pulse generator 72 in the counting pulse unit or circuit 70. The sequence of counting pulses which is thus produced is applied to the five-stage forward counter 83 of the counting and indicating unit 80. The counter 83 stops upon arrival of a thread pulse from the detecting circuit 16 via the storage member 81, when such thread pulse occurs within the monitoring interval. If no thread pulse arrives, then the counter 83 stops at a predetermined counting stage. Also, the counter 83 may furnish a cut-off pulse to the counting pulse generator 72 which may be constituted by an astable multivibrator. The indicator 82 connected to the five-stage forward counter 83 comprises a light-emitting diode for each counting pulse or each group of counting pulses. Only that light-emitting diode lights-up which is associated with the counting pulse which coincides with the thread signal. For example, a green light-emitting diode lights-up when the thread signal occurs within a predetermined or reference range and no control pulse is supplied to the relay 93 for cutting-off the weaving machine WM. However, if the thread signal occurs before or after the predetermined or reference range, for example, a red light-emitting diode lights-up and a cut-off pulse is supplied. Depending upon the construction of the indicator 82 the same also may be employed for error indication of a defective run or operation of the weaving machine WM, because the position of the thread signal enables such interpretations. Specifically, the signal processing and evaluating circuit 15 can be adjusted or set by means of the adjustable monostable or one-shot multivibrator 62 such that always the same light-emitting diode lights-up when the thread signal occurs at the correct moment of time. When the thread signal does not occur at the correct moment of time, then the corresponding indication can be fixedly maintained which simplifies the error detection.
The thread recognition circuit 40 in the detecting circuit 16 differentiates between fluff or the like originating from the threads and the weft thread 6. A fluff particle will only produce a short pulse. In the case of a short pulse the integrator 42, due to its rise time, cannot reach a value corresponding to the threshold value of the series-connected second comparator 43. The threshold value is selected and adjusted in relation to a true thread pulse. Thus, a fluff-generated pulse can be unequivocally distinguished from a thread pulse.
Thread vibration is also filtered out by the thread recognition circuit 40. When the weft thread 6 leaves the range of the sensing or scanning beam of rays 7 for a short period of time, this short period of time will be insufficient for the integrator 42 to lower the voltage value below the threshold value of the second comparator 43. Therefore, the integrator 42 does not change its output signal. The thread pulse remains at the storage member 81.
The transmitter 10 may be arranged in the sensing or scanning head 1 such that the transmitter is located on the rear side of the loom reed 2 and the receiver 11 on the front side thereof. Due to the geometric conditions in a reed with integrated weft-thread channel or passage 5 such a transmitter and receiver arrangement can be advantageous because, due to the shorter distance between the weft thread 6 and the receiver 11, there is obtained a larger scanning or sensing field. Such larger scanning field may compensate for the higher contrast obtained at larger distances.
A second embodiment of the weft-thread monitoring apparatus according to the invention is illustrated in the schematic block circuit diagram of FIG. 6. In the monitoring and control circuit 17* thereof there is provided a pulse generator or trigger 50*, an inverter 51*, the input side 51a of which is connected to the pulse generator 50*, a storage member 81*, a first input 84* of which is connected to the pulse generator 50* and a second input 85* of which is connected to the output 37* of the second comparator 43* in the thread signal recognition circuit 40*. There is also provided a controllable control member 23* comprising a sample-and-hold member or circuit, a first input 30* of which is connected to an output 14* of a comparator 24* and a second input 31* of which is connected to the pulse generator 50*. A first input 12* of the comparator 24* is connected to the receiver 26* and a second input 13* to a reference or set voltage generator 25* The other components like the transmitter 21* and the current source 22* correspond to those described hereinbefore with reference to FIG. 3. At its output side 51b the inverter 51* is connected to a second input 97* of an AND-gate 91*, the first input 96* of which is connected to the output 86* of the storage member 81*. The AND-gate 91* is connected in series with a dynamic monostable or one-shot multivibrator 95* and such, in turn, again is connected to a relay 93* for controlling the weaving machine or loom WM and the last-mentioned components together form a control unit 90*. The operation of the weft-thread monitoring apparatus is just described in FIGS. 8a and 8b portraying the respective case of a present weft thread and an absent weft thread.
According to a third embodiment of the inventive weft-thread monitoring apparatus, the operation of which is briefly illustrated in FIG. 9, the signal processing and evaluating circuit, as shown in FIG. 7, comprises a control unit or circuit 90** which is directly controlled by a pulse generator 50** and a storage member 81**. The storage member 81** has a first input 84** connected to the pulse generator 50**, a second input 85** connected to the output side of the thread recognition circuit 40** and an output 86**. The control unit 90** contains a dynamic AND-gate 95**, the first input 96** of which is connected to the output 86** of the storage member 81** and the second input 97** of which is connected to the pulse generator 50**. The output 98** of the dynamic AND-gate 95** is connected to a second monostable or one-shot multivibrator 92** which, in turn, is connected to a relay 93** controlling the weaving machine or loom WM. The detecting circuit 16** includes the same components and operates in the same way as the detecting or detector circuit 16 described heretofore with reference to FIG. 3.
In a fourth embodiment of the apparatus as shown in FIG. 10, the control or regulation circuit 20' comprises a transmitter 21' which is controlled by an amplitude-controlled oscillator 22'. The latter is controlled by a controllable control member 23' which, for instance, is constituted by a sample-and-hold member or circuit, and a first input 30' of which is connected to the output 14' of a comparator 24'. The second input 31' of the controllable control member 23' is connected to the pulse generator 50. The comparator 24' has a first input 12' connected to the receiver 26' via a selective filter 27', a rectifier 28'-1 and a smoothing member 28'-2, and a second input 13' connected to a reference or set voltage generator 25'. In the comparator 24' the signal received from the smoothing member 28'-2 is compared with the reference or set voltage generated by the reference voltage generator 25'. Comparable to the arrangement shown in FIG. 3 concerning the first embodiment of the inventive monitoring apparatus here too a similar thread recognition circuit 40' is connected to the output side of the smoothing member 28'-2. In this embodiment while the transmitter 21' produces a pulsating beam of rays, this embodiment still functions generally in the same manner as the first embodiment operating with non-alternating and a controlled light intensity. The monitoring and control circuit (here not shown) is connected to the output side of the thread recognition circuit 40' and can be constructed like any one of the circuits 17, 17* or 17** described hereinbefore.
A fifth embodiment of the apparatus according to the invention is illustrated in FIG. 11, which shows a different control or regulation circuit 20" which comprises an oscillator 22" connected to the transmitter 21". The signal generated by the receiver 26" arrives at a first input 12" of a comparator 24" via a selective amplifier 27", a rectifier 28"-1 and a smoothing member 28"-2 to which there is also connected a thread recognition circuit 40". At the comparator 24" the signal is compared to the constant reference or set voltage which is generated by the reference or set voltage generator 25" and supplied to a second input 13" of the comparator 24". The output 14" of the comparator 24" is connected to the first input 30" of the controllable control mcmber 23", the second input 31" of which is connected to the pulse generator 50. The output 32" of the controllable control member 23", which also may be constituted by a sample-and-hold member or circuit, is connected to a second input 35" of the selective amplifier 27", the first input 34" of which is connected to the receiver 26". When the switch contained in the controllable control member 23" is closed, the signal is supplied to the selective amplifier 27" and controls the same. When a non-zero difference is detected in the comparator 24", the range at the selective amplifier 27" is readjusted. The intensity control operation is terminated by the pulse generated by the pulse generator 50, and the selective amplifier 27" is maintained at its last adjusted operating range. The monitoring and control circuit (not shown) is connected to the output of the thread recognition circuit 40" and can be constructed like any one of the circuits 17, 17* or 17** as described hereinbefore.
In other arrangements like that shown in FIG. 12, the sensing or scanning beam of rays 7' extend along two or more straight lines which form the circumference or outline of a polygon. In the arrangement of FIG. 12 as well as that of FIG. 13 one or more mirrors 8 or other suitable reflectors are employed for deflecting the beam of rays. Such path of rays may be advantageous for a particularly compact construction of the sensing or scanning head 1 or for satisfying special spatial conditions at the reed 2.
In the arrangements of FIGS. 12 and 13 the transmitter 10 and the receiver 11 are located on the same side of the reed 2 in contrast to, for instance, the arrangement of FIG. 1 where the transmitter 10 and the receiver 11 are arranged at opposite sides of the reed 2.
Furthermore, the sensing beam of rays emitted by the transmitter may be either totally or partially masked by the inserted weft thread.
According to further possible constructions of the inventive weft-thread monitoring apparatus, the signal processing and evaluating circuit comprises microprocessors which are designed to perform all of the switching functions of the circuit combinations described hereinbefore.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. Accordingly,
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The weft thread monitoring apparatus contains a detecting circuit incorporating the functions of a thread recognition circuit and a control circuit for controlling the intensity of a thread sensing or scanning beam which is affected by extraneous effects like outside light, the presence of fluff and other influences. A monitoring and controlling circuit defines monitoring and control intervals to differentiate between thread signals which are respectively correctly and incorrectly related to the operating cycle of the weaving machine and to possibly cut off the weaving machine. A sensing head can be simply mounted and dismantled at any desired location at the reed of the weaving machine so that different widths of the woven material or fabric can be manufactured using the same reed and the weft thread can be monitored. By periodic indication of the thread signal the correct run or operation of the weaving machine also can be monitored. The thread signal indication is conceived such that malfunctions can be recognized from such indication.
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BACKGROUND OF THE INVENTION
[0001] This invention relates generally to lighting and more particularly, to ceramic discharge chambers for a discharge lamp, such as a ceramic metal halide lamp or a high pressure sodium discharge lamp.
[0002] The present invention relates generally to lighting, and more specifically, to a ceramic arc chamber for a discharge lamp, such as a ceramic metal halide lamp. This invention relates particularly to a method of manufacturing ceramic arc chambers, and more particularly, to a method for forming ceramic arc chambers.
[0003] Discharge lamps produce light by ionizing a fill such as a mixture of metal halides and mercury with an electric arc passing between two electrodes. The electrodes and the fill are sealed within a translucent or transparent discharge chamber which maintains the pressure of the energized fill material and allows the emitted light to pass through it. The fill, also known as a “dose”, emits a desired spectral energy distribution in response to being excited by the electric arc.
[0004] Previously, the discharge chamber in a discharge lamp was formed from a vitreous material such as fused quartz, which was shaped into a desired chamber geometry after being heated to a softened state. Fused quartz, however, has certain disadvantages which arise from its reactive properties at high operating temperatures. For example, at temperatures greater than about 950 to 1,000° C., the halide fill reacts with the glass to produce silicates and silicon halide, reducing the fill constituents. Elevated temperatures also cause sodium to permeate through the quartz wall. These fill depletions cause color shift over time, which reduces the useful life of the lamp.
[0005] Ceramic discharge chambers were developed to operate at high temperatures for improved color temperatures, color renderings, and luminous efficacies, while significantly reducing reactions with the fill material. U.S. Pat. Nos. 4,285,732 and 5,725,827, for example, disclose translucent polycrystalline sintered bodies where visible wavelength radiation is sufficiently able to pass through to make the body useful for use as an arc tube.
[0006] Typically, ceramic discharge chambers are constructed from a number of parts extruded or die pressed from a ceramic powder and then sintered together. For example, referring now to European Patent Application No. 0587238, five ceramic parts are used to construct the discharge chamber of a metal halide lamp. Two end plugs with a central bore are fabricated by die pressing a mixture of a ceramic powder and inorganic binder. A central cylinder and the two legs are produced by extruding a ceramic powder/binder mixture through a die. After forming the part, it is typically air sintered between 900-1400° C. to remove organic processing aids. Assembly of the discharge chamber requires tacking of the legs to the cylinder plugs, and the end plugs into the end of the central cylinder. This assembly is then sintered to form joints which are bonded by controlled shrinkage of the individual parts. Obviously, a simplified form of the product would be achieved by the reduction in the number of components separately formed. Moreover, the step of properly joining the compounds is time consuming, expensive and a potential point of failure.
[0007] Typically, ceramic discharge chambers are constructed from a number of parts extruded or die pressed from a ceramic powder. For example, end plugs with the central bore may be fabricated by die pressing a mixture comprising a ceramic powder and an organic binder. A central cylinder, and the two legs may be produced by extruding a ceramic powder/binder mixture through a die. Assembly of the discharge chamber involves the placement and tacking of the legs to the end plugs and the end plugs into the ends of the central cylinder. This final assembly is then sintered to form four centered joints which are bonded by controlled shrinkage of the individual parts. The conventional ceramic discharge chamber method of construction has a number of disadvantages. For example, the number of component parts is relatively large and introduces the corresponding number of opportunities for variation and defects. Also, the conventional discharge chamber includes four bonding regions, each of which introduces an opportunity for lamp failure by leakage of the fill material if the bond if formed improperly. Each bonding area also introduces a region of relative weakness, so that even if the bond is formed properly, the bond may break during handling or be damaged enough in handling to induce failure in operation.
[0008] Another disadvantage relates to the precision with which the parts can be assembled and the resulting effect in the light quality. It is known that the light quality is dependent to a substantial extent on the voltage across the electrode gap, which in turn is dependent on the size of the gap consistently achieve the gap size within an acceptable tolerance without significant effort devoted to optimizing the manufacturing process. Accordingly, it would be desirable to minimize the component parts necessary to manufacture the ceramic arc chamber. However, divergent shrinkage rates of variously shaped components and other factors have limited the ability to manufacture in a more efficient manner.
BRIEF SUMMARY OF THE INVENTION
[0009] According to an exemplary embodiment of the invention, a method is provided for making a component of a ceramic discharge chamber by forming a ceramic composition including a ceramic powder, a binder, and a grain growth inhibitor. The ceramic powder has a tap density of greater than about 1.0 gm per cc. The ceramic composition is then die pressed to form the desired ceramic discharge chamber preform component. The preform component can then be assembled with additional preform components into a presintered discharge chamber and sintered to join the components via controlled shrinkage.
[0010] The preform components of the present invention can facilitate the assembly of an arc discharge chamber from fewer components than demonstrated previously. Moreover, the present method allows intricate shaped components to be die pressed. More specifically, the end cap members can be die pressed in the shape of the disk shaped body and leg extension. This clearly provides a manufacturing simplicity versus conventional manufacturing steps which included the extrusion of leg portions which must then be secured to end caps or extensive machining.
[0011] Exemplary embodiments of the invention can be used to improve the performance of various types of lamps, such as metal halide metals, high pressure mercury vapor lamps, and high pressure sodium vapor lamps.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Other features and advantages of the invention will be readily understood upon reading the following detailed description. in conjunction with the drawings, in which:
[0013] [0013]FIG. 1 illustrates a light source which includes a ceramic discharge chamber according to the exemplary embodiment of the invention; and
[0014] FIGS. 2 A- 2 C illustrate components of a discharge chamber for a metal halide lamp.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] [0015]FIG. 1 illustrates a discharge lamp 10 according to an exemplary embodiment of the invention. Discharge lamp 10 includes a discharge chamber 50 which contains two electrodes 52 , 54 and fill material. Electrodes 52 , 54 are connected to conductors 56 , 58 , which apply a potential difference across the electrodes. In operation, the electrodes 52 , 54 produce an arc which ionizes a fill material to produce a plasma in the discharge chamber 50 . The emission characteristics of the light produced by the plasma depend primarily on the constituents of the fill material, the voltage across the electrodes, the temperature distribution of the chamber, the pressure in the chamber, and the geometry of the chamber. For a ceramic metal halide lamp, the fill may typically comprise a mixture of Hg, a rare gas such as Ar or Xe and a metal halide such as NaI, TlI DyI 3 . For high pressure sodium lamp, the fill material typically comprises sodium, a rare gas, and Hg. Other fill materials are also well known in the art, and the present invention is believed to be suitable for operation with any of those recognized ionizable materials.
[0016] As shown in FIG. 1, the discharge chamber 50 comprises a central body portion 60 and two leg portions 62 , 64 . The ends of the electrodes 52 , 54 are typically located near the opposite ends of the body portion 60 . The electrodes are connected to a power supply by the conductors 56 , 58 which are disposed within a central bore of each leg portion 62 , 64 . The electrodes are typically comprised of tungsten. The conductors typically comprise niobium and molybdenum which have thermal expansion coefficients close to that of alumina to reduce thermally induced stresses on the alumina leg portion 62 , 64 .
[0017] The discharge chamber 50 , is sealed at the ends of the leg portions 62 , 64 with seals 66 , 68 . The seal 66 , 68 typically comprise a disprosia-alumina-silica glass that can be formed by placing a glass frit in the shape of a ring around one of the conductors, eg. 56 , aligning the discharge chamber 50 vertically and melting the frit. The melted glass then flows down into the leg 62 , forming a seal between the conductor 56 and the leg 62 . The discharge chamber is then turned upside down to seal the other leg 64 after being filled with the fill material.
[0018] The leg portion 62 , 64 , extends axially away from the center of the discharge chamber 50 . The dimensions of the leg portions 62 , 64 are selected over the temperature of the seal 66 , 68 by desired amount with respect to the center of the discharge chamber 50 . For example, in a 70 watt lamp, the leg portion portions have a length of about 10-15 mm, an inner diameter of 0.8-1.0 mm and an outer diameter of about 2.5-3.0 mm to lower the temperature at the seal 66 , 68 to about 600 to 700° C., which is about 400° C. less than the temperature at the center of the discharge chamber. In a 35 watt lamp, the leg portions have a length of about 10-15 mm, an inner diameter of 0.7 to 0.8 mm and an outer diameter of about 2.0-2.5 mm. In a 150 watt lamp, the leg portions have a length of about 12-15 mm and an inner diameter of about 0.9-1.1 mm, and an outer diameter of about 2.5-3.0 mm. These dimensions, and others through the specification, are of course given as examples and are not intended to be limiting.
[0019] The body portion 60 of the discharge chamber is typically substantially cylindrical. For a 70 watt lamp, the body portion typically has an inner diameter of about 7 mm and outer diameter of about 8.5 mm. For a 35 watt lamp, the body portion typically has an inner diameter of about 5 mm and an outer diameter of about 6.5 mm. For a 150 watt lamp, the body portion typically has an inner diameter of about 9.5 mm and an outer diameter of 11.5 mm.
[0020] An exemplary embodiment of the invention is provided in FIGS. 2A, 2B and 2 C, demonstrating a discharge chamber formed from three components. FIGS. 2 A- 2 C illustrate components of a discharge chamber formed from three elements. In FIG. 2B, a body member 122 is shown which is substantially cylindrical. The body member 122 of FIG. 2B can be formed by injection molding, die pressing, or by any other technique known in the art. For example, the body member 122 can also be formed by extrusion. The composition used may comprise, for example, 75% by weight alumina powder, 22% by weight of water soluble polyacrylamide and 3% by weight of stearate. The alumina powder may also be doped with magnesia.
[0021] The leg member 124 is depicted which includes a leg portion 112 and a transition portion 114 . Both the leg portion 112 and the transition portion 114 include a central bore 109 which houses one of the two electrodes and the conductor. Transition portion 114 may be generally in the form of a plug which fits inside the end of the body member 122 . Transition portion 114 typically has a circumference which is greater than the circumference of the leg portion 112 . Transition portion 114 typically includes a radially directed flange 115 which projects radially outwardly from transition portion 114 . The radially directed flange 115 provides a shoulder 117 which rests against the end 119 of the body member 100 during assembly and fixes the relative axial position of leg member 124 with respect to the body member 122 . “Axiar” refers to an axis through the central bores 107 , 109 in leg portions 112 , 126 . The radially directed flange 115 provides the advantage of the total length of the assembled discharge chamber, e.g. measured from the end 118 of leg member 120 to the opposite end 116 of leg member 124 can be maintained to within a tight dimensional tolerance. The total length of the discharge chamber typically effects the separation between the electrodes, since the electrodes are typically referenced to the ends 116 , 118 of the leg portions, 120 , 126 during assembly. For example, the conductor may be crimped at a fixed distance from the end of the electrode, which crimp rests against of the leg portion to fix the axial position of the electrode with respect to the leg portion. Because the axial position of the electrodes is fixed with respect to the leg portions, the separation of the electrodes is determined by the position of the leg member 124 with respect to the body member 122 which can be precisely controlled by the radially directed flange 115 . The radially directed flange 115 thus allows the electrodes to be consistently positioned to have a precise separation distance, which provides consistency and quality of the light produced.
[0022] The leg members 120 , 124 are constructed by die pressing a mixture of ceramic powder in a binder. Typically, the mixture comprises between about 80 and 99% by weight ceramic powder and about 1 and 20% by weight organic binder, preferably between about 95 and 98% and 2 and 5%, respectively. The ceramic powder may comprise alumina (Al 2 O 3 ) having a purity of at least 99.98% and a surface area of about 2-10 meters squared per gram. The alumina powder will have a tap density greater than 1 g/cc. Alumina powder may be doped with magnesia to inhibit grain growth, for example in an amount equal to 0.03%-0.2%, preferably 0.05% by weight of the alumina. Accordingly, the present ceramic powder mixture allows die pressing of the complex leg member shape without tacking the leg to the body or extensive machining.
[0023] Other ceramic materials which may be used include non-reactive refractory oxides and oxynitrides such as yttrium oxide and hafnium oxide and compounds of alumina such as yttrium-alumina-garnet and aluminum oxynitride. Binders which may be used individually or in combination include organic polymers, such as polyols, polyvinyl alcohol, vinyl acetates, acrylates, cellulosics and polyesters.
[0024] Subsequent to formation, the binder is removed from the green part, typically by thermopyrollisis, to form a bisque-fired part. The thermopyrollisis may be conducted, for example, by heating the green part in air from room temperature to a maximum temperature of about 900-1100° C. over 48 hours, then holding the maximum temperature from 1-5 hours, and cooling the part. After thermopyrollisis, the porosity of the bisque-fired part is typically about 40-50%. The bisque-fired part is then machined. For example, a small bore may be drilled along the axis of the solid cylinder which provides bore 107 in leg member 120 . Next a large diameter bore may be drilled along the portion of the axis to form the chamber 101 . Finally, the outer portion of the originally solid cylinder may be machined away along part of the axis, for example, by lathe, to form an outer surface of leg portion 126 . The machined parts are typically assembled prior to sintering to allow the sintering step to bond the parts together.
[0025] According to an exemplary method of bonding, the densities of the bisque-fired parts used to form the body member 122 and the leg members 120 , 124 are selected to achieve different degrees of shrinkage during the sintering step. The different densities in the bisque-fired parts may achieved by using ceramic powders having different surface areas. For example, the surface area of the ceramic powder used to form body member 122 may be 10-15 meters squared per gram, while the surface area of the ceramic body used to form the leg members 120 and 124 may be 2-4 meters squared per gram. The finer powder in the body member 122 causes the bisque-fired body member 122 to have a lower density than the bisque-fired leg members 120 and 124 made from the coarser powder. Because the bisque-fired body member is less dense than the bisque-fired leg members, the body portion shrinks to a greater degree (eg 3-10%) during sintering than the transition portion 114 to form a seal along transition portion 114 .
[0026] The sintering step may be carried out by heating the bisque-fired parts in hydrogen having a dew point of about 10-15°. Typically, the temperatures increase from room temperature to about 1300° C. over a two hour period. Next, the temperature is held to about 1300° C. for about 2 hours. Next, the temperature is increased by about 100° C. per hour up to a maximum temperature of about 1850-1880° C. Next, the temperature is held at 1850-1880° C. for about 3.5 hours. Finally, the temperature is decreased from room temperature for two hours. The resulting ceramic material comprises densely sintered polycrystalline aluminum.
[0027] An exemplary composition which has been used for die pressing the leg members 120 , 124 , comprises 95% by weight alumina powder having a surface area of 3-5 meters squared per gram, available from Reynolds Chemicals, as product number RC-HPT. The alumina powder is preferably spray dried and is formed via dry milling. The alumina powder is typically doped with magnesia in the amount of 0-0.05% of the weight of the alumina. The composition also includes 4% by weight polyvinyl alcohol and 1% by weight Carbowax 600, available from Interstate Chemical.
[0028] The alumina powder or other ceramic of choice, will have a tap density greater than 1.0 gram per cc as defined by ASTM B527-93 (1997). More preferably, the tap density will be in the range of 1.2 to about 1.5 grams per cc. The resultant ceramic powder composition can be die pressed according to a fill ratio of at least about 1.8.
[0029] Die pressing at approximately 10,000 pounds per square inch is typically employed. Preferably, a Model 602 Double Action Press from Pentronix, Inc. may be used as the die pressing equipment.
[0030] Although the invention has been described with reference to exemplary embodiments, various changes and modifications can be made without departing from the scope and spirit of the invention. These modifications are intended to fall within the scope of the invention, as defined by the following claims.
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A method of making a component of a ceramic discharge chamber comprising the steps of forming a ceramic composition including an aluminum powder, a binder and a grain growth inhibitor. The alumina powder has a tap density greater than 1.0 gram per cc. The ceramic composition is then die pressed to form a component preform. Next, the component preform is heated to remove at least a substantial portion of the binder.
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BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to liquid metal cooled nuclear reactors, and more particularly to improved viewers using ultrasonic signals, which are submerged in the liquid metal, for detecting in a liquid metal cooled nuclear reactors the presence of a floating core component.
Background of the Invention
In one construction of a liquid metal cooled nuclear reactor, the reactor core, heat exchangers and coolant circulating pumps are submerged in a pool of liquid metal coolant. In operation of this nuclear reactor it is necessary to be able to locate and identify components submerged in the pool, and to do so before moving rotating shields in the roof of the pool in order to ensure that all the normally suspended absorber rods have been inserted in the core.
Television cameras are unsuitable for use in the opaque liquid metal to locate and identify components submerged therein. Therefore ultrasonic signals in the mega hertz frequency range have been used to produce a television-like visual display.
However, in the past difficulty has been experienced in the transmission of ultrasonic signals from a submerged transducer because the transducer must be protected from the high temperature environment of the reactor coolant and because core components do not always float up perpendicularly.
As diagrammatically shown in FIG. 1, a prior art submerged viewer utilizing ultrasonic signals is seen to consist of a transducer 10 which functions both as a transmitter and as a receiver. The transducer 10 is driven by a driving mechanism 11 installed in the center of a rotating shield 12. The submerged prior art viewer further includes a dip stick 13 by which the transducer 10 is suspended from the rotating shield 12. Transducer 10 can descend lower than a lower part 14 of upper core structure 15. Core components 16 which consist of core fuel assemblies, blanket fuel assemblies, removable shielding assemblies and the like are located under the upper core structure 15. The gap between the lower part 14 of the upper core structure 15 and the core components 16 is small, for example, about 50 mm.
Normally, none of the core components 16 float upwardly, but one of the core components 16 can be slightly floated upwardly by the pressure of liquid metal and the like. In order to prevent any floating core components from colliding with the lower part 14 of the upper core structure 15, the submerged viewer detects the floating core components. Namely, the ultrasonic signals which are transmitted from the transmitter of transducer 10 are reflected by the handling head 17 of the floating core components and the reflected ultrasonic signals from the handling head 17 are scanned by the receiver of transducer 10. Accordingly, when the viewer detects a floating core component, the action of the upper core structures 15, for example, control rod driving mechanism, are stopped to prevent the floating core components from colliding with the upper core structures 15.
Furthermore, as diagramatically shown FIG. 2, another prior art submerged viewer utilizing ultrasonic signals is seen to include a transducer 10 set aside from the center of rotating shield 12, and reflector plates 18 in the reactor vessel. The ultrasonic signals which are transmitted from the transmitter of transducer 10 are reflected by the reflecting plates 18 and the reflected ultrasonic signals from the reflector plates 18 are scanned by the receiver of the transducer 10.
Theoretically, prior art viewers submerged in liquid metal can detect floating core components effectively. However actually reflected ultrasonic sounds from the handling head 17 of the floating core components (in FIG. 1) or from the reflecting plates 18 (in FIG. 2) are not always received by the receiver of the transducer 10, for reasons hereinafter described. This is true because the handling head 17 of the core component 16 has, as shown in FIG. 3, a hexagonal cross-section. Therefore, the ultrasonic signals which are transmitted from the transmitter of the transducer 10 are not reflected to the receiver of the transducer 10 because of torsion or inclination of the handling head 17 owing to any thermal stress in the handling head 17 or to the pressure of liquid metal. Also, in the prior art embodiment of FIG. 2, the reflecting plates 18 are installed in the hot liquid metal and are so distorted or inclined owing to thermal stress therein so that the reflected ultrasonic signals from the reflecting plates 18 may not be scanned by the receiver of the transducer 10.
SUMMARY OF THE INVENTION
Accordingly, it is the object of this invention to provide an improved submerged viewer for detecting floating core components in a liquid metal coolant pool within a liquid metal cooled nuclear reactor, of the type in which transducer means transmits and receives ultrasonic signals, driving means is coupled to the transducer means for scanning the reactor with transmitted ultrasonic signals, and display means is provided for depicting an image of received ultrasonic signals reflected off the floating core components, wherein each core component is provided with at least one continuously curved surface for reflecting ultrasonic signals to the transducer means. The reflecting surface can be either concave or convex, or the core component can be provided with plural reflecting surfaces, at least one of which is concave and at least one of which is convex.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a diagrammatic longitudinal cross-sectional view illustrating the construction of a reactor vessel using a prior art submerged viewer for detecting floating core components;
FIG. 2 is a view similar to that of FIG. 1 showing a reactor vessel using another prior art submerged viewer;
FIG. 3 is a prespective view of a handling head of a reactor core component;
FIG. 4 is a view similar to that of FIG. 1 illustrating one embodiment of this invention;
FIG. 5 is a view similar to that of FIG. 3 illustrating the improved core component reflecting surfaces according to this invention;
FIG. 6 is a view similar to that of FIG. 3 showing an inclined core component according to this invention;
FIG. 7 is a fragmentary sectional view of the core component handling head shown in FIG. 5;
FIG. 8 is a view similar to that of FIG. 7 showing another embodiment of this invention; and,
FIG. 9 is a view similar to that of FIG. 7 showing one more embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, and more paticularly to FIG. 4 thereof, there is shown a reactor 20 which includes a reactor vessel 21 in which liquid metal coolant 22, for example liquid sodium, is contained to exchange heat energy between the hot liquid metal and some cooler region not shown). The construction has core components 16 which consists of core fuel assemblies, removable shielding assemblies and the like, and upper core structure 15 which consists of a control rod driving mechanism, failed fuel detection system, temperature detector, flow meter, acoustic detector and the like in the reactor vessel 21. There is provided a rotating shield 12 from which upper core structure 15 is suspended over the reactor vessel 21.
There is provided a driving mechanism 11 in the center of the rotating shield 12. The ultrasonic signals transmitting and receiving means 23 for scanning the floated handling head 17 of the core components 16 are connected to the driving mechanism 11. The emitting and receiving means 23 comprises a dip tube 13 housing an ultrasonic transducer unit 10 which is rotable about the longitudinal axis of the dip tube 13 and slidably guided along the dip tube 13. Thus the transducer unit 10 is submerged in liquid metal which is at a tolerable temperature. The driving mechanism 11 which controls the transducer unit 10 is controlled by a control device 24. An oscillator 25 generates the ultrasonic signals and transmits them to transducer unit 10. An image display circuit 26, for example a CRT display, is connected with the transducer unit 10 through an electrical control circuit 27.
Referring now to FIG. 5, there is shown in greater detail the handling head 17 of core component 16 which reflects the transmitted ultrasonic signals from the transmitter of the transducer unit 10 to the receiver of the transducer unit 10. The handling head 17 of each core component 16 is installed on the respective core components 16 via a spacer pad 16A.
In operation, ultrasonic signals are generated by the oscillator 25 and transmitted to the lower end of the dip tube 13 and to the transducer 10 which is connected to the lower end of the dip tube 13. The control device 24 controls the action of the dip tube 13 and the transducer unit 10. Consequently, by the control of the control device 24, the transducer unit 10 is submerged in liquid metal and the dip tube 13 is rotable about the longitudinal axis and slidably guided along the dip tube 13 so that all regions of the reactor vessel 21 can be scanned.
The ultrasonic signals which are emitted from the transducer unit 10 are reflected against the handling head 17, when one of the core components 16 floats upwardly. Then the reflected signals are received by the transducer unit 10 and transmitted to the image display circuit 26, disposed outside the reactor vessel 21, through the electrical control circuit 27. Thus the image display circuit 26 provides an indication of the floated core component on its display unit. Then the operator can stop conducting the fuel exchanges when he sees the floated core component on the display unit of the image display 26.
The reflecting surface 28 mounted upon the core components 16 via the spacer pad 16A consists of 4 continuous convex curved surfaces, as shown in FIG. 5. Thus, the reflecting surface 28 has such a construction that ultrasonic signals emitted from the transducer unit 10 are returned to the transducer unit 10, even if the handling head 17 is distorted or inclined owing to thermal stress or to the pressure of the liquid metal.
FIG. 6 shows the inclined core component.
FIG. 7 shows a cross-sectional view of a handling head 17 of core component 16. The transducer unit 10 (not shown in FIG. 7) emits ultrasonic signals 31 and 32 to the handling head 17 of the core component. The ultrasonic signal 31 is reflected in a different direction than that of the transducer unit 10, but the ultrasonic signal 32 is reflected in the direction of the transducer unit 10, because the signal 32 is emitted to the center 33 of the convex surface 28.
The ultrasonic signals 31A and 32A are reflected in the same direction as the ultrasonic signals 31 and 32. Accordingly, when the transducer unit 10 is lowered below the upper part of the handling head 28 or the handling head 28 floats up too highly, the transducer unit 10 can receive the reflected signals.
Distance L between the centers 33 and 33A of the handling head 28 is preferably smaller than the range with which the ultrasonic signals are emitted from the transducer unit 10, because at least a beam of the ultrasonic signals is transmitted to the center of the handling head.
In FIG. 8 the reflecting surface 37 consists of continuous concave surfaces. The transducer unit 10 emits the ultrasonic signals 34 and 35 to the handling head 17 of the core component 16. The ultrasonic signals 35 is reflected in a different direction from that of the transducer unit 10, but the ultrasonic signal 34 is reflected to the transducer unit 10, because the signal 34 is emitted to the center 36 of the concave surface 37.
FIG. 9 shows another embodiment of this invention. In FIG. 9 the reflecting surface 38 consists of concave surface 39 and convex surface 40. The transducer unit 10 emits the ultrasonic signals 41 and 42 to the reflecting surface 38 of the handling head 17. The ultrasonic signal 42 is reflected in the different direction than that of the transducer unit 10, but the ultrasonic signal 41 is reflected to the transducer unit 10, because the signal 41 is emitted to the center 44 of the curved surface 38.
The above teachings disclosed in conjunction with FIGS. 4-9 also apply to an embodiment using reflector plates 18 shown in FIG. 2. Thus if reflector plates are used in combinations with a core component of the type shown in FIG. 3, the reflector plates 18 can be provided with at least one continuously curved reflecting surface, or more than one reflecting surface (convex and/or concave) in order to improve reflection of ultrasonic signals to the transducer 10.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. For example, while it is presently envisioned that the handling heads 17 of the core components 16 have a circular cross-section in a plane perpendicular to the longitudinal axis of the component 16, other cross-sectional shapes may be possible so long as the continuously curved reflecting surfaces are provided. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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A submerged ultrasonic viewer for use in a liquid metal cooled fast reactor vessel to detect floated reactor core components. The viewer, which includes an ultrasonic transducer, a transducer scanning drive mechanism and a related electrical control circuit, an image display circuit, and a reflecting surface, i.e. a handling head of a core element or a reflecting plate, is improved to enhance image accuracy by providing the reflecting surface with at least one continuously curved surface having a convex or a concave contour, or plural continuously curved surfaces with concave and convex contours.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a divisional application of U.S. patent application Ser. No. 12/625,481 filed on Dec. 29, 2009 to which application these inventors claim domestic priority.
BACKGROUND OF THE INVENTION
The present invention generally relates to agricultural equipment, and devices which are utilized with agricultural equipment for controlling dust and other particulates generated from operation of the equipment. In particular, a mobile harvester is disclosed which is used for harvesting crops, such as nuts and/or fruits, where the harvester utilizes high volume air generated by an on-board fan to separate crops from foreign matter. The disclosed harvester addresses problems presented by the deposition of particulate matter into the air through the air exhaust of the harvester. The disclosed harvester comprises means for reducing dust and other particulate matter generated by the operation of the machinery which, by the nature of its operation, would otherwise generate substantial quantities of dust and disperse it into the atmosphere. The general mechanisms employed by the disclosed harvester capture and immobilize dust particles before the particles are dispersed into the atmosphere by the fan exhaust emitted from the machinery.
Dust generation by agricultural and construction machinery is a known problem, particularly in arid areas. To name just a few problems caused by the dust generation, dust particles result in air pollution, water pollution, soil loss, human and animal health problems, and potentially hazardous reductions in visibility. In addition, the dust can adversely impact the health of various plants. In an effort to reduce dust production, some air pollution control districts impose various operating limitations on farm machinery or otherwise impose different dust control measures.
Dust generation from nut and fruit harvesting equipment can be particularly problematic. These devices typically utilize high volume fans to separate nuts and/or fruit from the debris which may be picked up by the harvesting equipment, including leaves, branches, dirt clods, soil, etc. (collectively, “foreign material”). However, a large portion of the foreign material is typically blown out through the fan discharge, resulting in the dispersion of a large volume of dust into the atmosphere. An example of such a harvester is disclosed in U.S. Pat. No. 4,364,222, which is incorporated herein by this reference. In these devices, a mixture of fruit or nuts (generally referred to as “crops”) and foreign material is picked up and deposited on conveyors enclosed by a housing connected to a fan inducing a vigorous flow of air through the conveyors. Various baffles, walls and guide plates direct the air so as to enhance the separation of the desirable crops from the foreign material. However, a substantial volume of foreign material is typically discharged into the atmosphere with a minimum amount of processing, thus creating a large discharge of dust.
SUMMARY OF THE INVENTION
The system described herein utilizes a primary separation methodology comprising an “air stream cleaning chain” to remove the larger particles of foreign material from the air stream before these particles are passed through the fan, pulverized, and discharged into the atmosphere. The collected larger particles of foreign material are thereafter deposited on a separate conveyor for discharge through an air lock and collected or disposed of as solid material rather than being entrained in the air stream and discharged through the fan exhaust. Not only does this greatly reduce dust produced by the discharge but it also greatly reduces fan wear by preventing the foreign material from passing through the discharge fan. The system further utilizes a fine particle collection methodology which is applied to the air stream which has passed through the air stream cleaning chain, which air stream contains fine particulate matter.
Harvested crops, such as fruit or nuts, and associated foreign material are gathered together at the front end of the harvesting unit by gathering means and then picked off the ground using lifting means such as a pick up belt or conveyor. The crops and foreign matter are eventually transferred onto a primary cleaning chain. As crops and foreign matter are transferred from the primary cleaning chain to an elevator chain, air is pulled through the cleaning chain and the articles conveyed thereon by the high volume fan. The air stream generated by the fan is effective in for removing the foreign material from the crops. It is to be appreciated that through the various stages of the device, a fraction of the crops and foreign material may be dropped from the harvester. Thus, the utilization of the terms “crops” and “foreign matter” are not intended to mean that the volume of these materials remain constant as they are transported through the stages of the invention.
The air stream cleaning chain is the key component of the primary separation methodology. The air stream cleaning chain may comprise, but is not limited to, a chain of about 4 feet in width which allows air to pass through the chain but stops larger foreign material such as grass, leaves, dirt clods, etc. Other embodiments of this component could include but are not limited to various widths, lengths, and structure of material that would accomplish the purpose of stopping foreign material while allowing the air to pass through. This allows the air stream cleaning chain to remove much of the foreign material from the air stream and delivering the foreign material to the cross conveyor discharge belt to be discharged from the machine through the air lock rather than being discharged through the fan.
Following this primary separation, the air discharge from the fan, which may include fine dust particles, is directed through an air baffle or air stream discharge duct, through which the air stream is discharged from the unit. The air stream discharge duct comprises dust particle suppression means comprising liquid introduction means and particulate collection means.
Liquid is introduced into the dust-laden air stream through liquid introduction means, such as spray tips, jets, or other orifices. For example, spray tips comprising a variety in number and tip size may be used for this purpose. As another embodiment, the system may utilize multiple manifolds of spray tips to offer various options of liquid volume to be introduced into the dust infused air stream. As another embodiment, the liquid introduction means may comprise nozzles contained within the walls of the air stream discharge duct. The liquid introduction means causes a pressurized liquid, such as water, to be sprayed into the dust-laden air stream, essentially creating a curtain of mist for the air stream to pass through.
The dust particle suppression system further comprises a dust scrubber, such as a wafer brush drum, through which the air stream passes after having passed through the spray of the liquid introduction means. The wafer brush drum consists of multiple wafer brushes mounted on a brush attachment sleeve. The wafer brush drum is typically rotated in a concurrent direction with the discharged air flow so as not to cause undue back pressure on the air system. The moistened air stream flows through the rotating wafer brush drum, which radially extending members collect small pieces of moist dirt from the air stream. The accumulated dust particles are discharged from the wafer brush drum as solids, thus allowing generally clean air to be discharged from the harvesting unit.
The disclosed dust suppression system may be adapted for use in any application which presents a high velocity air discharge to minimize the dust pollution from the discharge.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a left hand view of a harvester comprising an embodiment of the disclosed dust suppression system.
FIG. 2 is a right hand view of a harvester comprising an embodiment of the disclosed dust suppression system.
FIG. 3 is a front view of a harvester comprising an embodiment of the disclosed dust suppression system.
FIG. 4 is a rear view of a harvester comprising an embodiment of the disclosed dust suppression system.
FIG. 5 is a top view of a harvester comprising an embodiment of the disclosed dust suppression system.
FIG. 6 is an isometric view of the left hand side of a harvester comprising an embodiment of the disclosed dust suppression system.
FIG. 7 is an isometric view of the right hand side of a harvester comprising an embodiment of the disclosed dust suppression system.
FIG. 8 is a sectional view of a harvester along line 8 - 8 of FIG. 6 .
FIG. 9 is a sectional view of a harvester along line 9 - 9 of FIG. 6 , with a portion of the housing removed to show the fan rotor and drum brush.
FIG. 10 is a top view of an embodiment of the harvester.
FIG. 11 is a sectional view taken along line 11 - 11 of FIG. 10 .
FIG. 12 is a partial isometric showing a portion of the upper housing for for an embodiment of the disclosed dust suppression system.
FIG. 13 shows a partial front view of the housing for an embodiment of the harvester.
FIG. 14 is a sectional view taken along line 14 - 14 of FIG. 13 .
FIG. 15 is a partial top view of the housing for an embodiment of the harvester.
FIG. 16 is a partial isometric view of the housing for an embodiment of the harvester.
FIG. 17 is a partial sectional view showing, among other things, the relative positions of the air stream cleaning chain and the cross conveyor discharge belt which may be utilized in an embodiment of the disclosed harvester.
FIG. 18 shows a partial isometric view of a fan-brush combination which may be utilized in an embodiment of the disclosed harvester, showing the flow direction.
FIG. 19 shows a partial side view of the fan-brush combination shown in FIG. 18 .
FIG. 20 shows a partial top view of the exterior of the housing for the fan-brush combination shown in FIG. 18 .
FIG. 21 shows a partial front view of the fan-brush combination shown in FIG. 18 , showing an option for placement for liquid spray tips.
FIG. 22 shows a partial isometric view of a fan brush combination which may be utilized in an embodiment of the disclosed harvester.
FIG. 23 shows another view of a fan brush combination which may be utilized in an embodiment of the disclosed harvester.
FIG. 24 shows a view of a liquid introduction means which might be utilized in an embodiment of the disclosed harvester.
FIG. 25 shows a close up view of another liquid introduction means which might be utilized in an embodiment of the disclosed harvester.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Now with reference to the figures, FIG. 1 shows an embodiment of a harvesting unit 10 which may comprise the dust suppression system disclosed herein. This type of harvesting unit 10 is mobile, having ground conveyance means such as wheels 12 , but it might also comprise tracks, rollers, etc. Harvesting unit 10 gathers harvested crops, such as nuts, fruits and the like, from the ground surface, where the crops will typically have been deposited from the shaking of trees or other harvesting method. The crops are typically deposited in a spread out configuration, forming a carpet on the ground surface. This type of harvesting unit 10 is well suited for the processing of almonds, but could also be utilized in the gathering of a variety of other crops lying on a ground surface after having been removed from a tree. In addition to almonds, the harvested crop may be another variety of nut, such as cashews, chestnuts, hazelnuts, macadamia nuts, pecans, walnuts and tung nuts. Certain fruits, such as figs and oranges, and any fruit, nut or vegetable, as conventionally known to require collection and processing from the ground, may also be gather with this type of harvester, and the present dust suppression system employed. It is to be appreciated that while the Figures herein show a harvester 10 which is equipped to be towed by a tractor or other towing vehicle, the present dust suppression system may equally be utilized with a self-propelled harvesting unit. The various conveyors, chains, drive wheels, etc. of the harvester will be driven by the means known in the art, typically by hydraulic motors.
The type of harvesting unit 10 which may comprise the dust suppression system disclosed herein generally comprises a collection means for collecting the agricultural products, such as crops 14 , from the ground surface S. Because the crops 14 are blanketed across the ground dispersed among other foreign matter 16 , such as leaves, twigs, dirt, gravel, dirt clods, etc., the collection means will gather a combination of all of these materials into the harvesting unit. The foreign matter 16 will typically comprise a mixture of larger and smaller particles, and some foreign matter will comprise dirt or other relatively fine grained particles. The collection means may comprise brushes, conveyors, or a sweeping array as disclosed in U.S. Pat. Nos. 7,131,254 and 7,412,817 which were invented by some of the inventors herein and which are incorporated herein in their entireties by this reference. One embodiment of the collection means may comprise a rotating sweeper 18 and/or pickup belt 20 which gather the agricultural products and foreign matter from the ground S. The collection means directs all of the gathered materials onto a primary chain 22 . The primary chain 22 has a receiving end 24 which receives the crops and foreign matter which have been collected by the collection means. At the end opposite the receiving end 24 , the primary chain comprises a delivery end 26 to which substantially all of the crops and foreign matter are delivered. However, it is to be appreciated that the primary chain 22 , and the other chains of most harvesters, are typically linked chain with openings, such that smaller foreign matter and perhaps smaller crops will fall through back onto the ground surface S. Therefore, while a substantial amount of the crops and foreign matter will reach the receiving end 24 , some of the crops and foreign matter may have fallen through the openings in the primary chain 22 .
The harvesting unit 10 further comprises an elevator chain 28 . The elevator chain 28 receives crops and foreign matter from primary chain 22 . The crops are carried up elevator chain 28 and discharged through discharge chute 30 to a storage container, the ground, or other repository for the crops. Adjacent to elevator chain 28 is the end 32 of a ductwork or housing 34 which may be oriented along the lengthwise axis of the harvesting unit 10 . An opening is defined at the end 32 of the housing by the top 36 , side pieces 38 , and bottom 40 . A fan 42 is disposed within housing 34 within its own fan housing 46 . Fan 42 generates an air stream A by pulling air from the opening at the end 32 of the housing 34 and discharging the air into discharge duct 44 on the opposite site of the fan 42 . The air stream A flows through housing 34 , with the direction of the air stream generally moving from the elevator chain 28 toward the fan 42 . The fan 42 may thus be considered to have a suction side which is oriented toward end 32 and at least a portion of elevator chain 28 and a discharge side which begins on the opposite side of the fan, with the generated air stream discharging into air stream discharge duct 44 . As suction is pulled by the air stream A through the openings in elevator chain 28 , and through the crops and foreign matter being transported on the elevator chain, the lighter foreign matter is carried in the air stream toward fan 42 through housing 34 .
Disposed between fan 42 and elevator chain 28 is an air stream cleaning chain assembly 48 . The air stream cleaning chain assembly 48 comprises the primary separation methodology for removing foreign material from the air stream before much of the foreign material is passed through the fan 42 and discharged into the atmosphere. The air stream cleaning chain assembly 48 may comprise air stream cleaning chain 50 , drive roller 52 and idler rollers 54 . As air stream cleaning chain 50 is rotated about the idler rollers 54 , a portion of the air stream cleaning chain is continually positioned to be normal to the general direction of the air stream A. Air stream cleaning chain 50 allows the air stream to pass through it, but stops the larger particles of foreign material, such as leaves, grass, etc., because the air stream cleaning chain comprises a plurality of closely spaced links, wherein the openings between the links are relatively small. Air stream cleaning chain 50 may have a width of approximately four feet in width.
Foreign material which is stopped by the air stream cleaning chain 50 is discharged from the harvesting unit 10 by discharging means which transport the larger particles of the foreign matter collected on the air stream cleaning chain to the exterior of the harvesting unit. The discharging means may comprise a cross conveyor discharge belt 56 which is disposed below the air stream cleaning chain 50 . Foreign material accumulated on the air stream cleaning chain is deposited onto the cross conveyor discharge belt 56 , which transports the larger particles of the foreign material to a disposal duct through an air lock assembly 58 .
The finer particles of foreign material will be carried through the openings in air stream cleaning chain 50 and transported through housing 34 by air stream A through fan 42 and into air stream discharge duct 44 , which is on the discharge side of the fan. The air stream discharge duct 44 comprises a further mechanism for removing particulates from the air exhaust of the harvester 10 , which is utilized to remove smaller particles which passed through the air stream cleaning chain 50 . This mechanism employs injecting water or other appropriate liquid into the air stream A as it enters the air stream discharge duct 44 . As shown in FIGS. 18 through 25 , the air stream discharge duct 44 comprises liquid introduction means such as a plurality of spray tips 60 , or other liquid introduction means, such as directional jets 160 shown on FIG. 25 . Directional jets 160 may be set within the inside wall of air stream discharge duct 44 and may be installed and directed to provide a curtain of liquid spray through which the air stream A, with its entrained dust particles, passes. Other liquid introduction means may be utilized. For example, spray tips comprising a variety in number and tip size may be used for this purpose. As another embodiment, the system may utilize multiple manifolds of spray tips to offer various options for the introduction of the liquid into the dust infused air stream. The harvester 10 may comprise liquid storage tanks for storing the liquid utilized for the liquid sprayed into the air stream discharge duct 44 , and the related pumps and conduits required for the liquid injection process. Alternatively, the storage tanks and pumps may be carried on a separate apparatus.
The air stream discharge duct 44 may comprise additional means for suppressing the fine dust particles transported in the air stream A. The air stream discharge duct may further comprise a dust scrubber assembly 62 . Dust scrubber assembly 62 may comprise a rotating wafer brush drum 64 . The wafer brush drum consists of multiple wafer brushes 66 mounted on a brush attachment sleeve 68 , or other collection members which radially extend from the brush attachment sleeve. The wafer brush drum 64 may be rotated in a concurrent direction with the flow of air stream A so as not to cause undue back pressure on the air system. Because of the liquid introduction means discussed above, the air stream A reaching the wafer brush drum is moistened. As the moistened air stream A flows through the wafer brushes, small pieces of moist dirt are scrubbed from the air stream, accumulating on the collection members such that the air being discharged through air exhaust 70 has been substantially cleaned of particulate matter. Aggregated solids may be discharged from the apparatus through solids discharge chute 71 .
Air stream discharge duct 44 connects to fan housing 46 at flange 72 . Portions of air stream discharge duct 44 may be easily removable to gain access to the various components of the dust scrubber assembly 62 and the liquid introduction means contained therein. For example, flange 72 may be held together with a quick-release mechanism 74 and air stream discharge duct 44 may be hinge connected at the flange to allow the air stream discharge duct to pivot outwardly so there is easy access to the internal components.
While the above is a description of various embodiments of the present invention, further modifications may be employed without departing from the spirit and scope of the present invention. Thus the scope of the invention should not be limited according to these factors, but according to the following appended claims.
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A mobile harvesting unit which utilizes a high volume fan to separate crops from foreign matter, has a dust suppression system which substantially reduces particulates which are discharged with the fan exhaust. The dust suppression system has two stages. The first stage separates larger particles of foreign matter by deploying an air stream cleaning chain upstream of the fan. The second stage is contained within a air stream discharge duct. Within the air stream discharge duct, a liquid, such as water, is sprayed into the dust entrained air stream. The moistened air stream flows through a plurality of collection members which extend radially from a brush drum, where the moistened dust particles are accumulated on the collection members, such that the volume of dust particles contained within the air discharged from the harvesting unit is substantially reduced.
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FIELD OF INVENTION
[0001] The present invention relates to a turbocharger, as well as to a drive system which contains such a turbocharger.
BACKGROUND INFORMATION
[0002] Internal combustion engines with turbochargers are basically known in the motor vehicle sector. Typically, an exhaust gas flow out of the combustion engine is used to drive a turbine wheel. This turbine wheel is for example coupled via a shaft to a compressor wheel which ensures a compression of supplied fresh air in the combustion space. Such a precompression or “charging” leads to an increased engine power or increased torque compared to conventional internal combustion engines. However, with internal combustion engines charged in such a manner, there exists the problem of the so-called “turbolag”, which in particular occurs on running up and accelerating from low rotational speeds of the vehicle, thus when the internal combustion engine is to be rapidly accelerated into regions of increased power. This is due to the fact that the increased air quantity requirement on the air feed side may only be provided with some delay (amongst other things caused by the inertia of the system of the turbine wheel and compressor wheel).
SUMMARY OF INVENTION
[0003] The present invention relates to a turbocharger which supplies precisely the correct quantity of fresh air with the smallest possible delay, and which furthermore is simple in its construction and is susceptible to trouble as little as possible.
[0004] The turbocharger according to the present invention contains a turbine wheel as well as a compressor wheel connected thereto, wherein an electric motor is provided on the side of the compressor wheel which is distant to the turbine wheel, and a rotor of the electric motor which is connected to the compressor wheel in a rotationally fixed manner, is designed in a freely projecting manner.
[0005] Given an increased fresh air demand (e.g. ascertained by control electronics), the electric motor serves for an additional acceleration of the compressor wheel by the electric motor. Electric motors are favourable for this, since these may be accelerated with a large torque without a noticeable run-up delay.
[0006] It is further advantageous that the electric motor in the present case is not arranged between the turbine wheel and the compressor wheel. Such an arrangement would lead to thermal problems and represents a large design modification of conventional (purely mechanical) turbochargers. Apart from the increased design effort, the repair effort with such constructions is considerable.
[0007] It is therefore advantageous that a sequence “turbine wheel, shaft (mounting), compressor wheel, electric motor” seen in the axial direction is given in the present case. Thus only the electric motor is subjected to the temperature of the surroundings, so that a thermal decomposition of the stator winding etc. may not occur.
[0008] The particular advantage lies in the freely projecting end on the other side of the compressor wheel. The rotor of the electric motor is attached here. According to the invention, it is not necessary here to attach a further bearing location, in order to thus mount the rotor on both sides. Such a bearing location on the one hand, under certain circumstances, would upset the electrical characteristics of the electric motor and under certain conditions would represent a static redundancy. Furthermore, the friction work in the system is unnecessarily increased by way of such a bearing. Moreover, the supply of fresh air is also hindered by such a bearing, since suitable struts/members reduce the inlet air opening in size towards the compressor wheel.
[0009] Furthermore, the design difference to purely mechanical turbochargers is conceivably small with the “projecting” rotor, so that an electric motor may be supplemented on conventional turbochargers in this way, in a very inexpensive, modular and easily repairable manner.
[0010] The drive system according to the invention, apart from the inventive turbocharger, comprises an internal combustion engine. An “internal combustion engine” in the context of the present invention is to be understood as any motor which requires fresh air/fresh gas as well as produces exhaust gas, so that a suitable turbocharger may be applied here. Furthermore, the drive system also comprises a storage device for electrical energy. Here, preferably the electric motor of the turbocharger is connected to the storage device for electrical energy, for the removal of electrical energy in a motor operation of the turbocharger and for feeding electrical energy in a generator operation of the turbocharger.
[0011] In this manner, on the one hand excess “mechanical energy” may be extracted into electrical energy again, and the energy balance of the drive system is once again improved by way of this. As a whole therefore, a very good closed-loop control of the turbocharger results, since apart from acceleration of the compressor wheel or turbine wheel, a suitable “braking procedure” is also possible.
[0012] It is also particularly advantageous with this drive system, when the electric motor of the turbocharger or the electrical storage device connected to it, may be additionally connected to an electromotoric drive of a motor vehicle. This electromotoric drive may for example be a hub electric motor (or another electric motor provided in the drive train), which is fastened on a drive wheel of the motor vehicle. In this manner, an additional provision of torque or motor power is achieved on accelerating in modern so-called “hybrid vehicles”, since apart form the internal combustion engine motor, it is also the electrical hub motors which are responsible for the acceleration. A braking effect and thus a recovery of kinetic energy into electrical energy may be achieved with braking procedures by way of the switch-over of the electrical hub motors into generator operation, and this electrical energy is intermediately stored in a suitable storage device. If the electric motor of the turbocharger is now connected to this storage device, then the complete electrical energy may be “managed” in a central manner, in order to be able to fall back on this at any time, in a useful manner.
[0013] Apart from this, it is of course also possible for the turbocharger system and the electrical hub motors (or other motors in the drive train) to have electrical storage devices which are independent of one another.
[0014] Preferably, one is to provide control electronics in the drive system for determining the rotational speed of the turbine wheel or compressor wheel, actual values of the pressure conditions on the turbine housing side and the compressor housing side, as well as further values which are of relevance with regard to the torque for the internal combustion engine, for the control of electrical energy or for the provision of an optimal torque with a low consumption.
[0015] Advantageous formations of the turbocharger according to the invention are described in the following advantageous further designs.
[0016] One advantageous further design envisages the turbine wheel and the compressor wheel being permanently connected to one another in a rotationally fixed manner. This means that no coupling between the turbine wheel and the compressor wheel is given, by which means the mechanical construction and the susceptibility to failure of the system would be increased. Instead of this, one strives to limit the moved rotational masses by way of a light rotor, a light compressor wheel, a light shaft and a suitably low-mass turbine wheel.
[0017] The housing of the turbocharger is preferably constructed in a modular manner, i.e. a compressor housing for the compressor wheel is given, apart from a turbine housing for the turbine wheel. The turbine housing is preferably connected to an exhaust fan which leads exhaust gas from the individual cylinders of the internal combustion engine, to the turbine wheel. The design demands are somewhat different than on the compressor housing which surrounds the compressor wheel, on account of the thermal loading of the turbine housing. The actual mounting of the turbine wheel and the compressor wheel preferably takes place exclusively between the turbine wheel and the compressor wheel. I.e. that no additional mounting is given on the side of the compressor wheel which is distant to the turbine wheel, since it is indeed here that the stator of the electric motor projects freely. Preferably, a bearing housing is provided between the turbine housing and the compressor housing, which serves for receiving bearing elements for the turbine wheel and the compressor wheel.
[0018] The electric motor preferably contains a stator which has an essentially hollow-cylindrical shape and which surrounds the rotor in a concentric manner. Here, it is advantageous that the stator may be designed as part of the inner wall of the compressor housing. The stator may for example also be applied as an insert into a corresponding opening of the compressor housing. The advantage with these embodiments is the fact that only an as small as possible design change of conventional mechanical turbochargers is necessary, so that cost- and competitive advantages may be realised by way of this, in particular with large-scale production.
[0019] The rotor of the electric motor preferably has a rotor magnet which is surrounded by a sheathing. The rotor magnet is mechanically protected by way of this. One may also have an influence on the type of magnetic field in this manner. The rotor magnet may be designed such that it is partly or completely integrated into the compressor wheel. If the compressor wheel consists of fibre-reinforced or non-reinforced plastic, then on production, the rotor magnet may be directly peripherally injected with the plastic mass, by which means an inexpensive large-scale manufacture is possible.
[0020] The sheathing of the rotor is preferably designed in a “cylinder-like” manner.
[0021] It is advantageous with regard to manufacturing technology, for the rotor magnet to be hollow in the inside in regions for placing on a common shaft with the compressor wheel. An inexpensive manufacture is possible in this manner.
[0022] The compressor wheel may also be of a non-metallic material, preferably of a reinforced or non-reinforced plastic. The electromagnetic field of the electric motor is practically no longer influenced by way of this.
[0023] One further advantageous design envisages the rotor gap between the rotor and the stator representing an inlet air opening for the compressor wheel. This in turn means that the electric motor hardly gets in the way of the air feed flow, and that no additional air feed openings need to be provided, which would unnecessarily increase the flow resistance. It is therefore even possible for the inlet opening to be free of struts between the rotor and stator. Here, such a provision of struts is not necessary due to the omission of the “counter bearing”.
[0024] The inlet opening may be provided with a large cross-sectional area, depending on the dimensioning of the rotor or stator. Preferably, the smallest inner diameter of the stator is 1.5- to 8-times, preferably 2- to 4-times the size of the largest outer diameter of the rotor. The specified lengths here in each case relate to the greatest extensions or smallest extensions of the participating elements, but only in the region of the electrically or magnetically effective elements (thus only over the length of the rotor magnet for example) and a subsequent thickening (for example in the region of the compressor wheel) is not important here.
[0025] Here, the nominal voltage of the electric motor may be more than 12V, for example 24 or 48 V, for increasing the energetic efficiency.
[0026] It is particularly advantageous for the electric motor to be able to be switched over from motor operation into generator operation. If the charging pressure (in the turbine housing) reaches a certain nominal value, then additional energy is produced using a converter capable of a return feed. Furthermore, ideally one may do away with a waste-gate/pressure dose for blowing out excess exhaust gas pressure, by way of the energetic conversion of the braking energy.
[0027] The control of the motor/generator operation permits the targeted closed-loop control of the charging procedure. The rotor rotational speed, which, as a characteristic variable, is important for the closed-loop control, may be acquired with the help of a Hall-sensor, which is integrated in the motor, or via the motor control. Thus the combustion process of the piston motor may be therefore optimised. The control is preferably affected via the central motor management.
BRIEF DESCRIPTION OF DRAWINGS
[0028] The present invention is now explained by way of several figures. There are shown in:
[0029] FIG. 1 a shows a first exemplary embodiment of a turbocharger according to the present invention, in a part section;
[0030] FIG. 1 b shows a section of the turbocharger from FIG. 1 a , according to A;
[0031] FIG. 1 c shows a section of the turbocharger of FIG. 1 a , according to B;
[0032] FIG. 1 d shows a part exploded drawing of the turbocharger of FIG. 1 a;
[0033] FIG. 2 a shows a second exemplary embodiment of a turbocharger according to the present invention, in a part section;
[0034] FIG. 2 b shows a view of the turbocharger shown in FIG. 2 a;
[0035] FIG. 3 a shows a third exemplary embodiment of a turbocharger according to the present invention, in a part section; and
[0036] FIG. 3 b shows a section of the turbocharger according to FIG. 3 a in a section plane D.
DETAILED DESCRIPTION
[0037] The basics of the present invention are to be shown hereinafter by way of the first embodiment according to FIGS. 1 a to 1 d.
[0038] FIGS. 1 a to 1 d show an electrically modified mechanical turbocharger 1 which may be coupled to a turbine housing 5 on an internal combustion engine. After the combustion, the exhaust gas is collected by way of the exhaust gas fans shown in FIG. 1 a and is used for driving a turbine wheel 2 . The turbine wheel 2 is surrounded by the turbine housing 5 and is essentially deduced from a conventional mechanical turbocharger. A bearing housing 7 connects to the turbine housing 5 , and then a compressor housing 6 . A compressor wheel 6 is attached in this compressor housing 6 , and compresses the air fed through an inlet opening (this inlet opening is in particular easily seen in FIG. 1 c ) and leads it to the combustion space of the internal combustion engine in a manner which is not shown here. The compressor wheel 3 on the left side in FIG. 1 a shows a continuation, to which a rotor 4 a of an electric motor is given. The rotor 4 a is attached centrally in the inlet air opening 4 e.
[0039] A stator 4 b which has an essentially hollow-cylindrical shape and is represented as part of the inner wall of the compressor housing in the region of the inlet air opening, is provided around the rotor 4 a . Here, the stator 4 b is even provided as an insert into a suitable opening, so that this may be assembled very easily. Here therefore in FIG. 1 a , the rotor gap between the rotor 4 a and the stator 4 b is the inlet air opening 4 e for the compressor wheel. With this, the inlet air opening 4 e is free of struts between the rotor and the stator also according to FIG. 1 a . The smallest inner diameter of the stator (see “d S ” in FIG. 1 d ) is 1.5 times larger than the largest outer diameter d R of the rotor.
[0040] The rotor 4 a of the electric motor 4 comprises a rotor magnet 4 c which here is surrounded by an sheathing (see e.g. FIG. 1 d ). With this, the sheathing is designed in an essentially “beaker-shaped” manner, wherein the base of the beaker is almost completely closed towards the compressor wheel (disregarding a centric assembly bore).
[0041] The compressor wheel may (but need not) be of a non-metallic material, here with one embodiment, for example of a non-reinforced plastic, and the influence on the electromagnetic field of the electric motor is minimised. The rotor magnet 4 c in turn is hollow in regions for placing on a common shaft with the compressor wheel. Here, a bore 4 c of the rotor magnet is to be accordingly seen in FIG. 1 d . Furthermore, it may be seen that a sequence of elements is shown in the sequence of the rotor (consisting of the rotor magnet 4 c and sheathing 4 d ), the compressor wheel 3 , shaft 8 , turbine wheel 2 , which minimises a thermal loading of the electric motor. The shaft 8 here in the present embodiment is designed such that the turbine wheel 2 , compressor wheel 3 as well as rotor 4 a are firmly (rotationally fixedly) connected to one another, thus may not be separated by a rotation clutch or free-wheel.
[0042] However, it is basically possible to provide such a clutch within the framework of the present invention, if it is the case for example that the turbine wheel 2 is very high, but however the design effort would in turn also be increased by way of this.
[0043] The nominal voltage of the electric motor 4 in FIG. 1 a here is 12V, but other voltages (for example 48V for hybrid vehicles) are also possible.
[0044] The electric motor may be operated in motor operation (for accelerating and avoiding a “turbolag”), as well as in generator operation (for recovering energy). If the charging pressure (in the turbine housing) reaches a certain nominal value, then additional energy is produced by way of using a converter capable of return feed. Ideally, one may do away with a wastegate/pressure dose for blowing out excess exhaust gas pressure, as is represented in FIG. 1 b , numeral 9 , by way of this energetic conversion of the braking energy in generator operation.
[0045] The turbocharger according to the invention is used in a drive system according to the invention for motor vehicles which contains an internal combustion engine connected to the turbocharger, as well as a storage device for electrical energy. The electric motor of the turbocharger 1 here is connected to the storage device for electric energy for taking electrical energy in a motor operation of the turbocharger 1 , and for feeding in electrical energy in a generator operation of the turbocharger. In a particularly preferred embodiment, the electric motor of the turbocharger is connected to an electrical storage device, wherein this electrical storage device is additionally connectable to an electromotoric drive of a motor vehicle. This may be a “hub motor” of a motor vehicle or another electric motor, which is provided in the drive train of a motor vehicle (for example in the region of the gear). This connection of the electrical turbocharger to a hybrid vehicle is particularly energy efficient.
[0046] Control electronics for determining the rotational speed of the turbine wheel 2 or the compressor wheel 3 , actual values of pressure conditions on the turbine housing side and compressor housing side, as well as further values relevant to the torque for the internal combustion engine are provided for the efficient control of the drive system or the turbocharger.
[0047] The most important components of the first embodiment according to FIGS. 1 a to 1 d are shown in FIG. 1 d , at the top right as a part exploded drawing. Here, it is to be seen that it is the case of a turbocharger 1 which comprises a turbine wheel 2 as well as a compressor wheel 3 connected thereto, wherein an electric motor 4 is provided on the side of the compressor wheel which is distant to the turbine wheel consisting of rotor 4 a and stator 4 b , and a rotor 4 a of the electric motor 4 which is connected to the compressor wheel 3 in a rotationally fixed manner is designed in a freely projecting manner.
[0048] This “freely projecting” manner is advantageous, since the design effort is reduced by way of this and for example a static overdimensioning of the total mounting is avoided. “Freely projecting” is to be understood as those arrangements with which the rotor is not mounted in a separate and permanent manner. Possibly provided “support cages” etc., which are to prevent a bending of the freely projection rotor which may be too large, for example on account of bending resonance, are not to be seen in the context of “bearings”.
[0049] FIGS. 2 a and 2 b show a second embodiment of the invention. Here, the stator is represented in a somewhat different manner, specifically in the direct vicinity of the rotor (with a relatively small rotor gap), and the inlet air opening to the turbine wheel 3 runs radially outside the stator 4 b ′. The electrical feed to the stator is effected by way of webs which are provided in the gap space of the inlet air opening.
[0050] A third embodiment is shown in the FIGS. 3 a and 3 b . Here, the rotor magnet 4 has been partially integrated into the compressor wheel 3 on manufacture. The stator forms the inner contour of the compressor housing. It has a Hall-probe, with whose help the rotor rotational speed may be continuously determined.
[0051] The electric motor may be operated in motor operation (for accelerating and avoiding a “turbolag”) as well as in generator operation (for recovering energy). If the charging pressure (in the turbine housing) reaches a certain nominal value, then additional energy is produced by way of using a converter capable of return feed. Ideally, one may do away with a wastegate/pressure dos for blowing out excess exhaust gas pressure, as is represented in FIG. 1 b , numeral 9 , by way of this energetic conversion of the braking energy in generator operation.
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A turbocharger includes a turbine wheel, a compressor wheel connected thereto, an electric motor situated on the side of the compressor wheel which is distant to the turbine wheel, and a rotor connected to the compressor wheel in a rotationally fixed manner and designed in a freely projecting manner. A drive system for motor vehicles includes a turbocharger. The turbocharger is characterised by a very spontaneous response behaviour, as well as the possibility for energy recovery.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a National Stage of International Application No. PCT/EP2011/064873 filed Aug. 30, 2011, claiming priority based on French Patent Application No. 10 56905 filed Aug. 31, 2010, the contents of all of which are incorporated herein by reference in their entirety.
The invention relates to a method of using composite material to fabricate a mechanical member such as a rod for an aircraft landing gear strut.
BACKGROUND OF THE INVENTION
It is known, in particular from patent document FR 2 932 409, to fabricate such a rod by using a mandrel on which one or more layers of carbon fibers are braided in radial superposition on one another.
That assembly is then installed in a mold in order to inject resin into the various layers carried by the mandrel prior to polymerizing the resin, e.g. by heating it, thereby constituting a rigid blank for a rod, which blank can be machined at its interfaces in order to form lugs therein.
The braiding of the layers of reinforcing fibers is then performed with a braiding installation as shown in FIG. 1 , where it is referenced 1 . The installation essentially comprises a ring 2 extending in a vertical plane, with the central axis AX of the ring thus being horizontal. The ring 2 carries a set of reels 3 carrying reinforcing fibers, the fibers converging on a region that is situated on the axis AX and that is offset from the plane of the ring.
When the braiding cycle is started, the mandrel, referenced 4 , is moved along the central axis AX so as to pass through the ring 2 beyond the point where the fibers converge. Simultaneously, the reels carried on the ring 2 by motor-driven movable supports are actuated so as to reel out fibers in order to fabricate a sock of reinforcing fibers on the outside face of the mandrel 4 .
Once the mandrel has passed right through the ring, i.e. once it is situated beyond the fiber convergence point, it is covered over its entire length by the sock.
The layer of reinforcing fibers is then cut between the mandrel and the ring, and the mandrel is removed and then put back behind the ring in order to pass through it once more so as to form a second layer of reinforcing fibers that is superposed radially on the first.
Thus, as shown diagrammatically in FIG. 2 , it is possible to fabricate a general structure comprising the mandrel in its central region, which mandrel forms a support for two or more layers of braided fibers 6 , 7 that extend all around the mandrel, over its entire length.
Specifically, as shown in FIG. 3 , a braided layer comprises firstly interlacing fibers 8 and 9 that are inclined, e.g. at about 30°, on either side of the axis AX, and secondly longitudinal fibers 10 that are parallel to the axis AX, and that are held in position by the interlacing fibers 8 and 9 that interlace them.
In practice, and as can be seen in FIG. 3 , each layer of braided fibers is made up of a plurality of sublayers, levels, or thickness, each comprising a series of longitudinal fibers 10 situated beside one another in a comb arrangement. The interlacing fibers 8 , 9 interlace the longitudinal fibers 10 of the various sublayers together so as to form a coherent whole.
When the layers of braided fibers have been applied on the mandrel, the longitudinal fibers 10 of each sublayer are distributed uniformly about the mandrel 4 that carries them, i.e. they are regularly spaced apart from one another around the mandrel 4 , as shown diagrammatically in FIG. 4 .
In service, such a mechanical member is subjected to mechanical loading circumstances that are relatively complex, and as a result it is subjected to stresses that differ from one region of the member to another.
With a member fabricated by braiding, that situation leads to selecting the thickness of reinforcing fibers for depositing over the entire mandrel as a function of the maximum stress to which the member is to be subjected, even though the maximum stress actually corresponds only to a particular region of the member under consideration.
It follows that in many of its zones, the member is thus overdimensioned, thereby pointlessly penalizing the total weight of the member.
OBJECT OF THE INVENTION
The object of the invention is to propose a solution for remedying that drawback.
SUMMARY OF THE INVENTION
To this end, the invention provides a method of fabricating a mechanical member made of composite material, the method comprising a plurality of operations of braiding and depositing layers of braided reinforcing fibers by means of a braiding machine, each operation comprising braiding a layer of reinforcing fibers and depositing it on a mandrel by moving the mandrel along a central axis of the braiding machine, the various layers of braided fibers being superposed radially on one another, each layer of braided fibers having both longitudinal fibers extending parallel to a main direction of the mandrel, and also interlacing fibers that are inclined relative to the main direction, the method being characterized in that at least one braiding and deposition operation is configured to form and deposit a braid that presents, in at least one cross-section of the member, a density of longitudinal fibers that differs depending on whether consideration is given to a first angular region around the center of gravity of the mandrel in said cross-section or to a second angular region of the same extent around the center of gravity.
With this solution, the mechanical member presents greater thickness in an entire portion that extends over its entire length, and smaller thickness in the opposite portion.
The invention also provides a method as defined above, including at least one operation of braiding and depositing a layer of braided fibers that is performed to constitute a layer of braided fibers having longitudinal fibers of different sizes, and including longitudinal fibers of large size situated in a first region of the braided layer and longitudinal fibers of small size situated in a second region of the braided fiber.
The invention also provides a method as defined above, wherein a braiding machine is used having a braiding ring carrying reels of longitudinal fibers arranged in such a manner that each layer of braided fibers is made up of a plurality of superposed sublayers, each including a series of longitudinal fibers in a comb arrangement, wherein one region of the ring is loaded with reels of large-size longitudinal fibers and another region of the ring is loaded with reels of small-size longitudinal fibers, and wherein the proportion of reels carrying large-size fibers and of reels carrying small-size fibers varies gradually from one region of the ring to another.
The invention also provides a method as defined above, including at least one operation of braiding and depositing a layer of braided fibers, wherein the mandrel is positioned to have its main axis radially offset relative to the central axis of the braiding machine while the mandrel is being moved along the central axis of the braiding machine, so as to braid and deposit a layer of braided fibers presenting a quantity of longitudinal fibers that is greater in a first region that is closer to the central axis of the braiding machine than in a second region that is farther from the central axis of the braiding machine.
The invention also provides a method as defined above, wherein the provision of longitudinal fibers having different sizes is combined with a radial offset of the main axis of the mandrel relative to the central axis of the braiding machine.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a diagrammatic perspective view of a braiding machine with a mandrel that is to receive a layer of braided fibers;
FIG. 2 is a diagrammatic cross-section view showing the layers making up a prior art rod of composite material;
FIG. 3 is a diagrammatic perspective view showing a portion of braided reinforcing fibers made up of two sublayers;
FIG. 4 is a diagrammatic cross-section view showing the longitudinal fibers of a sublayer forming part of a braided layer in a prior art rod;
FIG. 5 is a diagrammatic cross-section view showing the longitudinal fibers in a sublayer of a braided layer in a rod obtained in accordance with a first implementation of the invention;
FIG. 6 is a diagrammatic cross-section view showing the longitudinal fibers in a sublayer of a braided layer in a rod obtained in accordance with a second implementation of the invention;
FIG. 7 is a diagrammatic view of a portion of a ring of a braiding machine arranged to form a braid having longitudinal fibers of different sizes in accordance with the first implementation of the invention;
FIG. 8A is a diagrammatic side view showing an axial offset performed in the braiding operation in accordance with the second implementation of the invention;
FIG. 8B is a diagrammatic view in a cross-section plane of the FIG. 8A rod showing the mandrel together with the longitudinal fibers of one of the sublayers of the various braided layers carried by the mandrel;
FIG. 9 is a perspective view of a first example of a rod suitable for being fabricated in accordance with the method of the invention;
FIG. 10A is a diagrammatic side view showing an axial offset performed in the braiding operation in accordance with the second implementation of the invention in order to fabricate a rod including an off-center intermediate lug;
FIG. 10B is a diagrammatic view in a first cross-section plane of the FIG. 10A rod showing its mandrel and the longitudinal fibers of one of the sublayers of the braided layers carried by the mandrel;
FIG. 10C is a diagrammatic view in a second cross-section plane of the FIG. 10A rod showing its mandrel and the longitudinal fibers of one of the sublayers of the various braided layers carried by the mandrel;
FIG. 11A is a perspective view of a rod having an eccentric intermediate lug that may advantageously be fabricated in accordance with the method of the invention;
FIG. 11B is a first cross-section view of the FIG. 1A rod; and
FIG. 11C is a second cross-section view of the FIG. 11A rod.
DETAILED DESCRIPTION OF THE INVENTION
The idea on which the invention is based is to form and deposit on a mandrel layers of reinforcing fibers that are braided in such a manner that the longitudinal fibers of the layers present density that is greater on one side of the mandrel than on the other.
This may be achieved by providing longitudinal fibers in one region that are of greater size than the longitudinal fibers in another region of the braided layer, where this corresponds to a first implementation as shown in FIG. 5 . This may also be achieved by using longitudinal fibers that are all of the same size, but by placing them in greater quantity in one region than in another region of the layer of reinforcing fibers, with this corresponding to a second implementation shown in FIG. 6 .
In order to illustrate the density difference, FIGS. 5 and 6 thus show two angular regions or sectors S 1 and S 2 having the same angular extent, both centered on the center of gravity G of a cross-section of the mandrel 11 of the fabricated member, and arranged in such a manner as to be opposite each other. The region S 1 is situated in the top portion of the member while the region S 2 is situated in the bottom portion of the member.
In the configuration of FIG. 5 , each of the regions S 1 and S 2 has three longitudinal fibers, however the longitudinal fibers 12 G included in the top region S 1 are each of greater section than the longitudinal fibers 12 included in the bottom region S 2 . Thus, the density of longitudinal fibers is significantly greater in the top region than in the bottom region because the fibers in the top region are of section that is greater than the section of the fibers in the bottom region.
In the configuration of FIG. 6 , the longitudinal fibers 12 are all of the same size, i.e. of the same section, but the top region S 1 has five of them, whereas the bottom region S 2 has only three. In this configuration also, the density of longitudinal fibers is greater in the sector S 1 than in the sector S 2 , because the number of fibers in the top region is greater than the number of fibers in the bottom region.
In the first implementation of the invention, the reels of the large-size longitudinal fibers 12 G are placed in the top portion of the ring 13 of the braiding machine shown in part in FIG. 7 , and the reels of the smaller-size longitudinal fibers 12 are placed in the remainder of the ring.
In FIG. 7 , the reels of the large-size longitudinal fibers 12 G are represented by squares, whereas the reels of the smaller-size longitudinal fibers 12 are represented by triangles.
As mentioned above, each layer of braided fibers is made up of a plurality of thicknesses or sub-thicknesses, each including a series of longitudinal fibers in a comb arrangement, i.e. arranged side by side. In the example of FIG. 7 , the ring 13 includes, for this purpose, five concentric annuluses of reinforcing fiber reels that are spaced apart radially from one another relative to the central axis AX so as to form a layer of braided fibers that is made up of five sublayers.
In order to avoid having too great a change of thickness in the transition region between the fine longitudinal fibers 12 and the thick longitudinal fibers 12 G, it is advantageous to provide a particular distribution of the various reels on the ring of the braiding machine.
Specifically, and as shown in FIG. 7 , the reels are arranged on the annulus 13 in radial columns, each having five reels. A transition zone is provided that is situated in the angular sector referenced T in FIG. 7 , which sector lies between the bottom region of the ring 13 in which each of the radial columns has five reels of small-size longitudinal fibers and the top region of the ring in which each of the radial columns has five reels of large-size reinforcing fibers.
In this transition zone T there are four radial columns of reels referenced 16 to 19 . The first radial column 16 of reels has one reel of large-section longitudinal fibers followed by four reels of small-section fibers, this first column being adjacent to a column of the bottom portion, i.e. a column having only reels of small-size fibers.
The second column 17 , adjacent to the first, has two reels of large-section longitudinal fibers followed by three reels of small-section longitudinal fibers. The third column 18 , adjacent to the second, has three reels of large-section fibers followed by two reels of small-section fibers.
The fourth column 19 , adjacent to the third has four reels of large-section fibers and only one reel of small-section fibers, and this fourth column is adjacent to a column of the top region of the ring, i.e. a column having five reels of large-size fibers.
This transition zone T ensures that the increase in the thickness of the layer of braided reinforcing fibers is gradual instead of being sudden, which contributes to obtaining a uniform level of tension during braiding for all of the fibers in the braided layer.
It will thus be understood that fabricating a mechanical member in accordance with the first implementation consists in equipping the braiding machine with longitudinal fibers of large size and with longitudinal fibers of small size, as described above with reference to FIG. 7 .
A mandrel is then installed on the central axis AX of the braiding machine, the mandrel being arranged concentrically on this axis. The mandrel is then moved along the central axis while simultaneously the braiding machine is activated to form the braid of reinforcing fibers in a convergence zone of the fibers that is situated substantially on the central axis AX while being spaced apart from the ring 13 . The main function of the mandrel 11 is to support the various braided layers, or “preforms”, and to define the inside shape of the part.
Once the mandrel has passed through the reinforcing fiber convergence zone, it carries a layer of braided fibers. The layer may then be cut between the mandrel and the ring, prior to reinstalling the mandrel at the entrance to the ring 13 on the axis AX so as to move it once more along the axis in order to form and deposit a new layer of reinforcing fibers on the first braided layer.
Analogous steps are performed to form a predetermined number of reinforcing fiber layers that are radially superposed on one another on the mandrel, which is typically a generally tubular hollow part.
Once all of these layers have been deposited, the resulting element presents a thickness in its top region that is significantly greater than the thickness that it presents in its bottom region, with the difference in thickness corresponding to a difference in longitudinal fiber density.
The assembly is then placed in a mold in order to inject resin into the various deposited layers, prior to triggering a heating cycle for polymerizing the resin. The blank that is obtained at this stage is subsequently machined to form a finished part.
In the second implementation of the invention, the increase in the density of longitudinal fibers in the top region of each layer of braided fibers is obtained by offsetting the mandrel 11 radially relative to the central axis AX of the braiding machine along which the mandrel is moved in order to form and deposit the layers of braided fibers.
As shown diagrammatically in FIGS. 8A and 8B , the main axis AP of the mandrel is thus offset downwards relative to the central axis AX of the braiding machine, by an offset value written e.
In general manner, the main axis AP of the mandrel 11 corresponds to the axis defined by the centers of gravity of two cross-sections of the mandrel situated in a portion of the mandrel that corresponds to the body of the fabricated member, i.e. to a regular portion of the mandrel, such as its tubular portion.
Forming and depositing a layer of reinforcing fibers in accordance with this second implementation of the invention thus consists in moving the mandrel along the axis AX of the braiding machine while keeping it offset downwards relative to said axis AX.
Under such conditions, when the mandrel 11 reaches the fiber convergence zone, it is offset downwards relative thereto so that the braid that is formed progressively as the mandrel 11 advances through this convergence zone has a larger quantity of longitudinal fibers in its top region than in its bottom region, as shown diagrammatically in FIG. 8B .
Once the mandrel has passed right through the convergence zone, the fiber braid is cut between the mandrel and the ring. The mandrel is then returned to the entrance of the ring so as to form and deposit a new layer of reinforcing fibers.
As in the first implementation, once the predefined number of braided fiber layers has been deposited on the mandrel, the assembly is placed in a mold for resin to be injected and polymerized, prior to being machined in order to form a finished part.
In both its first and second implementations, the invention makes it possible to fabricate simple rods such as the rod 21 of FIG. 9 comprising a generally tubular main body and presenting ends, each provided with at least one lug.
However the invention is also applicable to fabricating mechanical members of more complex shape, such as for example the rod 22 shown in FIG. 11 , having a central body that is generally tubular with a lug at each end, but also having an intermediate lug. This intermediate lug is referenced 23 and is situated between its ends, and it extends radially relative to the main axis AP of the rod.
The rod 22 may be fabricated in accordance with the second implementation of the invention, i.e. by fitting the braiding machine with longitudinal fibers, all having the same size, but with the mandrel 11 being offset away from the central axis AX of the braiding machine.
In practice, the mandrel 11 is then positioned to offset its main axis AP relative to the axis AX so as to bring the intermediate lug 23 closer to the central axis AX, as shown in FIG. 10A .
Thereafter, the mandrel 11 is moved through the braiding machine along the axis AX while conserving this offset e so as to form and deposit thereon a braid of reinforcing fibers.
Once the mandrel has gone past the reinforcing fiber convergence point, the fibers are cut between the mandrel and the ring of the braiding machine. The mandrel is then returned to the entrance of the braiding machine, still with the radial offset e, and it is then moved along the axis AX in order to form and deposit another layer of reinforcing fibers.
Thus, and as shown diagrammatically in FIG. 10B , in an ordinary cross-section of the rod, i.e. in a portion of its main body that is tubular in shape, the quantity of reinforcing fibers is greater in the top portion than in the bottom portion.
In the region corresponding to the intermediate lug 23 , shown in cross-section in FIG. 10C , the reinforcing fibers are distributed uniformly over this lug and they are present in sufficient quantity to confer appropriate mechanical strength on the lug, even though it constitutes a projection extending radially from the body of the rod.
The value e of the offset may thus be adjusted so that the quantity of longitudinal fibers in the top portion is greater than in the bottom portion in the ordinary section of the rod and also in the intermediate lug 23 .
This adjustment corresponds to a rod of the kind shown in FIG. 11A , which presents a greater thickness of fibers in its top region in its ordinary section as shown in FIG. 11B and also in its section through the intermediate lug 23 , as shown in FIG. 11C .
In analogous manner, the rod 23 of FIG. 11 may also be fabricated using the first implementation of the invention, i.e. by fitting the top portion of the ring of the braiding machine with fibers of size that is greater than that of the other fibers, and without offsetting the mandrel relative to the central axis AX while forming and depositing layers of reinforcing fibers.
In the above-described examples, two implementations of the invention are described separately, i.e. firstly the possibility of loading the ring of the braiding machine with fibers of different size, and secondly the possibility of radially offsetting the mandrel relative to the axis of the braiding machine in order to obtain densities of longitudinal fibers that differ between one region and another region in each braided layer.
It should be observed that both of those approaches that are described separately above can advantageously be used in combination. For example, it is possible to load the ring of the braiding machine with longitudinal fibers of large size in the top region and with longitudinal fibers of normal size in the other regions, and also to offset the mandrel relative to the axis of the braiding machine so as to obtain an even greater difference in reinforcing fiber density.
The invention provides the following advantages in particular:
In general, the invention makes it possible to vary the thickness of material so as to reinforce and thicken zones that are subjected to greater stresses, thus making it possible to fabricate a high performance structural part at a competitive production cost.
This fabrication technique is particularly adapted to rocker type parts, i.e. to parts that are subjected to “three point” bending. Specifically, these parts are subjected to mechanical stresses that seek to bend them always in the same direction.
By way of example, for downward bending, the bottom portion of the part is stressed in traction, whereas its top portion is stressed in compression. The traction and compression stresses are of substantially the same value, but the material of the fibers generally presents compression strength that is less than its traction strength. Consequently, it is appropriate to reinforce the part in its top portion, since that is where it is subjected to compression stress, but not in its bottom portion where it is stressed in traction only.
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A method of fabricating a mechanical member for aircraft, including a plurality of operations of braiding and depositing layers of braided reinforcing fibers on a mandrel ( 11 ) by using braiding machine. Each operation comprises braiding a braided layer and depositing it by moving the mandrel ( 11 ) along a central axis of the braiding machine. Each of the various superposed braided layers comprises both longitudinal fibers ( 12, 12 G) that are parallel to a main direction of the mandrel ( 11 ), and interlacing fibers that are inclined. At least one operation is configured to form and deposit a braided layer having, in at least one cross-section of the member, a density of longitudinal fibers that differs depending on whether consideration is given to one angular region (S 1 ) or another angular region (S 2 ) of the same extent around the center of gravity (G) of the mandrel ( 11 ) in the section under consideration.
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CROSS REFERENCE TO RELATED APPLICATION
This is a Continuation Application of Application No. 08/482,647 filed on Jun. 7, 1995, now abandoned, which is a Continuation Application of Application No. 08/114,870, filed on Aug. 31, 1993, now issued U.S. Pat. No. 5,463,500. The invention of the present application is further related to Application No. 08/480,263 filed on Jun. 7, 1995, now issued U.S. Pat. No. 5,790,323, which is a Continuation Application of Application No. 08/115,166 filed on Aug. 31, 1993, now issued U.S. Pat. No. 5,515,209, which was filed on even date and assigned to the same assignee as the assignee of Application No. 08/114,870.
This invention is related to an application entitled "LIGHT-WEIGHT HIGH-MAGNIFICATION CLINICAL VIEWER", Ser. No. 08/115,166, filed on even date herewith and assigned to the same assignee as the assignee of the present invention, now U.S. Pat. No. 5,515,209.
BACKGROUND OF THE INVENTION
A. Field of the Invention
The present invention relates to magnification viewers worn by surgeons and dentists. In particular, it relates to a compact, light-weight, comfortable-to-wear, high magnification viewer having an extremely wide field of view and good image quality.
B. Description of the Prior Art
Magnification viewers are worn by dentists and surgeons for extended periods of time during clinical procedures so as to provide clarity of view while avoiding a "hunched-over" position that can result in debilitating neck and back strain, which can have an adverse effect on the success of the operation. By permitting the clinician to operate at a greater working distance from the patient, higher magnification viewers also reduce the clinician's exposure to aerosols.
Because clinicians use magnification viewers during surgery and other procedures requiring manual precision, it is important that they be light-weight, comfortable, and have good clarity and wide field of vision while providing high magnification.
Clinical magnification viewers are generally made according to the "Galilean telescope" design, having a single objective lens and a single eyepiece lens. Galilean telescopes are characterized by relatively narrow fields of view which are mainly limited by the diameter of the objective lens. The basic Galilean design, however, produces substantial chromatic aberration ("coloring") and, hence, poor image quality.
The magnification, or power, of a Galilean telescope is proportional to the focal length of the objective and inversely proportional to the focal length of the eyepiece. Overall viewer length is proportional to the sum of the focal lengths of the objective and eyepiece.
Since the viewer should be kept as short as possible to reduce torque on the nose and wearer discomfort, an eyepiece with a shorter focal length is usually employed when an increase in magnification is desired. However, to retain a good field of view without vignetting, the diameter of the objective must be increased. If this is done while keeping the focal length of the objective the same, the "speed" of the lens increases, which results in a lower resolution quality. It also mandates an excessively large package. One method of overcoming the "speed" problem is to use a more complicated objective lens, though at the cost of greatly increased weight and strain and discomfort to the wearer.
The so-called Kellner design (from Kellner, U.S. Pat. No. 1,197,742 "Lens System") in general use today contains a heavy doublet objective and a singlet eyepiece lens. While image quality is adequate at lower magnifications, at higher magnifications, excessive coloring results in poor image quality. Moreover, the field of view is relatively limited.
It is known that image quality in prior art magnification viewers can be enhanced by the use of "very high index flint glass". However, this method has not been in general use, since "very high index flint glass" makes the viewer too heavy for practical use.
Finally, prior art magnification viewers require lens mounting barrels of differing sizes in order to provide a wide range of focusing or working distances. As such, the manufacturing costs for prior art viewers are relatively high.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a compact, light-weight, high-resolution, high-magnification viewer with a wide field of view that is comfortable to wear over extended periods of time.
A further object of the present invention is to provide a magnification viewer having better color quality than prior art magnification viewers.
A further object of the invention is to provide a magnification viewer having a wider field of view even at high magnification levels than the prior art magnification viewers.
A further object of the present invention is to provide a higher resolution magnification viewer while maintaining small diameter lenses than prior art magnification viewers.
A further object of the present invention is to provide a more compact magnification viewer than prior art viewers.
A further object is to provide a lighter-weight magnification viewer having superior image quality than previous magnification viewers.
A further object of the present invention is to provide a magnification viewer having relatively light lens elements while improving image quality using high index glass.
A further object of the invention is to provide method for making a magnification viewer in which all lenses for an entire series of working distances require just a single mounting barrel assembly.
In accordance with one embodiment of the invention, the magnification viewer includes a two-element objective lens and a single-element eyepiece lens. Use of multiple lenses allows for a more compact package. The doublet objective serves to reduce vignetting while providing a wide field of view and reduced chromatic aberration. Image quality is further enhanced, while keeping the weight of the viewer down, through the use in the objective of light-weight high index glass. Moreover, the invention permits the use of a mounting barrel of a common size for a series of working distances.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective drawing of the viewer as attached to a pair of glasses;
FIG. 2 is a diagram illustrating the viewer having a two-element objective and a single-element eyepiece;
FIG. 3a is a sectional view of the mounting barrel of the magnification viewer; and
FIG. 3b is an end view of the mounting barrel illustrated in FIG. 3a.
DETAILED DESCRIPTION OF THE INVENTION
One embodiment of the present invention, FIG. 1, includes a pair of magnification viewers 10, attached to a pair of eyeglasses, 12.
Optics for the magnification viewer 10 are shown in FIG. 2. The viewer according to the invention includes a single-element eyepiece lens including element I and a two-element objective lens including elements II-III. R1, R2, etc. represent the radii of respective refractive surfaces; S 1 represents the thicknesses of the air space; and T 1 , T 2 etc. represent the thicknesses of the lens elements.
The magnification viewer could be made of a single eyepiece and a single objective lens. However, chromatic aberrations would result in poor image quality. In the alternative, the objective lens could be made a doublet, as in the Kellner system. However, the Kellner system provides relatively poor image quality.
Image quality can be improved through the use of very high index flint glass in element II of the objective lens. However, this has not been done in the past since the use of very high index flint glass, coupled with a greater number of lens elements, of course, greatly increases the weight of the viewer which, again, is undesirable (e.g., standard very high index flint glass, such as Schott Optical Glass Company type SF6 has a specific gravity of 5.18 grams per cubic centimeter).
Consequently, the invention uses "light-weight high index glass" of the type available from various manufacturers such as Schott and Ohara (e.g., Schott type SFL6, which has a specific gravity of only 3.37 grams per cubic centimeter). The resulting doublet is reduced in weight while providing reduced aberrations and higher image quality.
The invention provides advantages in the manufacturing process, as well. Prior art magnification viewers have been designed such as to require mounting barrels of differing sizes in order to achieve a range of working distances, which result from variations in the radii of curvature of the various lenses.
A sectional view of the mounting barrel 14 is shown in FIG. 3a; an end view is shown in FIG. 3b. It is known that the radii of curvature for the various lens elements used in the doublet objective are kept the same for viewers of differing working distances. Thus, to change the viewer's working distance, the radii of curvature of the eyepiece, lens element I (See also FIG. 2), must be altered. However, in order to reduce manufacturing costs, a method in accordance with one aspect of the present invention is disclosed in which only the exterior radius of curvature R 1 of lens element I is changed. The interior radius of curvature R 2 of lens element I is kept constant. This allows for the use across various working distances of only one mounting barrel 14, having an inner rim 16 (FIG. 3) sized to accept an eyepiece having that single interior radius of curvature R 2 . Thus, by designing several eyepiece lenses that have the same radius of curvature R 2 facing the same doublet objective, and changing only radius of curvature R 1 , all lenses for an entire series of working distance require just a single mounting barrel assembly. This allows for a reduction in both manufacturing cost and complexity.
The objective lens 60 is mounted at one end 20 of the mounting barrel 14. The eyepiece lens I is mounted at the opposite end 22. Both are sealed in place in a conventional manner. The eyepiece lens I is fixed in place such that its face having the constant radius of curvature R 2 fits within the mounting barrel facing the doublet objective.
Exemplary construction data for a viewer built according to the preferred embodiment shown in FIG. 2 are given in TABLE 1, TABLE 2, and TABLE 3. These represent, respectively, the "Viewer with Exemplary Standard Working Distance", "Viewer with Exemplary Long Working Distance", and "Viewer with Exemplary Extra Long Working Distance" configurations.
TABLE 1______________________________________Viewer with Exemplary Standard Working DistanceElement n.sub.d v.sub.d Radius Thickness Separation______________________________________I 1.517 66.2 R.sub.1 = 55.780 T.sub.1 = 1.0 S.sub.1 = 21.14 R.sub.2 = 25.110II 1.805 25.4 R.sub.3 = 93.987 T.sub.2 = 1.5 R.sub.4 = 48.006III 1.517 64.2 R.sub.4 = 48.006 T.sub.3 = 6.5 R.sub.5 = 30.240______________________________________
TABLE 2______________________________________Viewer with Exemplary Long Working DistanceElement n.sub.d v.sub.d Radius Thickness Separation______________________________________I 1.517 64.2 R.sub.1 = 49.030 T.sub.1 = 1.0 S.sub.1 = 21.14 R.sub.2 = 25.110II 1.805 25.4 R.sub.3 = 93.987 T.sub.2 = 1.5 R.sub.4 = 48.006III 1.517 64.2 R.sub.4 = 48.006 T.sub.3 = 6.5 R.sub.5 = 30.241______________________________________
TABLE 3______________________________________Viewer with Exemplary Extra Long DistancesElement n.sub.d v.sub.d Radius Thickness Separation______________________________________I 1.517 64.2 R.sub.1 = 44.860 T.sub.1 = 1.0 S.sub.1 = 21.14 R.sub.2 = 25.110II 1.805 25.4 R.sub.3 = 93.987 T.sub.2 = 1.5 R.sub.4 = 48.006III 1.517 64.2 R.sub.4 = 48.006 T.sub.3 = 6.5 R.sub.5 = 30.240______________________________________
The radius, thickness, and separation dimensions are given in millimeters. Roman numerals identify the lens elements in their respective order from the eyepoint side to the object side; n d represents the refractive index of each element; v d is the Abbe dispersion number; R 1 , R 2 , etc., represent the radii of the respective refractive surfaces, in order, from the eyepoint side to the object side; T 1 and S 1 etc., represent the thicknesses of the lens elements and air spaces, respectively, from the eyepoint side to the object side, T 1 being the thickness of the first element I and S 1 being the thickness of the airspace between I and II. The thicknesses T 1 and S 1 etc. are measured along the optical centerline.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. Thus, it is to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described above.
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The light-weight clinical viewer includes a two-element objective lens and a single-element eyepiece lens. Use of multiple lenses allows for a more compact package. The doublet objective serves to reduce vignetting while providing a wide field of view and reduced chromatic aberration. Image quality is further enhanced, while keeping the weight of the viewer down, through the use in the objective of light-weight high index glass. Moreover, the invention permits the use of a single mounting barrel assembly for different eyepieces to reduce manufacturing costs.
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Genus and species: Rosa hybrida.
Denomination: ‘KORpot040’.
BACKGROUND
‘KORpot040’ originated from a controlled crossing in a breeding program of two distinct parents during the summer of 2010 in a controlled environment in Offenseth-Sparrieshoop, Germany between an un-named Rosa hybrida seedling as the seed or female parent (unpatented) and another un-named Rosa hybrida seedling as the pollen or male parent (unpatented).
The objective of the cross/hybridization was to create a new and distinct rose plant with unique qualities, such as:
1. Compact and uniform growth and flowering under greenhouse conditions when grown as a potted floral plant; 2. Abundant, long lasting, and attractive flowers and foliage; 3. Resistance to diseases encountered in greenhouse and nursery culture; and 4. Suitability for production from softwood cuttings in floral and nursery containers.
The resulting seeds from the cross were planted during the following winter in 2010 and were evaluated. The resulting seedlings exhibited distinctive physical and biological characteristics. ‘KORpot040’ was selected in April 2011 as a single plant from the seedling beds in Offenseth-Sparrieshoop, Germany due to its superior characteristics. ‘KORpot040’ was first asexually propagated by rooting softwood cuttings in June 2011 at a nursery in Offenseth-Sparrieshoop, Germany and asexually propagated for further evaluation. This new and distinctive rose variety was subsequently named ‘KORpot040’.
The initial and other subsequent asexual propagations were conducted in controlled environments and demonstrate that ‘KORpot040’ reproduces true to type in successive generations of asexual reproduction via rooting softwood cuttings.
CROSS REFERENCE TO RELATED APPLICATIONS
Plant Breeder's Right for ‘KORpot040’ were applied for with the European Community Plant Variety Office on Feb. 6, 2014, File No. 2014/0282. ‘KORpot040’ has not been made publicly available or sold more than one year prior to the priority date of this application.
SUMMARY
The following are the most outstanding and distinguishing characteristics of this new variety when grown under normal horticultural practices in Jackson County, Oreg.
1. ‘KORpot040’ has dark red, medium sized flowers, which have good durability; and 2. ‘KORpot040’ has a compact, upright to bushy habit.
DESCRIPTION OF THE PHOTOGRAPHS
This new miniature rose plant is illustrated by the accompanying photographs which shows an overall view of the plant and individual parts of the plant. The colors shown are as true as can be reasonably obtained by conventional photographic procedures.
FIG. 1 shows a whole plant approximately 4 months of age and grown in a glasshouse in a nursery in Offenseth-Sparrieshoop, Germany.
FIG.2 shows a close-up of the individual parts of 4 month old plant observed and growing in a nursery in Jackson County, Oreg.
DETAILED DESCRIPTION
The following is a description of ‘KORpot040’, as observed growing in November 2014 in a nursery in Jackson County, Oreg. on plants of 4 months of age. Color references are made using The Royal Horticultural Society (London, England) Colour Chart, 2001 except where common terms of color are used.
Classification:
Family .—Rosaceae. Species.—Rosa hybrida. Common name .—Miniature rose. Variety .—‘KORpot040’.
Parentage:
Female parent .—Un-named rose plant (unpatented). Male parent .—Un-named rose plant (unpatented).
Plant:
Growth .—Moderately vigorous. Habit .—Compact; upright to bushy. Size .—When grown as a 10.5 cm pot plant, the average plant height is 15.0 cm to 25.0 cm and the average plant width is 15.0 cm to 20.0 cm. Winter hardiness .—Due to the variety's principal use in greenhouses, winter hardiness has not been evaluated.
Stems:
Color .—Young wood: RHS 144A (Yellow-Green). Older wood: RHS 146B (Yellow-Green). Intonations: RHS 182A (Greyed-Red) present on youngest wood only. Stem surface texture .—Young and old wood are hispid. Length.— 20.0 mm to 23.0 mm average length when grown under commercial greenhouse floral production. Diameter .—Average is 3.0 mm.
Prickles:
Quantity .—Abundant; average of 25 to 30 large prickles with an additional 60 or more small prickles per each 10 cm of stem. Shape .—Linear. Size .—Average length of large prickles is 4.0 mm and average length of small prickles is 1.0 mm to 2 mm. Color .—Immature prickles: RHS 145C (Yellow-Green) with anthocyanin intonations of RHS 182A (Greyed-Red). Mature prickles: RHS 145C (Yellow-Green) with anthocyanin intonations of RHS 182D (Greyed-Red).
Leaves:
General .—Normally 5 to7 leaflets on normal leaves in middle of the stem. Venation pattern .—Pyramidal net pattern. Leaf size.— 110.0 mm to 130.0 mm in length and 60.0 mm to 70.0 mm in width. Abundance .—Very abundant.
Leaflets:
Size .—Average size of the terminal leaflet is 40.0 mm to 55.0 mm in length and 20.0 mm to 25.0 mm in width. Shape .—Ovate. Base .—Obtuse. Apex .—Acute. Margins .—Serrated. Surface appearance .—Upper side: Semi-glossy. Under side: Matte. Texture .—Upper side: Smooth. Under side: Leathery. Color, mature foliage .—Upper surface: RHS 137A (Green) and RHS 139A (Green). Lower surface: RHS 147B (Yellow-Green). Color, immature foliage .—Upper surface: RHS 141A (Yellow-Green). Lower surface: RHS 146B (Yellow-Green). Color, most immature foliage .—Upper surface: RHS 144A (Yellow-Green). Lower surface: RHS 146B (Yellow-Green). Anthocyanin intonation: RHS 178A (Greyed-Red) present on leaflet margins and lower surfaces of most immature foliage. Arrangement .—Odd pinnate. Venation .—Reticulate. Stipules .—Size: 12.0 mm in length and 4.0 mm to 5.0 mm in width. Color: RHS 146C (Yellow-Green). Anthocyanin: RHS 182C (Greyed-Red) minimally present on upper surface of midrib and on stipitate glands. Stipitate glands: Abundant on margins. Margins: Glandular toothed. Texture: Glabrous. Apex: Apiculate. Base: Winged. Petiole .—Length: Average is 18.0 mm to 23.0 mm. Diameter: Average is 1.0 mm to 1.5 mm. Color: Upper side: RHS 146B (Yellow-Green). Underneath: RHS 146C (Yellow-Green). Margins: Glandular toothed, with limited numbers of stipitate glands. Anthocyanin: RHS 182A (Greyed-Red) on margins and upper surface of midrib. Prickles: None observed. Stipitate glands: Limited numbers of stipitate glands present on margins. Texture: Upper surface is papillate with light pubescence while underneath is glabrous. Petiole rachis .—Length: Average is 18.0 mm to 23.0 mm. Diameter: Average is 1.0 mm to 1.5 mm. Color: Upper surface: RHS 146B (Yellow-Green). Underneath: RHS 146C (Yellow-Green). Anthocyanin: RHS 182A (Greyed-Red) present on upper surface of midrib, margins, stipitate glands, and prickles. Margins: Glandular toothed. Prickles: A few small prickles underneath. Stipitate glands: Limited numbers of stipitate glands on margins and underneath.
Flower bud:
Size .—Upon opening, 20.0 mm to 25.0 mm in length from base of receptacle to distal end of bud and 10.0 mm to 15.0 mm diameter at its widest point. Form .—Long; pointed ovoid. Color .—As the sepals first unfold, the bud color is RHS 59A (Red-Purple) and RHS 60A (Red-Purple); when one-quarter open, the upper surface of the petals is RHS 53A (Red) and the lower surface is RHS 46A (Red).
Sepals:
Color .—Upper surface: RHS 144A (Yellow-Green) with intonations of RHS 144B (Yellow-Green) on the base. Lower surface: RHS 144A (Yellow-Green). Size .—Average is 20.0 mm to 27.0 mm for the length and 5.0 mm to 7.0 mm for the width. Shape .—Strong foliaceous appendages on 3 of the five sepals. Apex .—Apiculate. Base .—Flat at union with receptacle. Quantity .—Five. Surface texture .—Upper side: Hoary. Lower surface: Hispid. Margins .—Cilliate and glandular toothed margins observed. Stipitate glands .—Abundant numbers of stipitate glands on lower surface and some margins.
Flower:
Blooming habit .—Recurrent; floriferous. General .—Multiple flower buds per inflorescence, generally 1 to 3; occasionally, 1 flowering lateral present below initiation of the inflorescence, typically 1 flower per lateral; flowers held upright. Fragrance .—Absent. Duration .—On the plant 15 to 20 days; senesced petals drop away cleanly. Size .—Medium for a miniature rose; when open, the average flower diameter is 40.0 mm to 45.0 mm and the average flower height is 25.0 mm. Overall shape .—Round. Shape of flower when viewed from the side .—Upon opening, upper part and lower part: Flattened convex. Open flower, upper part and lower part: Flattened convex. Color .—Upon opening, petals: Outermost petals: Outer side and inner side: RHS 46A (Red). Innermost petals: Outer side: RHS 46A (Red) and RHS 53A (Red), with intonations of RHS 155C (White) occasionally present on midrib. Inner side: RHS 46A (Red) and RHS 53A (Red). Upon opening, basal petal spots: Basal petal spot, outermost petals: Outer side: RHS 155C (White). Inner side: RHS 155C (White). Size: Average is 2.0 mm to 4.0 mm in height and 3.0 mm to 5.0 mm in width. Basal petal spot, innermost petals: Outer side and inner side: RHS 155C (White). Size: Average is 2.0 mm to 5.0 mm in height and 2.0 mm to 3.0 mm in width. After opening, petals: Outermost petals: Outer side: RHS 60A (Red-Purple). Inner side: RHS 46A (Red). Innermost petals: Outer side: RHS 60A (Red-Purple), with intonations of RHS 155C (White) occasionally present on midrib. Inner side: RHS 46A (Red). After opening, basal petal spots: Basal petal spot, outermost petals: Outer side and inner side: RHS 155C (White). Size: Average is 2.0 mm to 5.0 mm in height and 3.0 mm to 5.0 mm in width. Basal petal spot, innermost petals: Outer side: RHS 155C (White). Inner side: RHS 155C (White). Size: Average is 3.0 mm to 5.0 mm in height and 2.0 mm to 3.0 mm in width. General tonality .—On open flowers, RHS 46A (Red); no change in the general tonality at the end of the eighth day; afterwards, general tonality is RHS 46C (Red). Petals .—Petal count: Very double; approximately 75 petals under normal conditions. Petal reflex: Outermost petals reflex very slightly; reflex occurs one by one. Shape: Outermost petals are obovate and innermost petals are elliptic. Apex: Outermost petals obtuse and innermost petals are acute. Base: Outermost and innermost petals are cuneate. Margin: Entire. Petal size: 10.0 mm to 24.0 mm in length and 6.0 mm to 26.0 mm in width. Petal arrangement: Formal. Texture: Upper and lower surfaces are leathery. Pedicel .—Surface: Abundant stipitate glands and small prickles. Length: 45.0 mm to 65.0 mm average. Diameter: 2.0 mm to 4.0 mm average. Color: RHS 144A (Yellow-Green). Strength: Strong. Texture: Hispid. Peduncle .—Surface: Abundant stipitate glands and small prickles. Length: 25.0 mm to 65.0 mm average. Diameter: 2.0 mm to 3.0 mm average. Color: RHS 144A (Yellow-Green). Strength: Strong.
Petaloids:
Petaloid count .—Average of 20 per flower. Size.— 7.0 mm to 10.0 mm in length and 3.0 mm to 6.0 mm in width. Color .—Inner side: RHS 53A (Red) on marginal and middle zones, RHS 155A (White) on basal zone and intonations on midrib. Outer side: RHS 53A (Red) on marginal and middle zones, RHS 155A (White) on basal zone and intonations on midrib. Texture .—Inner side and outer side are smooth. Margins .—Entire and undulated petaloid margins observed. Shape .—Most commonly obovate with some petaloids highly irregular. Apex .—Obtuse. Base .—Attenuate.
Reproductive organs:
Pistils .—Quantity: Average is approximately 60 present. Stigmas: Location: Slightly superior to equal in position to anthers. Color: RHS 158C (Yellow-White). Diameter: 0.5 mm to 1.0 mm. Styles: Length: About 5.0 mm to 6.0 mm. Color: RHS 158A (Yellow-White), with intonations of RHS 52C (Red). Stamens .—Quantity: Approximately 60 on average and regularly arranged. Anthers: Size: Average is 3.0 mm in length and 1.5 mm in width. Pollen: Generally present. Color: RHS 163B (Greyed-Orange). Filaments: Color: RHS 5A (Yellow). Length: 3.0 mm to 5.0 mm. Receptacle .—Surface: Abundant stipitate glands and small prickles. Color: RHS 144B (Yellow-Green). Shape: Urn-shaped. Texture: Hispid. Size: 5.0 mm to 6.0 mm in height and 6.0 mm to 8.0 mm in width.
Hips and seed formation: None observed. Disease resistance: Above average resistance to Powdery mildew ( Sphaerotheca pannosa ) and Botrytis ( Botrytis cinerea ) diseases under normal growing conditions in Jackson County, Oreg.
COMPARISON WITH PARENTAL LINES
The new rose plant may be distinguished from the female or seed parent, an un-named seedling, by the following combination of characteristics:
1. ‘KORpot040’ has more flowers with longer durability than the female parent. 2. ‘KORpot040’ has less vigorous, more compact growth than the female parent.
The new rose plant may be distinguished from the male or pollen parent, an un-named seedling, by the following combination of characteristics:
1. ‘KORpot040’ has dark red flowers, whereas the male parent has hot-pink colored flowers. 2. ‘KORpot040’ has medium-sized flowers for a miniature rose, whereas the male parent has large flowers.
When ‘KORpot040’ is compared to the commercial comparison rose variety ‘KORhedani’ (U.S. Plant Pat. No. 19,598), the following differences are noted in Table 1.
TABLE 1
Characteristic
‘KORpot040’
‘KORhedani’
Petal count
Approximately 75 petals
Approximately 30 to
under normal conditions.
32 petals under
normal conditions
Average number of
25 to 30 large prickles, and
Less than 1
prickles per 10.0 cm of
upwards of 60 small
stem
prickles.
Average open flower
40.0 mm to 45.0 mm
55 mm
diameter
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A new and distinct variety of rose with long lasting, red flowers, and attractive foliage with above-average disease resistance; the new variety exhibits compact, upright to bushy growth with abundant flowers; and the new variety propagates well from cuttings and by grafting.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is directed toward endless fabrics, and more particularly, fabrics used as industrial process fabrics in the production of, among other things, wet laid products such as paper, paper board, and sanitary tissue and towel products; in the production of wet laid and dry laid pulp; in processes related to papermaking such as those using sludge filters, and chemiwashers; in the production of tissue and towel products made by through-air drying processes; and in the production of nonwovens produced by hydroentangling (wet process), melt blowing, spunbonding, and air laid needle punching. Such industrial process fabrics include, but are not limited to nonwoven felts; embossing, conveying, and support fabrics used in processes for producing nonwovens; filtration fabrics and filtration cloths. The term “industrial process fabrics” also includes but is not limited to all other paper machine fabrics (forming, pressing and dryer fabrics) for transporting the pulp slurry through all stages of the papermaking process. Specifically, the present invention is related to fabrics of the variety that may be used to mold cellulosic fibrous web into a three-dimensional structure and in making nonwoven textiles.
[0003] 2. Description of the Prior Art
[0004] During the papermaking process, a cellulosic fibrous web is formed by depositing a fibrous slurry, that is, an aqueous dispersion of cellulose fibers, onto a moving forming fabric in the forming section of a paper machine. A large amount of water is drained from the slurry through the forming fabric, leaving the cellulosic fibrous web on the surface of the forming fabric.
[0005] Typically, the newly formed cellulosic fibrous web proceeds from the forming section to a press section, which includes a series of press nips. The cellulosic fibrous web passes through the press nips supported by a press fabric, or, as is often the case, between two press fabrics. In the press nips, the cellulosic fibrous web is subjected to compressive forces which squeeze water therefrom, and which adhere the cellulosic fibers in the web to one another to turn the cellulosic fibrous web into a paper sheet. The water is accepted by the press fabric or fabrics and, ideally, does not return to the paper sheet.
[0006] The paper sheet finally proceeds to a dryer section, which may include at least one series of rotatable dryer drums or cylinders, which are internally heated by steam. The newly formed paper sheet is directed in a serpentine path sequentially around each of the drums by a dryer fabric, which holds the paper sheet closely against the surfaces of the drums. The heated drums reduce the water content of the paper sheet to a desirable level through evaporation.
[0007] It should be appreciated that forming, pressing and dryer fabrics all take the form of endless loops on the paper machine and function in the manner of conveyors. It should further be appreciated that paper manufacture is a continuous process which proceeds at considerable speed. That is to say, the fibrous slurry is continuously deposited onto the forming fabric in the forming section, while a newly manufactured paper sheet is continuously wound onto rolls after it exits from the dryer section.
[0008] In the production of some paper products, such as paper towels, facial tissues and paper napkins, through-air drying for example replaces the press dewatering described above. In through-air drying, the newly formed cellulosic fibrous web is transferred from the forming fabric directly to an air-pervious through-air-drying (TAD) fabric.
[0009] Air is directed through the cellulosic fibrous web and through the TAD fabric to continue the dewatering process. The air is driven by vacuum transfer slots, hot-air blowers, vacuum boxes or shoes, predryer rolls and other components. The air molds the web to the topography of the TAD fabric, giving the web a three-dimensional structure.
[0010] After the cellulosic fibrous web is molded on the TAD fabric, it is transported to the final drying stage, where it may also be imprinted. At the final drying stage, the TAD fabric transfers the web to a heated drum, such as a Yankee drying drum, for final drying. During the transfer, portions of the web may be densified in a specific pattern by imprinting to yield a structure having both densified and undensified regions. Paper products having such multi-region structures have been widely accepted by consumers. An early TAD fabric, which created a multi-region structure in the web by imprinting the knuckle pattern of its woven structure thereon, is shown in U.S. Pat. No. 3,301,746.
[0011] A subsequent improvement in TAD fabrics was the inclusion of a resinous framework on the woven structure of the fabric. TAD fabrics of this type may impart continuous or discontinuous patterns in any desired form, rather than knuckle patterns, onto the web during imprinting. TAD fabrics of this type are shown in U.S. Pat. Nos. 4,514,345; 4,528,239; 4,529,480; and 4,637,859.
[0012] In addition, or as an alternative, to an imprinting step, the value of paper products manufactured using through-air drying may be enhanced by an embossing step, which adds visual appeal and contributes bulk, softness and extensibility to the web. The embossing step is often done as a final or near-final step, when the paper web is dry, in an embossing calender where the paper product passes through a nip formed by two rolls: one smooth and one with a patterned surface. The paper sheet will take on a degree of the pattern from the roll surface as it is pressed between the two rolls. Some sheet thickness is lost however, which is undesirable.
[0013] In other applications, the fabric may be used in the formation and patterning of wetlaid, drylaid, meltblown and spunbonded nonwoven textiles.
SUMMARY OF THE INVENTION
[0014] The present invention is an industrial process fabric designed for use as a forming, pressing, drying, TAD, pulp forming, or an engineered fabric used in the production of nonwoven textiles, which is in the form of an endless loop and functions in the manner of a conveyor. The fabric is itself embossed with the topographic features ultimately desired for the product to be manufactured. A method for embossing the fabric with the desired pattern is also disclosed.
[0015] The method for embossing the fabric envisions the use of a device having embossments thereon which are heated (or the fabric pre-heated) having two opposed elements between which the fabric may be compressed at preselected levels of compression for preselected time intervals. For example, the device may be a two-roll calender, one or both rolls of which may be engraved or etched, which allows for continuous embossing. A platen press, with upper and lower platens might also be used if the application warrants it.
[0016] An embossing medium is used which has a preselected embossing pattern, and is capable of being readily changed from one embossing pattern to another, for example, by changing the engraved calender rolls.
[0017] In addition, the embossing method provides versatility in making desired embossed fabrics for multiple applications. The properties of the desired embossed fabric depend upon the control of certain process variables under which embossing takes place and selection of fabric substrate. The process variables include time, temperature, pressure, gap setting and roll composition.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Thus the advantages of the present invention will be realized, the description of which should be taken in conjunction with that of the drawings wherein:
[0019] [0019]FIG. 1 is an enlarged top plan view of an embossed forming fabric incorporating the teachings of the present invention;
[0020] [0020]FIG. 2 is an enlarged sectional view of the embossed fabric shown in FIG. 1;
[0021] [0021]FIG. 3 is a top plan view of a paper sheet formed with an embossed forming fabric of FIG. 1; the sheet was formed at a speed of 800 meters per minute with a sheet basis weight of 27 grams per square meter;
[0022] [0022]FIG. 4 is a top plan view of a paper sheet formed with an embossed forming fabric of FIG. 1 at a speed of 1200 meters per minute with a sheet basis weight of 16 grams per square meter; and
[0023] [0023]FIG. 5 is a schematic cross sectional view of the embossing device which comprises a two roll calender.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Turning now more particularly to the drawings, FIG. 1 shows a top enlarged view of an embossed fabric 10 which, by way of example, is a forming fabric used in papermaking. As aforesaid, the embossed fabric may also, however, be a press fabric, a dryer fabric, a TAD fabric, a pulp forming fabric, or an engineered fabric (i.e. a fabric used in making a nonwoven textile in the wetlaid, drylaid, meltblown and spunbonding process). Generally, each of these types of fabric 10 may be woven preferably from yarns extruded from a polymeric resin material, such as polyamide and polyester resin materials. A variety of yarns including multifilaments and monofilaments may be used. A variety of weave patterns, none of which are critical for the practice of the present invention, are used for this purpose, and, as is well-known to those of ordinary skill in the art, the fabrics may be of either single or multiple layers, woven or nonwoven, and can include batt fiber. Also, it is well-known that the permeability of the support fabric plays an integral role in the development of sheet properties, both physical and aesthetic.
[0025] As to the fabric 10 shown, square or diamond shaped elements 12 are embossed upon the fabric 10 . This is a result of an in-plane deformation of the fabric 10 as shown in FIG. 2. In this regard, the fabric 10 is deformed or compressed in area 14 . One side 16 of the fabric 10 includes the embossment whereas the opposite side 18 remains flat. Embossment may be in-plane, as shown, or out-of-plane where the material of the fabric 10 is displaced resulting in a raised portion on one side and a corresponding depression on the other side.
[0026] Turning briefly now to FIGS. 3 and 4, there is shown a plan view of a paper product produced using the embossed fabric 10 of FIGS. 1 and 2. The paper sheet 19 shown in FIG. 3 was produced at a speed of 800 meters per minute with a sheet basis weight of 27 grams per square meter in the forming section of a papermaking machine. As can be seen, the embossment 12 in fabric 10 results in the appearance of diamond shaped patterns (darker spots) in the paper sheet.
[0027] [0027]FIG. 4 illustrates a paper sheet 22 produced with the embossed fabric 10 at a speed of 1200 meters per minute and a sheet basis weight of 16 grams per square meter. Here also the embossment 12 in fabric 10 resulted in the appearance of diamond shaped patterns 24 in the sheet.
[0028] As can be seen, an embossed fabric forms a pattern in the material being formed. It should be noted that the invention envisions the use of the fabric so embossed in an endless loop. This endless loop operates in the manner of a conveyor rather than a dandy roll, calender roll, or other type of paper or textile embossing process.
[0029] Turning now to FIG. 5 there is shown the preferred embodiment of the invention which allows the embossing process on the fabric to be carried out continuously by way of a two roll calender 30 . While a calender is envisioned as a preferred method, the use of a platen press might also be used, if circumstances warrant.
[0030] As shown, a two-roll calender 30 is formed by a first roll 32 and a second roll 34 . The calender (one or both rolls) may be engraved or etched to provide for the embossing.
[0031] The fabric 10 is fed into the nip 36 formed between the first and second rolls 32 , 34 , which are rotating in the directions indicated by the arrows. The rolls 32 , 34 of the calender 30 are heated to the appropriate temperature. The rotational speed of the rolls 32 , 34 is governed by the dwell time needed for the fabric 10 to be embossed in the nip 36 , the necessary force being provided by compressing the first and second rolls 32 , 34 together to the required level.
[0032] The present invention may be used to emboss forming fabrics for the manufacture of contoured paper sheets having a predetermined Z-direction topography in an approach alternative to embossing dry or semi-dry paper sheets during the papermaking process using a calender nip for example, and for the manufacture of planar sheets having a predetermined regular pattern of heavy and light sections, differing from one another in the quantity of fibers therein and the density of those regions also. Of course, as aforementioned, embossed press fabrics, dryer fabrics, TAD fabrics, pulp forming fabrics, and engineered fabrics are also envisioned. Fabrication of the fabrics may involve different paths and variables. In this regard, many alternative fabrics are envisioned, the production of which takes into account the process utilized, the variables involved, and the fabric to be embossed.
[0033] With reference to the process utilized, various alternates are available. The use of a two roll calender is contemplated as previously discussed. This may involve using two calender rolls both made of steel. One calender roll can be embossed with the other being smooth. Alternatively, one may be embossed i.e. a raised embossment (male) with the other having a matching inverse embossment in the female sense. Rather than using two steel calender rolls, one may be steel with the embossment thereon (or on a sleeve carried thereon), with the other having a softer polymeric cover which may be smooth or also have a pattern thereon.
[0034] The extent to which the fabric is embossed can be varied. It can be the full width of the fabric or any portion or segment thereof.
[0035] A heating or pre-heating of the fabric being embossed may be desirable and accordingly, a heating device may be utilized. This may be done, for example, by way of a hot-air oven, a heated roll which may be one or both rolls of the calender as aforementioned, infrared heaters or any other means suitable for this purpose.
[0036] Turning now to the fabric on which the embossment is to occur, such a fabric may be any fabric consistent with those typically used in current papermaking or nonwoven textile processes. The fabric is preferably of the type that has a woven substrate and may be a forming, press, dryer, TAD, pulp forming, or an engineered fabric, depending upon the particular application in which the fabric is to be utilized.
[0037] Other base support structures can be used, including a structure formed by using strips of material spiraled together as taught by U.S. Pat. Nos. 5,360,656 and 5,268,076, the teachings of which are incorporated herein by reference. Also when used as a press fabric, staple fiber is applied to the base substrate on one or both sides of the substrate by a process of needling. Other structures well known to those of ordinary skill in the art can also be used.
[0038] The variables that ultimately control the formation of the fabric include the temperature of the rolls and fabric, the pressure between the rolls, the speed of the rolls, the embossing or roll pattern, and the gap between the rolls. All variables need not be addressed in every situation. For example, when employing a gap setting between the rolls, the resulting pressure between the rolls is a manifestation of the resistance to deformation of the fabric. The hydraulics of the machinery maintains the gap between the rolls. The rolls may have different temperature settings, and pre-heating of the fabric may or may not be used depending upon the circumstances involved.
[0039] The method described results in an altered topography and permeability of the resulting fabric. A pattern similar to the pattern of the embossing roll will be transferred to the fabric. This pattern may stem from in-plane deformation, where the nominal caliper of the fabric remains constant and areas comprising the pattern are compressed. In this situation the fabric has a patterned side and a smooth side. The pattern could also result from out-of-plane deformation where the nominal fabric caliper has increased due to physical movement of material out of the original plane of the fabric. In this situation the pattern exists on both sides, with one side consisting of a protuberance with a corresponding cavity on the opposite side. In this situation compression may or may not occur.
[0040] Changes in permeability to fluid (air and water) of the fabric can be affected by carefully controlling the amount of compression in the patterned areas. High temperatures and pressures could ultimately result in fusion of the fibers in the embossed areas, completely sealing the areas. This would result in a “perm-no perm” situation. Compression to varying degrees without fusion could result in a situation where the permeability of the fabric in the embossed areas is less than the original permeability, but not reduced to zero. As the application warrants, the permeability in these areas could be altered over a range of desired values.
[0041] Thus it can be seen that through the selection of the process desired (and, of course, the elements to implement the process), controlling of the variables involved, and selecting the type of fabric to be embossed, the aforedescribed method provides for versatility in creating the desired embossed industrial process fabric.
[0042] Thus by the present invention its advantages are realized and although preferred embodiments have been disclosed and described in detail herein, its scope should not be limited thereby, rather its scope should be determined by that of the appended claims.
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An industrial process fabric is embossed in a device, such as a continuously operating two-roll calender having a preselected embossing pattern. The roll(s) of the calender may alternatively themselves be engraved or etched to provide the embossing. Embossing takes place with controlled temperature, pressure, speed and gap (between the rolls) settings. The fabric may be a forming, press, dryer or TAD fabric used in paper and pulp production, pulp forming fabric or an engineered fabric used to produce nonwoven textile products by meltblowing, spunbonding, hydroentangling or air laid needle punching.
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FIELD OF THE INVENTION
The present invention relates to a catalytically active component of a catalyst, which comprises single phase oxides, based on metal doped yttrium ortho-cobaltate, catalysts comprising the catalytically active component, methods for the oxidation of ammonia in the presence of said catalysts comprising said catalytically active component and the use thereof.
BACKGROUND OF THE INVENTION
Currently, nitric acid is produced industrially via the catalytic oxidation of ammonia, over a platinum or platinum alloy-based gauze catalyst. This process, known as the Ostwald process, has essentially remained unchanged, since its inception in the first decades of the twentieth century. Ostwalds's patent was dated 1902 and when combined with Haber's development of synthesising ammonia, in 1908, the basis for the commercial production of nitric acid, which is used today, was in place.
The combustion of ammonia is carried out over a platinum based metal or alloy catalyst in the form of a gauze or mesh or net. A number of gauzes are installed together, and they constitute the gauze pack. The upper-most gauzes have compositions optimised for the combustion of ammonia, and are referred to as the combustion gauzes. Gauzes with other compositions may be located below the combustion gauzes, and these may have other roles, as described below. The whole stack of gauzes is referred to as the gauze pack. The gauzes are produced either by weaving or knitting.
The operating temperatures of the plants are typically 830 to 930° C. and the range of pressures is from 100 kPa to 1500 kPa. Typically, the combustion gauzes are installed in the plant for between six months and two years, depending on the plant operating conditions. Plants operating at high pressures typically have shorter campaigns than low-pressure plants.
The duration of the campaign is governed by a loss in the selectivity of the catalyst, towards the desired nitric oxide product, through the increased formation of unwanted nitrogen and nitrous oxide by-products. The loss of selectivity is related to a number of phenomena. During combustion, platinum is lost through the formation of PtO 2 vapour. Some of the platinum may be recovered by the installation of palladium metal based gauzes, directly below the platinum based combustion gauzes. The PtO 2 vapour alloys with the palladium, therefore, platinum is retained in the catalytically active zone. However, due to the depletion of platinum in the upper combustion zone of the gauze pack, not all of the ammonia is immediately combusted. If the ammonia is combusted in the palladium gauze region, the selectivity towards nitric oxide is reduced, and secondly, if ammonia and nitric oxide coexist in the vapour phase for a period of time, nitric oxide is reduced by ammonia, through a homogeneous reaction. This leads to both nitric oxide and ammonia losses. A final mechanism for loss of selectivity is related to the fact that the platinum is lost from the combustion gauzes at a higher rate than the other alloying elements (typically rhodium). This leads to rhodium enrichment of the gauze surface which leads to selectivity loss.
Over the last sixty years, many attempts have been made to replace the expensive platinum-based combustion catalyst with a lower cost catalysts, based for example on metal oxides. To date, the only commercially available oxide based catalyst for ammonia combustion, was developed by Incitec Ltd (Australia). This is based on a cobalt oxide phase. However, in terms of its selectivity of combustion of ammonia to the desired nitric oxide product, its performance is inferior to that of platinum-based systems. The cobalt oxide based systems have shown selectivity levels of circa 90%, in commercial units, compared to the 94 to 98% achieved with platinum based catalysts.
The use of mixed oxides with the perovskite structure, such as rhombohedral lanthanum cobaltate, as catalysts for ammonia oxidation, has received much attention. However, when considering the conditions that the catalyst is subjected to in industrial ammonia oxidation, it can clearly be seen that they are not suitable for stability reasons. Ammonia oxidation on an industrial scale, takes place at temperatures from 830 to 930° C. and at pressures from 100 kPa to 1500 kPa. The concentration of ammonia is in the range of 8.5 to 12 mol %, depending on plant conditions, with the remainder of the gas consisting of air. Thus the gas feed for oxidation has a composition of approximately 10 mol % NH 3 , 18.7 mol % O 2 and the balance being nitrogen. When the ammonia is oxidised to NOx (NO+NO 2 ), with an efficiency of 95%, the gas composition is approximated by 9.5% NOx, 6% O 2 and 15% water vapour. (The balance of gas composition is nitrogen and some 800 to 2000 ppm of N 2 O). Thus the ammonia oxidation catalyst is subjected to high temperatures and a gas environment that contains oxygen and water vapour. These are the ideal conditions for the evaporation of metal ions, in the form of hydroxides and oxyhydroxides. Thus material will be lost from the catalytic reaction zone as vapour phase species, which will in turn be deposited downstream in a cooler zone of the reactor system.
If considering evaporation from mixed oxides (those that contain more than one metal component), it most often has an incongruent evaporation process. This is the situation where one component in the oxide has a higher evaporation rate than another or than the others. If considering the lanthanum cobaltate perovskite system, when heated in an atmosphere containing oxygen and water vapour, cobalt species, such as CoOOH, have much higher vapour pressures than the dominant lanthanum species La(OH) 3 . The effect of this is that cobalt evaporates to a larger extent than lanthanum, thus incongruent evaporation. The result of preferential cobalt evaporation is that in time, the non-stoichiometry limit of the lanthanum cobalt perovskite X will be exceeded (LaCo 1-X O 3 where X and 0<X≈<0.03). When the limit is exceeded, La 2 O 3 will be precipitated. When operating, La 2 O 3 does not have a negative effect on the catalyst performance. However, when the plant is shut-down or when it trips, the oxide catalyst is exposed to the ambient air. On cooling in air, the free La 2 O 3 will hydrate; forming La(OH) 3 . 1 mole of La 2 O 3 will form 2 moles of La(OH) 3 , which involves a 50% expansion of the volume of the free lanthanum species. This results in a mechanical disintegration of the catalyst.
Different perovskite type oxidation catalysts are known for use in different oxidation reactions. Examples of such catalysts and reactions are mentioned below.
Pecchi, G et al., “Catalytic performance in methane combustion of rare-earth perovskites RECo o,50 Mn 0,50 O 3 (RE: La, Er, Y)”, Catalysis today 172 (2011) page 111-117. This article describes physic-chemical properties for compounds where Co and Mn are present in equimolar quantities. The catalytic activity is related to methane combustion.
Russian patent RU2185237 describes catalysts for use in ammonia oxidation. The active catalyst is a composition with perovskite structure of the formula Mn 1-x R 1+x O 3 , wherein R=Y, La, Ce or Sm and X=0−0.596. A catalyst support of alumina is used. However, this patent describes a method of producing N 2 O, which is used in various areas as in semiconductors, perfume industries, in medicine and food industry. The catalysts show increased activity and selectivity for N 2 O and low selectivity for NO, which is the opposite of what is wanted for nitric acid production.
EP 532 024 relates to a catalyst for catalytic reduction of nitrogen oxide. More particularly, it relates to a catalyst for reduction of nitrogen oxide using a hydrocarbon and/or an oxygen-containing organic compound as a reducing agent, which is suitable for reducing and removing harmful nitrogen oxide present in emissions from factories, automobiles, etc. It is used a perovskite type compound oxide on a solid carrier. This catalyst selectively catalyses a reaction of nitrogen oxide with the reducing agent so that nitrogen oxide in emissions can be reduced efficiently without requiring a large quantity of the reducing agent.
SUMMARY OF INVENTION
The object of the invention is to find an oxide system suitable to be used as oxidation catalyst. A further object is to find a catalyst especially for ammonia oxidation where problems with swelling of the catalyst is avoided. Still a further object is to find a catalyst with high selectivity towards NOx and giving low levels of the undesired N 2 O.
These and other objects of the invention are obtained by the oxide systems as described in the enclosed patent claims.
The present invention thus provides a catalytically component of a catalyst, comprising a catalytically active single phase oxide based on metal doped yttrium ortho-cobaltate oxide systems, with the general formula YCo 1-X M X O 3 , where X has values between 1>X>0, and M is a metal including manganese, iron, chromium, vanadium and titanium, aluminium or a transition metal, or an alkaline earth metal. Preferably X is greater than 0.1. In an embodiment of the invention the oxide phases has the general formula YCo 1-X Mn X O 3 where X has values between 1>X>0, preferably 0.5>X>0, and in particular embodiments of the invention catalytically active component has the formula YCo 0.9 Mn 0.1 O 3 , YCo 0.8 Mn 0.2 O 3 , YCo 0.7 Mn 0.3 O 3 , YCo 0.5 Mn 0.5 O 3 , YCo 0.9 Ti 0.1 O 3 or YCo 0.9 Fe 0.1 O 3 .
Another embodiment of the invention concerns a catalyst for the oxidation of ammonia where the metal doped yttrium ortho-cobaltate is supported on a refractory support phase. The refractory support phase may be selected from the group consisting of cerium dioxide, zirconium dioxide, alumina, yttrium oxide, gadolinium oxide, and a mixed oxide of these refractory oxides, silicon carbide, and sodium zirconium phosphate type phases.
The invention also concerns a method for the oxidation of ammonia in the Ostwald process wherein a gas blend comprising ammonia and oxygen is converted in presence of a catalyst comprising a catalytically active single phase oxide based on metal doped yttrium ortho-cobaltate oxide systems, with the general formula YCo 1-X M X O 3 , where X has values between 1>X>0. Preferably the catalyst has a selectivity towards NOx (NO+NO 2 ), exceeding 90%, and a selectivity towards N 2 O (<0.05%).
Another embodiment of the invention concerns the use of a catalyst comprising stable, single phase oxides, based on a metal doped yttrium ortho-cobaltate oxide systems, with the general formula YCo 1-X M X O 3 , where X has values between 1>X>0, and M is a metal including manganese, iron, chromium, vanadium and titanium, aluminium or a transition metal, or an alkaline earth metal for the selective oxidation of ammonia. Preferably the oxide phase has the general formula YCo 1-X Mn X O 3 where 1>X>0 or is selected from YCo 0.9 Mn 0.1 O 3 , YCo 0.8 Mn 0.5 O 3 , YCo 0.7 Mn 0.3 O 3 , YCo 0.5 Mn 0.5 O 3 , YCo 0.9 Ti 0.1 O 3 or YCo 0.9 Fe 0.1 O 3 .
DETAILED DESCRIPTION OF THE INVENTION
The current invention is a catalyst especially for high temperature ammonia oxidation, which is resistant to the above hydration issues of lanthanum containing mixed oxides. An evaluation of the hydration resistance of large metal ions that may adopt a trivalent oxidation state shows that the following are candidates: Scandium, yttrium, gadolinium, terbium, dysprosium, holmium, erbium, ytterbium and lutetium.
Scandium is eliminated as it is too small to form an ortho cobaltate phase. Terbium, dysprosium, holmium, erbium, ytterbium and lutetium are suitable in terms of their ionic radii and hydration resistance, but they are very expensive. However, yttrium meets the set requirement in terms of ionic radii, when in the trivalent oxidation state and its hydration resistance.
Yttrium and cobalt, in a 1:1 mole ratio form a stable orthorhombic phase YCoO 3 —yttrium ortho-cobaltate. When this mixed oxide phase is tested under industrially relevant ammonia oxidation conditions (a feed-stock containing 10% ammonia, 18% oxygen and a balance of inert gas or nitrogen, at a temperature of 900° C.), it combusts ammonia to a mixture of NOx (NO+NO 2 ), N 2 and N 2 O. However, the selectivity towards the nitrogen containing oxides that are desired in the production of nitric acid (NOx) is lower than that obtained by platinum-based catalysts and is in the range of 91.3%. Examination of the YCoO 3 phase prior to and after the ammonia oxidation test, using X-ray powder diffraction, shows clearly that there has been a reduction of the YCoO 3 phase
2YCoO 3 →Y 2 O 3 +2CoO (1)
It is known that the CoO phase demonstrates some activity towards ammonia oxidation, but the selectivity towards desired NOx products is low—high levels of N 2 and N 2 O are produced.
Thermo-gravimetric analysis of the YCoO 3 , in air shows that the YCoO 3 phase reduces according to equation 1, at a temperature of 970° C. When combusting ammonia at 900° C., as in industrial plants, the 900° C. temperature is that of the product gas directly downstream of the catalyst. The temperature of the catalyst is significantly higher than the gas temperature. Therefore, pure YCoO 3 is not sufficiently stable for use as an industrial ammonia oxidation catalyst.
From the literature, it is known that the yttrium ortho-ferrate phase YFeO 3 and the yttrium ortho-manganate phase YMnO 3 , are stable in air, up to high temperatures (1500 and 1350° C., respectively). An approach to improve the stability of the yttrium ortho-cobaltate phase could be to replace a proportion of the cobalt with either iron or manganese (based on the fact that the pure iron and manganese yttrium phases are significantly higher in stability than the YCoO 3 phase. Two series of doped yttrium ortho-cobaltate phases were prepared, YCo 1-X Mn X O 3 and YCo 1-X Fe X O 3 . Thermo-gravimetric analysis of these two series of yttrium ortho-cobaltates demonstrated that both iron and manganese doping of the yttrium ortho-cobaltates, improved the stability of the phases. A surprising, and unexpected result, is that the manganese doping is more effective at stabilizing the yttrium ortho-cobaltates, than iron doping, given that the stability of the pure YFeO 3 is much higher than the pure YMnO 3 .
Samples of the YCo 1-X Mn X O 3 catalysts were tested for their catalytic performance towards ammonia oxidation, in a laboratory test reactor system. They were found to be active towards ammonia oxidation with a high selectivity towards the desired NO X product.
TABLE 1 Performance of YCo 1−X Mn X O 3 orthocobaltomanganates, sintered at 900° C., towards ammonia oxidation. Ignition temperature Selectivity N 2 O emission Sample ° C. towards NO x % ppm YCoO 3 271 91.3 50 YCo 0.9 Mn 0.1 O 3 264 95.4 22 YCo 0.8 Mn 0.2 O 3 248 95.5 22 YCo 0.7 Mn 0.3 O 3 273 96.9 23 YCo 0.5 Mn 0.5 O 3 257 94.3 37 YMnO 3 239 92.4 112
In the table the corresponding values for YCoO 3 and YMnO 3 are also included for comparison. These compounds do not form a part of the invention.
It is observed that manganese doped yttrium ortho-cobaltate (YCo 1-X Mn X O 3 ) exhibit both high selectivity towards the desired NOx product, along with low levels of the powerful N 2 O greenhouse gas. The compounds YCo 0.9 Mn 0.1 O 3 , YCo 0.8 Mn 0.2 O 3 , YCo 0.7 Mn 0.3 O 3 have especially low levels of N 2 O emission. X-ray powder diffraction analysis of the fresh and used manganese doped yttrium ortho-cobaltates show that these phases had not undergone a reduction towards:
2YTmO 3 →Y 2 O 3 +2TmO (2)
Where Tm is an oxide of cobalt and/or manganese. Thus the doping of yttrium ortho-cobaltate with a reduction resistant dopand, such as manganese leads to high selectivity towards NOx and low levels of the undesired N 2 O, under industrially relevant oxidation conditions.
By adding a dopant like Mn, Fe, Ti or other transitions metals, the catalyst stability have increased. Samples of the YCo 1-X M X O 3 catalysts where M is Fe or Ti, were tested for their catalytic performance towards ammonia oxidation, in the laboratory test reactor system. (See Table 2). Corresponding results for YCoO 3 is shown for comparison.
TABLE 2
Performance of YCo 1−X Fe X O 3 and
YCo 1−X Ti X O 3 towards ammonia oxidation.
Ignition
temperature
Selectivity
N 2 O emission
Sample
° C.
towards NO x %
ppm
YCoO 3
271
91.3
50
YCo 0.9 Fe 0.1 O 3
245
93.6
31
YCo 0.9 Ti 0.1 O 3
284
95.3
25
The catalysts may be prepared by co-precipitation, complexation, combustion synthesis, freeze-drying or solid-state routes, or by other state-of-the-art methods of producing mixed-metal oxides. The catalysts according to the present invention can be used to catalyse several reactions.
Examples of such uses are:
I. The catalysts may be used as oxidation catalysts,
II. as catalysts for the selective oxidation of ammonia
III. as catalysts for the oxidation of hydrocarbons
IV. as catalysts for the complete oxidation of hydrocarbons to CO 2 , in gas turbine power generation applications
V. as catalysts for the complete oxidation of hydrocarbons to CO 2 , at temperatures below 600° C., for the abatement of hydrocarbon emissions from vehicle exhaust gases.
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The present invention relates to a catalytically active component of a catalyst, which comprises single phase oxides, based on a metal doped yttrium ortho-cobaltate oxide systems, methods for the oxidation of ammonia 5 and hydrocarbon in the presence of said catalytically active component and the use thereof.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to small down-flow furnaces whose combustion gases are vented upward through a broad, radiator member curving inward to a flue.
2. Related Art
Down-flow furnaces, in which room air is delivered downward over heat-exchanger surfaces, have been used for many years, especially in mobile homes which utilize the balanced draft afforded by concentric flues. The room air is conventionally directed over a combustion chamber mounted in the lower part of a furnace cabinet, which serves as the primary heat exchanger. Heated air is discharged through a system of floor ducts. See for example U.S. Pat. Nos. 3,171,400, and 3,601,116. As shown in those patents, it is conventional to permit the upflow of combustion gases to the flue through a broad radiator member curved around the centrifugal blower; this radiator member serves as the final heat exchanger. The gas from the upper part of the combustion chamber is ducted to the radiator member by a short cylindrical flue connector.
In order to achieve much greater efficiency in the utilization of the fuel, much more complex furnaces have been designed, such as shown in U.S. Pat. No. 4,621,686, issued Nov. 11, 1986; these extract even the latent heat of condensation of combustion gases. That patent shows a finned heat exchanger positioned on a slant beneath the outlet of a centrifugal blower. A suction fan draws the gases downward, through the heat exchanger, removes the condensate, and expels the combustion. Such high-efficiency furnaces are costly to manufacture and have not proved to be popular.
SUMMARY OF THE INVENTION
The principal purpose of the present invention is to achieve a substantial increase in fuel efficiency over the simple furnace type, first referred to, at a modest increase in cost.
U.S. Pat. No. 3,171,400 shows what is believed to be the accepted practice -- using the shortest feasible flue connector from the combustion chamber, which serves as the primary heat exchanger, to the upward-leading curved radiator member. Instead, in the present invention the combustion gases leave the combustion chamber at its side opposite to the gas transfer member, and flow to the lower end of the radiator member through an intermediate heat exchanger positioned substantially horizontally directly beneath the outlet of the centrifugal blower. This added heat exchanger, so positioned, increases substantially the efficiency of fuel utilization, depending in part on whether a simple plurality of parallel tubes is used or whether this intermediate heat exchanger is a finned one.
The walls of the lower heating compartment through which the down-flow room air passes around the combustion chamber, must be fairly close to it to effect heat exchange from it. When the outlet of the centrifugal blower is centered above the combustion chamber, the size of the centrifugal blower may require it to project somewhat forwardly of this lower heating compartment, as shown in U.S. Pat. No. 3,171,400. If now a concentric flue is employed to draw the inlet air in an annulus outward of the flue for combustion gas, a saving of cabinet space is effected by drawing the inlet air forward just beneath the top of the furnace cabinet, and thence down in front of the forward wall of the lower heating compartment portion and thence into the front of the combustion chamber. By employing a downward-leading air delivery tube of circular cross-section, the draft so furnished is superior to that of inlet air supplied through relatively flat passages, as have heretofore conventionally been employed, especially those passages leading down through the interior of the heating compartment.
The utilization of such exterior supply of inlet air also simplifies construction where a draft-inducing and supplementary fan, sometimes called an inducer fan, is utilized. Since thermostatically-controlled furnaces operate intermittently, there is no natural draft until combustion has begun, so an induced draft may be required. Further, using a hydrocarbon fuel, the temperature of the combustion gas may be so reduced in the heat exchangers as to precipitate water, especially on start-up when the surfaces are cold. To clear this precipitate from narrow heat-exchange tubes, forced draft may be needed. Therefore, use of an inducer fan is especially important where, in order to obtain further increased efficiency, the intermediate heat exchanger is of finned tube construction. In practicing the present invention such an inducer fan is positioned at the lower end of the exterior downward air delivery tube, to cause air from it to flow sideward and then inward into the combustion chamber.
Whether this intermediate heat exchanger consists of simple tubes or finned tubes, the present furnace is unique in its use of three heat exchanger units: the combustion chamber walls, the new intermediate tubular heat exchanger, and the broad radiator which leads the combustion gases to the flue.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a furnace embodying the present invention, shown with its door removed and having a removable concentric flue at its top, the view being broken away at right to show portions behind the vertical air supply conduit, and broken away below to show the combustion chamber and the air supply to it.
FIG. 2 is a left side view taken along line 2--2 of FIG. 1 showing a louvered furnace door in place, and broken away to show the air supply from the lower end of the vertical conduit to a conventional gas burner.
FIG. 3 is a top view broken away to show the horizontal transverse plenum having an annular inlet from which the air flows forwardly to the vertical air supply conduit.
FIG. 4 is a horizontal section taken along line 4--4 of FIG. 1 showing a three-tube heat exchange unit embodying the present invention interposed intermediate between a top outlet of the combustion chamber and leading across, immediately beneath the blower outlet opening, to a conventional radiator member.
FIG. 5 is a fragmentary elevation corresponding to the mid-portion of FIG. 1, of an alternate finned tube heat exchanger unit installed between the combustion chamber and the radiator.
FIG. 6 is a partial sectional view taken along line 6--6 of FIG. 5.
FIG. 7 is a fragmentary view generally corresponding to the lower right portion of FIG. 1, showing an alternate inducer fan installation.
FIG. 8 is a fragmentary view generally corresponding to the lower right portion of FIG. 2, showing such alternate installation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The furnace of the present invention includes a downflow cabinet generally designated 10, seen in the front view FIG. 1 with its louvered door removed. The left side sectional view FIG. 2 shows the louvered door 12 in place with room air inlet louvers 14 opposite the upper portion of the downflow cabinet 10. The cabinet 10 has a left wall 15, a rear wall 16 and a right wall 17. At its base is a narrow structural base flange 18, which provides an outlet 19 for heated air.
The cabinet top wall 20 shown in FIGS. 1, 2 and 3 has an outer upstanding circular flange 22 spacedly surrounding an inner concentric flue collar connector 24 which serves as the outlet for the horizontal upper end portion 49 of a substantially conventional radiator member generally designated 50, hereinafter described.
Shown in FIGS. 1 and 2 as removably secured to the outer flange 22 and collar connector 24 are the lower end portions of a conventional concentric flue generally designated f, not part of the present invention, and removable upwardly as shown in phantom lines.
The annular space between the inner concentric connector collar 24 and the outer circular flange 22 serves as an annular inlet to a transverse plenum box 26, of which the cabinet top wall serves as a part. The plenum box 26 has a forward overhang portion 28 which, as seen in FIG. 1, extends farther forwardly than any of the other upper components, to provide inflow air communication to a downward leading air conduit 30 seen at the right in FIGS. 1-4.
Referring now to the other furnace cabinet portions, a horizontal separator shelf 32, best seen in FIGS. 1, 2 and 5, divides the cabinet 10 into an upper cabinet portion generally designated 33 and a lower cabinet portion generally designated 34, the latter enclosed beneath a separator shelf 32 by a lower forward cabinet wall 35 seen in FIG. 2 and broken away in FIG. 1. It is to be understood that all walls of the lower cabinet portion 34 are insulated in a conventional manner, which insulation is not here shown.
Supported upwardly from the structural base flange 18 and spacedly within the walls of the lower cabinet portion 34 is a heavy steel furnace combustion chamber generally designated 36. Its support may be by conventional means secured to the said walls such as vertically positioned angle brackets, not shown. The combustion chamber 36 may have a substantially cylindrical vertical side wall 37 penetrated near its lower edge by a large circular horizontal inlet flange 38, best seen in FIGS. 2 and 4. The combustion chamber 36 is completed by a bottom wall 39, which may be domed as shown, and a top wall generally designated 40 whose configuration is best seen in FIG. 1. Describing that configuration, it has a generally domed shape rising to a maximum height in its right side portion 41 seen in FIG. 1, but whose left top wall portion 42 rises to a plane.
Reverting to the radiator member generally designated 50 whose horizontal upper end portion 49 has heretofore been described: the radiator member 50 is substantially conventional, save for its positioning along the right side wall 17 of the cabinet 10, where it extends from a lower end portion 51, substantially at the height of the domed top wall 40 of the combustion chamber 36, through and beyond the horizontal separator shelf 32, and then curving to its horizontal upper end 49, which is bolted to the undersurface of the transverse plenum box 26. The radiator member 50 is, in its conventional form, a slender broad box-like member whose width, best seen in FIG. 2, is substantially the same as that of the combustion chamber 36, occupying the major portion of the width between the lower forward cabinet wall 35 and the rear cabinet wall 16. In conventional installations such a radiator member 50 serves as a second heat exchanger, the walls of the combustion chamber 36 serving as the primary heat exchange surface. Below the level of the separator shelf 32 and immediately above the radiator lower end 51 the inwardly-presented surface 52 of the radiator 50 has a planar inlet opening 53, seen in FIG. 4. A substantially similar planar combustion gas outlet (not shown) is formed in the planar top wall portion 42 of the combustion chamber top 40.
Two alternate forms of intermediate heat exchanger are here shown; a simple multi-tube intermediate exchanger generally designated 60, shown in FIGS. 1, 2 and 4, and a more complex intermediate heat exchanger of the finned tube type 70 which provides even greater heat efficiency, and is shown in FIGS. 5 and 6.
In the simpler embodiment 60, a plurality of tubes 62--as few as two--may be used. Their inlet portions extend upward from an inlet flange plate 64, which is readily bolted about the combustion gas outlet in the top planar portion 42 at the left side of the combustion chamber top wall. The tubes 62 are bent to extend horizontally and terminate in an outlet flange plate 66, bolted to the radiator inner side wall 52 about its inlet opening 53. In another form of intermediate heat exchangers, see FIGS. 5 and 6, an inlet flange plate 64' mounts a rectangular box portion 71 which extends upward to position a fore-and-aft manifold 72 at at a level opposite the lower portion 51 of the radiator 50. Extending from the manifold 72 to an outlet flange plate 66' at a small downward-sloping angle which may be 5°, are a plurality of heat exchange tubes 73 bearing transverse fins 74.
The separator shelf 32 mounts a conventional centrifugal blower 80, seen in FIGS. 1 and 2, which receives room air drawn in through the door louvers 14 through side openings 81 in the blower scroll, to be discharged downwardly. As seen in FIG. 1, the right side opening 81 is adjacent to the radiator member 50 at the right side wall 17 of the upper cabinet portion 33; the adjacency of the radiator member 50 to this side inlet 81 somewhat improves the heat transfer from the radiator 50.
The discharge opening of the blower scroll is positioned to correspond with an opening 82 in the separator 32. The opening 82 is positioned directly above the intermediate tubular heat exchange means 60 or 70, so that room air from the centrifugal blower 80 is directed upon and through said intermediate heat exchange means. Because of space limitations in the cabinet, it is not always possible to locate the flow opening from the blower 80 precisely over such intermediate heat exchange unit; to aid in directing the air thereover, a vane plate 83 may be added, as shown in FIGS. 1, 2 and 5, to direct the air most advantageously.
As compared with prior furnaces whose combustion gas passes directly from combustion chamber to radiator, interposing the simple multi-tube heat exchanger 60 may increase fuel efficiency roughly at least 10%. The finned tube heat exchanger 70 may improve efficiency by roughly 20%, but with this complication: since one of the products of combustion of hydrocarbon gas is water vapor, with increased efficiency this may condense in the relatively small gauge tubes 73, particularly at start-up when the tube walls are cold. The 5° slope of the tubes 73 partly overcomes this problem, as does supplying forced air by an inducer fan 89, now to be described.
The downward inlet air conduit 30 terminates in taperingly narrowed lower end air transfer member 85 which communicates sidewardly to the interior of an air box 87, seen in FIGS. 1 and 2. The air box 87 encloses that portion of the forward compartment wall 35 which leads into the circular inlet flange 38 of the combustion chamber 35. For a forced air supply, in the lower end of the air transfer member 85 there may be incorporated a downward-extending somewhat semi-cylindrical housing 88 enclosing an inducer fan 89, whose blades extend upwardly into the transfer member 85. The fan 89 is powered by an electric motor 90 to rotate on a horizontal axis in the direction shown by the curved arrow of FIG. 1, to induce a draft downward through the air conduit 30 and transversely into the combustion chamber 35.
Alternatively, as seen in FIGS. 7 and 8, such an inducer fan 89' may be accommodated in a housing 88' extending forward from the upper end of the transfer member 85, there mounting a similar motor 90' to rotate on a vertical axis.
Using the finned tube heat exchanger unit 70 of FIGS. 5 and 6, the operation of the inducer fan 89, 89' should not be discontinued immediately after combustion is started, because water vapor is likely to condense in the relatively small gauge tubes 73, at least before they are thoroughly heated by continuing operation. While the 5° slope of the tubes 73 tends to cause condensate to flow to the radiator lower end 51, the pressurized draft afforded by the inducer fan 89 drives the condensate along to the radiator end 51. While a drain 99 may be provided as shown in FIG. 5, with prolonged operation all components reach substantially higher temperatures at which condensation may not be expected to occur. At such higher temperatures any initial condensate may vaporize or at least separate into fine droplets, to be carried upward and discharged with the now hot flue gases.
Even with the simpler intermediate heat exchanger 60, an inducer fan 89 furnishes reliability in starting combustion. When the furnace is cold there is no natural draft; a fan 89 provides insurance against failure at start-up. With such an installation the inducer fan 89 need not operate after combustion has been commenced, thus saving electric current required for continuing operation.
The combustion system shown in the drawings is otherwise conventional. Mounted on the outer side of the air box 87 is a conventional gas valve 91, supplied through a gas supply tube 92, and projecting a conventional gas supply nozzle 93 and burner assembly generally designated 94 through the air box 87 and the combustion chamber inlet flange 38.
It will be apparent that other conventional combustion systems may be utilized, for example, oil burning systems, with substantially the same advantages as herein described.
As various modifications may be made in the constructions herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting.
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A furnace utilizing, in the upper portion of its cabinet, a blower acting downward through a separator opening to circulate room air past a combustion chamber whose gases flow upward through a sideward-positioned board radiator member which reaches up to the flue. A substantial increase in efficiency results from drawing the combustion gases out of the combustion chamber at the side opposite to the lower end of the broad radiator member, and interposing therebetween, directly beneath the separator opening, a plurality of tubes which serve as an intermediate heat exchanger. A still greater increase in efficiency is achieved by utilizing, instead, a finned tube heat exchanger across and beneath said separator opening; its heat transfer may be so great as to result in condensation of water vapor in the combustion gas. To purge this, a motorized inducer-blower is used in the inlet air system, driving the condensate through the finned tube heat exchanger to an appropriate drain.
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FIELD OF THE INVENTION
The present invention is directed to an implement with a readily removable snap-fit cartridge housing which is held in one's hand and used in manual activities. Examples of such implements include writing implements such a pens and pencils, cutting implements such as knives, awls and scribes, and other hand-held implements such as brushes, cosmetics applicators, soldering devices and computer styluses.
BACKGROUND OF THE INVENTION
In the past, traditional hand-held implements have generally been provided with a cylindrical shaft which is manipulated primarily by the thumb and index finger of the user acting in conjunction with each other to control the tip of the device so as to accomplish a specified task. The users of such traditional cylindrical shaft implements often utilize the middle finger in order to manipulate the implement. Additionally, the users of such traditional cylindrical shaft implements may often utilize the arch as a lever against the working thumb and index finger as a fulcrum, in order to manipulate the implement. Examples of traditional single tip hand-held implements are writing instruments such as pens and pencils, cutting instruments such as knives and awls, tools such as soldering devices and scribes, painting instruments such as brushes, cosmetics application equipment and digitalizing contacting devices such as computer styluses. During their use, the surface of such traditional implements contacts a relatively small surface area of the user's skin.
These traditional implements are generally configured so that in use the cylindrical shaft of the device extends along a direction between the thumb and index finger of the user and thence out away from the hand. This traditional orientation of manual implements can be considered to date back to a period of history when feather quills were used as writing implements. Thus, the elongated shape of the feather quill has tended to govern the basic design concept for the configuration of hand-held implements.
Most of the improvements to such traditional hand-held implements have concerned the working portions of the devices. For example, improvements in pens have primarily concerned new inks, ink flow mechanisms and delivery of the ink to the writing surface. Other developments regarding these traditional implements have related to aesthetics, or the ease with which such devices may be stored or transported. However, a fundamental disadvantage for these traditional implements is that they have only a single rigidly mounted working tip. The fundamental disadvantage for these traditional hand-held implements which are based upon the configuration of the feather quill is that the ubiquitous cylindrical shaft does not conform well to the surfaces of the user's fingers, palm or closed inner hand.
One of the less developed areas of hand-held implement design is the mounting of the tip in the body of the implement. One of the least developed areas of hand-held implement design is the interrelationship between the external shape of the implement and the natural shape of the user's hand. This interrelationship has a significant effect on the user's comfort and ability to control and manipulate the implement, particularly when the implement is to be used for a prolonged period of time. As previously stated, a fundamental disadvantage with hand-held implements whose external shape is based on a cylindrical shaft is that they do not conform to the contacted surfaces of the fingers which grasp the implement. Normally, such implements contact a relatively small proportion of the surface area of the user's fingers, leaving a large area of the thumb and fingers unused. Further, the direct physical contribution of the larger portions of the hand in using such hand-held implements is relatively small and the bulk of the user's hand is not used to dissipate the physical stress that accompanies the use of the hand-held implement. This situation eventually leads to discomfort for the user over a period of use, as the rigid surfaces of the implement exert pressure (in the form of negative leverage) and friction on the user's fingers. Thus, it is advantageous that a larger percentage of the surface area of the hand and fingers which work with a hand-held implement should contribute to controlling the hand-held implement.
Various attempts have been made to modify hand-held implements to reduce discomfort and fatigue. For example, implements have been produced which have soft rubber coating materials. However, such materials tend to reduce the control of the implement in the hand and easily become soiled. Also, it has been proposed to provide hand-held implements with different concave surfaces. However, these concave surfaces have not overcome the basic problems arising from the basic idea of a cylindrical shaft oriented to extend in a direction between the thumb and index finger of the user and out away from the hand.
SUMMARY OF THE INVENTION
The present invention is directed to providing an ergonomic hand-held implement with a snap-fit removable cartridge housing such that the cartridge housing can be readily removed and replaced without tools, unusual dexterity or any special skills.
Another object of the invention is to provide a ergonomic hand-held implement which can be held with a high degree of comfort for long periods of time with reduced fatigue of the hand.
Another object of the invention is to provide an ergonomic hand-held implement which allows for performing manual activity with a high degree of precision.
A further object of the present invention is to provide an ergonomic hand-held implement which provides less friction and pressure on the contacting surfaces of the hand, thereby reducing the development of blisters or calluses on the fingers or hand, for example, along the third finger which result from friction and pressure during extended use.
A still further object of the present invention is to provide an ergonomic hand-held implement of smaller dimensions, but which provides a greater proportion of it's surface in contact with the hand, thus enabling a greater degree of control and manipulation while simultaneously providing for greatly increased comfort.
The present invention accomplishes these and other objectives by providing a hand-held implement which has a snap-fit cartridge housing from which a working tool extends, for example, a pen or pencil point independent of the structural mounting requirements of the working tip. Thus, the implement can then be provided with an ergonomically shaped body, with the body preferably having a forward surface extending upwards from the bottom portion, and first and second side surfaces extending upward from the bottom surface and rearward from the front surface. The forward surface is adapted to be engaged by the index finger of the user, and the surfaces are oriented so that in use the implement extends in a direction which is no further toward the user's thumb than the user's index finger. The implement is of sufficient size so that the implement fits comfortably in the palm and does not extend outside the palm of the user, such that the instrument provides a greater conformation with the contours of the thumb, second and third fingers of the hand, and the closed palm, when the implement is in the position in which the device is used. In so doing, a relatively large contact area exists between the hand and the instrument. The increased area of contact decreases the pressure at any given point of contact, and the increased area of contact also allows for greater control of the instrument. The instrument of the present invention may be advantageously used in multiple manually performed activities utilizing hand-held instruments, including for example, writing, painting, cutting, soldering, surgery, and cosmetics application by simple replacement of the snap-fit cartridge housing.
Other objects, advantages and features of the present invention will be more readily appreciated and understood when considered in conjunction with the following detailed description as drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of the present invention will now be described with reference to the accompanying drawings, in which:
FIG. 1 illustrates a perspective view of a hand-held implement according to the present invention in a fully assembled state;
FIG. 2 illustrates a perspective view of a the hand-held implement according to the present invention as held in a hand;
FIG. 3 illustrates a side view of the hand-held implement shown in FIG. 1;
FIG. 4 illustrates a side view of the hand-held implement according to the present invention as held in a hand;
FIG. 5 illustrates the front view of the hand-held implement shown in FIG. 1;
FIG. 6 illustrates a rear view of the hand-held implement according to the present invention as shown in FIG. 1;
FIG. 7 illustrates a perspective view of a snap-fit cartridge housing according to the present invention;
FIG. 8 illustrates a perspective view of a hand-held implement according to the present invention;
FIG. 9 illustrates a sectional view of the first body panel according to the present invention shown in FIG. 10;
FIG. 10 illustrates a side view of a first body panel according to the present invention;
FIG. 11 illustrates an end view of a preferred snap-fit post according to the present invention;
FIG. 12 illustrates a sectional view of the second body panel according to the present invention shown in FIG. 13;
FIG. 13 illustrates a side view of a second body panel together with a cartridge housing according to the present invention;
FIG. 14 illustrates an end view of the second body panel shown in FIG. 13;
FIG. 15 illustrates a sectional view of the second body panel shown in FIG. 13;
FIG. 16 illustrates a sectional view of the second body panel shown in FIG. 13;
FIG. 17 illustrates a partial sectional view of the second body panel shown in FIG. 13;
FIG. 18 illustrates a side view of a pen cartridge according to the present invention;
FIG. 19 illustrates a side view of a snap-fit cartridge housing according to the present invention;
FIG. 20 illustrates an end view of a snap-fit cartridge housing according to the present invention;
FIG. 21 illustrates an end view of a second body panel according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the figures, it can be seen that the hand-held implement of the present invention is used to carry a working tip 10. In the illustrated embodiments, working tip 10 is a pen cartridge. However, the working tip can be any one of a variety of interchangeable devices which require precise manual control. Examples include other writing implements such as pencils and fountain pens, the blade for a cutting implement, a brush for painting, a brush or puff for cosmetic application, a soldering tip or a contacting device such as a computer stylus. The working tip is mounted in a snap-fit cartridge housing and extends from the bottom portion 12 of the implement.
In a preferred embodiment, extending upward from the bottom portion 12 is a forward surface 14 and first and second side surfaces 16 and 18, respectively. The side surfaces 16 and 18 extend rearward from the forward surface 14. As seen in FIGS. 2 and 4, in use, the forward surface is engaged by the index finger 15 of the user, the first side surface 16 is engaged by the thumb 17 of the user and the second side surface 18 is engaged by the third finger of the user.
In this preferred embodiment, the forward surface 14 is provided with a concave contour 20 adjacent the bottom portion 12. Similarly, the side surfaces 16, 20 and 18 are provided with concave contours 22 and 24 adjacent the bottom portion. The concave contours are smooth and gradual, without sharp edges. Similarly, the surfaces of the implement are joined smoothly, with rounded edges. These features enhance the level of comfort for the user of the implement.
In this preferred embodiment, the forward surface 14 also includes a convex contour 26 extending from the concave contour 20 to contour 30. Again, the two portions are joined smoothly.
This preferred embodiment of the implement is provided with a rearward surface 28. This surface is provided with a concave contour adjacent the bottom portion which is joined to the convex contour of the forward surface by the continuous convex contour 30. Again, contours 26, 28 and 30 are joined smoothly. The concave contour of the rearward surface 28 results in the implement having a reduced size in the area of the concave contours 20, 22 and 24. This permits the comfortable positioning of the third finger of the user during use, with the side of the third finger of the user engaging the concave contour 24 in the area of the end or middle joint of the finger. The convex contours 26 and 30 provide a somewhat bulbous upper portion which provides a feeling of security when the implement is held by the closed palm in the hand.
Additionally, as seen particularly in FIG. 6, the width of this embodiment of the implement decreases in the direction of the rearward surface, particularly in the area of the concave contours 20, 22 and 24. This taper provides increased comfort and control.
In a particularly preferred embodiment, the width of the implement is thin enough so as to facilitate storage of the implement in a pocket of the user's clothing.
Referring again to FIGS. 2 and 4, it can be seen that, in use, the meaty pads of the index finger of the user 15 extends along the forward surface 14 of this preferred embodiment of the implement. Thus, the present invention in use permits the hand of the user to assume a comfortable arched configuration, with the implement being substantially co-planar with the arch defined by the index finger and corresponding portion of the surrounding closed palm of the user. This preferred embodiment of the implement is of a sufficiently small length that it does not extend beyond the hand of the user, but rather fits within the user's hand. The bulbous upper portion extends well into the interior of the palm, with the area of convex contour 30 contacting the palm, particularly between the base of the user's index finger and the base of the thumb. When the user's hand is curled to grasp the instrument, the flesh between the thumb and fingers forms around the implement quite readily and can comfortably accept the bulbous upper portion of the implement.
In this preferred embodiment, the surfaces 12, 14 and 16 are oriented so that the implement in use will extend in a direction which is preferably essentially parallel to the user's index finger, but in any event, a direction which is no further toward the thumb of the user than the index finger. Thus, instead of extending in the direction of the user's thumb or the space between the thumb and index finger, the index finger defines the limit on the direction in which the implement extends with respect to the thumb. This relationship can also be conceptualized by considering the tool 10 as defining a longitudinal axis, which is identified by numeral 31 in FIG. 2. The longitudinal axis 31 is preferably substantially parallel to the index finger of the user, but in any event is not oriented outside of the index finger in the direction of the thumb.
Referring to FIG. 7, a snap-fit cartridge housing 40 according to the present invention is equipped with a working tip 10 and one or more coaxial recessed grooves 42. In a preferred embodiment, the cartridge housing 40 is cylindrical and elongated. However, the snap-fit cartridge can be any shape (including square, oblong, conical, etc.) and need not be elongated. A cartridge 44 extends from the snap-fit cartridge housing and contains the working tip 10.
Referring to FIG. 8, a perspective view of a hand-held implement according to the present invention is shown. It can be seen that the external shape of the body does not correspond to the external shape of the snap-fit cartridge housing 40. Both the body and the snap-fit cartridge housing 40 may independently have any longitudinal shape. Also, both the body and the snap-fit cartridge housing 40 may independently have any cross-sectional shape. In a preferred embodiment, the external shape of the hand-held implement is non-cylindrical. In a more preferred embodiment, the cross sectional area encompassed by the body is significantly larger than the cross sectional area encompassed by the snap-fit cartridge housing and the shortest dimension of the body is longer than the shortest dimension of the snap-fit cartridge housing. The first body panel 46 and the second body panel 47 of the hand-held implement according to the present invention enclose the snap-fit cartridge housing 40. The snap-fit cartridge housing 40 may be located anywhere within the body and extend from any facet of the body. A working tip 10 extends from the snap-fit cartridge housing 40. In a preferred embodiment, the cartridge 44 is a pen cartridge.
Referring to FIG. 9, a first body panel 46 according to the present invention is equipped with an elongated snap-fit post 48 mounted on the inner surface 50 of the first body panel 46. In a preferred embodiment, the snap-fit post 48 has a polygonal cross section and the first body panel 46 is non-cylindrical. The snap-fit post may be of any cross sectional shape and be located anywhere within the body. In a preferred embodiment, a first end of the elongated snap-fit post 52 is formed on the inner surface 50 of the first body panel 46. The snap-fit post 48 can also be fabricated so as to touch or fit into the inner surface 51 of the second body panel 47 in FIG. 13. The first body panel 46 is preferably equipped with an engagement tab 57. Engagement tab 57 cause snap-fit post 48 to engage the recessed groove 42 of the snap-fit cartridge holder 40 with greater resilience. In a preferred embodiment, the shape of the first body panel 46 is curved and the first body panel 46 is also equipped with at least one longitudinal ridge 54. In a more preferred embodiment, the shape of the first body panel 46 is convexo-concave and the first body panel is also equipped with one or more abutment tabs 56 which limit the rearward movement of the snap-fit cartridge housing 40. Abutment tabs 56 preferably extend outward from the inner surface 50 of first body panel 46 to the center line of the assembled body of the hand-held implement.
Referring to FIG. 10, a first body panel 46 according to the present invention is preferably equipped with three parallel ridges 54 which define a longitudinal snap-fit cartridge housing receptacle 58. In a preferred embodiment, the longitudinal snap-fit cartridge housing receptacle 58 is cylindrical. The first body panel 46 is preferably equipped with abutment tabs 56. The abutment tabs 56 are of a predetermined length which results in the tip 10 extending a desired distance from the bottom portion 12 of the hand-held implement. The snap-fit post 48 may be of any cross sectional geometry and size. A thicker snap-fit post 48 will engage the recessed grooves 42 of the snap-fit cartridge holder 40 with greater resilience. The snap-fit post 48 is preferably perpendicular to, and noncoplaner with the axis of the elongated snap-fit cartridge housing receptacle 58. The first body panel 46 is preferably equipped with a mounting ridge 59. The mounting ridge 59 is for the attachment of internal accessories. The accessories may include weights, electronic devices or mechanical devices such as a music box which is actuated by the removal of the snap-fit cartridge holder 40.
Referring to FIG. 11 a particularly preferred embodiment of a polygonal cross section snap-fit post 48 has straight wall lower base 60, sloping side walls 62, an upper surface 64, radii 65 at the upper edges and a reinforcing web 67. The straight wall lower base 60 improves the resiliency of the post while the radii 65 enhance the removability of the cartridge housing. The use of the terms "lower" and "upper" is relative to the orientation of the post shown in FIG. 11. In actual use, the orientation may be different. The reinforcing web 67 increases the rigidity of the snap-fit post 48 so that the recessed grooves 42 of the snap fit cartridge holder 40 are engaged with greater resilience.
Referring to FIG. 12, the second body panel 47 according to the present invention is preferably equipped with engagement tabs 66 which mate with the inner surface 50 of the first body panel 46. In a preferred embodiment, the shape of the second body panel 47 is convexo-concave and the second body panel 47 is also equipped with at least one longitudinal ridge 54. The second body panel also preferably has one or more abutment tabs 56 which limit the rearward movement of the elongated snap-fit cartridge housing 40.
Referring to FIG. 13, the snap-fit cartridge housing 40 fits within the elongated snap-fit cartridge housing receptacle 58 which is partially defined by the longitudinal ridges 54 and the abutment tabs 56 of the second body panel 47. It can be seen that this particularly preferred body panel has two abutment tabs 56 and five engagement tabs 66. In a preferred embodiment, second body panel 47 is equipped with a recessed slot 69. The recessed slot 69 is for the optional attachment of a spring clip to the hand-held implement. The spring clip (not shown) may be attached to an accessory such as a key chain, a lanyard or an electrical lead. The location of the recessed slot 61 preferably allows the accessory to extend from the hand-held implement and leave the hand through the bottom portion of the hand. Thereby not interfering with the use of the hand-held implement.
Referring to FIG. 14, an end view of the second body panel 47 can be seen. The second body panel 47 is equipped with a semicylindrical recess 68 which partially defines a cylindrical snap-fit cartridge housing receptacle orifice 70. However, the snap-fit cartridge housing receptacle orifice can be oval, polygonal or of variable cross section.
Referring to FIG. 15, the engagement tabs 66 are preferably molded into the inner surface 51 of the second body panel 47. In a preferred embodiment, the inner surface 51 of the second body panel 47 is equipped with three longitudinal ridges 54 and two abutment tabs 56 which partially define the snap-fit cartridge housing receptacle 58.
Referring to FIG. 16, a section of the body panel closer to the lower portion 12 than is FIG. 15 is shown. There can be seen the three longitudinal ridges 54 which are preferably molded into the inner surface 51 of the second body panel 47.
Referring to FIG. 17, a partial sectional view is shown. The upper surface of an engagement tab 66 is molded into the inner surface 51 of the second body panel 47 and contacts the inner surface 50 of the first body panel 46 when the two body panels are assembled. The edge of the second body panel 72 preferably includes a multifaced molded edge 74 having a raised ridge which engages the first body panel 46 and promotes a tight seal between the two body panels and structural rigidity of the hand-held implement. In a preferred embodiment, the first body panel and the second body panel are fused together by melting the raised ridge by sonic sealing.
Referring to FIG. 18, a pen cartridge 44 according to the present invention is shown. In a preferred embodiment, the pen cartridge 44 has straight side walls 76 and a conical working tip 10.
Referring to FIG. 19, a snap-fit cartridge housing 40 according to the present invention is shown. The snap-fit cartridge preferably includes two or more coaxial recessed groves 42. In a preferred embodiment, there are four coaxial recessed grooves 42. When at least one recessed groove 42 is provided at each end of the snap-fit cartridge housing, the snap-fit cartridge housing can be readily removed from the assembled body, and then reinserted backwards so that the working tip 10 of the implement is stored within the body. This allows the implement to be stored without the working tip 10 being outwardly exposed. In a particularly preferred embodiment, when the snap-fit cartridge is inserted into the assembled body, the snap-fit post 48 engages only the recess that is closest an end of the snap-fit cartridge housing due to the action of abutment tabs 56. In a preferred embodiment, the snap-fit cartridge housing 40 has a raised beveled edge 77. The raised beveled edge 77 improves the engagement with the snap-fit post 48 and facilitates insertion of the snap-fit cartridge housing 40 into the body of the hand-held implement by aligning the axis of the cartridge housing with the orifice defined by the semicylindrical recess 68.
Referring to FIG. 20 the snap-fit cartridge housing 40 according to the present invention preferably has a round cartridge receptacle 78. The depth of the coaxial groove 42 can be chosen to optimize the resilient engagement of the snap-fit cartridge housing 40 with the snap-fit post 48.
Referring to FIG. 21, an end view of the second body panel 47 can be seen. The second body panel 47 is equipped with a recess 79 which partially defines a rectilinear snap-fit cartridge housing receptacle orifice 80.
The hand-held implement can be of any suitable dimensions consistent with the above relationships. For example, the distance between the forward and rearward surfaces along the bottom portion can be about one inch (2.5 cm), the width of the forward surface at the bottom portion can be about three eights of an inch (1 cm), and the length of the implement, excluding the tool, can be about two and a quarter inches (5.5 cm). The implement can be scaled up or down so as to provide different implements of different sizes which can thereby accommodate users with different size hands. The implement of the present invention can be made of any material suitable for the intended purpose of the implement. Examples include various polymeric materials, metal, wood and glass. It should also be noted that the side surfaces 16 and 18, in the bulbous upper portion of the device, provide a relatively smooth flat surface which is well-suited for application of art work, logos and advertising.
While there is shown and described herein certain specific structures embodying this invention for the purpose of clarity of understanding, the same is to be considered as illustrative in character, it being understood that only preferred embodiments have been shown and described. It will be manifest to those skilled in the art that certain changes, 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 in the scope of the appended claims.
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A hand-held implement, is provided with a body including an elongated snap-fit post and an elongated snap-fit cartridge housing. The snap-fit cartridge housing includes a coaxial recessed groove and readily snap-fits into the body of the pen by the resilient engagement of the tip of the snap-fit post into the coaxial recessed groove of the snap-fit cartridge housing. The cartridge housing can be readily removed from the body of the pen and replaced with another cartridge housing inserted in its place. The body of the implement has external surfaces which define contours which match and ergonomically engage the surfaces of a user's thumb and fingers when the user grasps the implement, so as to provide a large surface area of contact between the user's hand and the implement. The increased area of contact between the user's hand and the implement, compared to traditional designs, decreases the required level of applied unit area pressure, and also provides for greater control consequently facilitating manipulation of the implement. The exterior of the implement is sufficiently small so that, while in use, the body of the implement does not extend outside or beyond the hand of the user. Such a hand-held implement may advantageously be used in all manually performed activities utilizing hand-held instruments, including for example, writing, painting, cutting, soldering, digitalizing and applying cosmetics.
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FIELD OF INVENTION
[0001] This invention relates to C34 peptide derivatives that are inhibitors of viral infection and/or exhibit antifusogenic properties. In particular, this invention relates to C34 derivatives having inhibiting activity against human immunodeficiency virus (HIV), respiratory syncytial virus (RSV), human parainfluenza virus (HPV), measles virus (MeV), and simian immunodeficiency virus (SIV) with long duration of action for the treatment of the respective viral infections.
BACKGROUND OF THE INVENTION
[0002] Membrane fusion events, while commonplace in normal cell biological processes, are also involved in a variety of disease states, including, for example the entry of enveloped viruses into cells. Peptides are known to inhibit or otherwise disrupt membrane fusion-associated events, including, for example, inhibiting retroviral transmission to uninfected cells.
[0003] HIV is a member of the lentivirus family of retroviruses, and there are two prevalent types of HIV, HIV-1 and HIV-2, with various strain of each having been identified. HIV targets CD4+ cells, and viral entry depends on binding of the HIV protein gp120 to the CD4 glycoprotein and a chemokine receptor on cell surface. C34 is known to exhibit anti-viral activity against HIV, including inhibiting CD4+ cell infection by free virus and/or inhibiting HIV-induced syncytia formation between infected and uninfected CD4+ cells. The inhibition is believed to occur by binding of C34 to the first heptad repeat region in gp41 and thus preventing the first and second heptad repeat regions from formating the fusigenic hairpin structure.
[0004] C34 is known to possess antifusogenic activity, i.e., it has the ability to inhibit or reduce the level of membrane fusion events between two or more entities, e.g., virus-cell or cell-cell, relative to the level of membrane fusion that occurs in the absence of the peptide. More specifically, WO 00/06599 teaches the use of C34 to inactivate gp41, and thus, prevent or reduce HIV-1 entry into cells.
[0005] While many of the anti-viral or anti-fusogenic peptides described in the art exhibit potent anti-viral and/or anti-fusogenic activity, C34, like all such peptides, suffers from short half-life in vivo, primarily due to rapid serum clearance and peptidase and protease activity. This in turn greatly reduces its effective anti-viral activity.
[0006] There is therefore a need for a method of prolonging the half-life of peptides like C34 in vivo without substantially affecting the anti-fusogenic activity.
SUMMARY OF THE INVENTION
[0007] In accordance with the present invention, there is now provided C34 peptide derivatives having an extended in vivo half-life when compared with the corresponding unmodified C34 peptide sequence. More specifically, the present invention is concerned with compounds of Formulae I-VIII illustrated below, which are capable of reacting with thiol groups on a blood component, either in vivo or ex vivo, to form a stable covalent bond.
[0008] Preferred blood components comprise proteins such as immunoglobulins, including IgG and IgM, serum albumin, ferritin, steroid binding proteins, transferrin, thyroxin binding protein, α-2-macroglobulin etc., serum albumin and IgG being more preferred, and serum albumin being the most preferred.
[0009] In another aspect of the invention, there is provided a pharmaceutical composition comprising the derivatives of Formulae I-VII in combination with a pharmaceutically acceptable carrier. Such composition is useful for inhibiting the activity of V, RSV, HPV, MeV or SIV.
[0010] In a further embodiment of the present invention, there is provided a method for inhibiting the activity of HIV, RSV, HPV, MeV or SIV. The method comprises administering to a subject, preferably a mammal, an effective amount of the compounds of Formulae I-VIII or a conjugate thereof, alone or in combination with a pharmaceutical carrier.
[0011] In a further aspect of the present invention, there is provided a conjugate comprising the compounds of Formulae I-VIII covalently bonded to a blood component.
[0012] In a further aspect of the present invention, there is provided a method for extending the in vivo half-life of the C34 peptide in a subject, the method comprising covalently bonding the compounds of Formulae I-VIII to a blood component.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The present invention meets these and other needs and is directed to C34 peptides derivatives of Formulae I-VIII having anti-viral activity and/or anti-fusogenic activity. These C34 peptides derivatives provide for an increased stability in vivo and a reduced susceptibility to peptidase or protease degradation. As a result, the compounds of Formulae I-VIII minimize the need for more frequent, or even continual, administration of the peptides. The present C34 derivatives can be used, e.g., as a prophylactic against and/or treatment for infection of a number of viruses, including human immunodeficiency virus (HIV), human respiratory syncytial virus (RSV), human parainfluenza virus (HPV), measles virus (MeV) and simian immunodeficiency virus (SIV).
[0014] The modification made to the native C34 peptide sequence allows it to react with available thiol groups on blood components to form stable covalent bonds. In one embodiment of the invention, the blood component comprises a blood protein, including a mobile blood protein such as albumin, which is most preferred.
[0015] The compounds of Formulae I-VIII inhibit viral infection of cells, by, for example, inhibiting cell-cell fusion or free virus infection. The route of infection may involve membrane fusion, as occurs in the case of enveloped or encapsulated viruses, or some other fusion event involving viral and cellular structures.
[0016] The blood components to which the present anti-viral C34 derivatives covalently bonds may be either fixed or mobile. Fixed blood components are non-mobile blood components and include tissues, membrane receptors, interstitial proteins, fibrin proteins, collagens, platelets, endothelial cells, epithelial cells and their associated membrane and membraneous receptors, somatic body cells, skeletal and smooth muscle cells, neuronal components, osteocytes and osteoclasts and all body tissues especially those associated with the circulatory and lymphatic systems. Mobile blood components are blood components that do not have a fixed situs for any extended period of time, generally not exceeding 5 minutes, and more usually one minute. These blood components are not membrane-associated and are present in the blood for extended periods of time in a minimum concentration of at least 0.1 μg/ml. Mobile blood components include serum albumin, transferrin, ferritin and immunoglobulins such as IgM and IgG. The half-life of mobile blood components is at least about 12 hours.
[0017] Protective groups may be required during the synthesis process of the present C34 derivative. These protective groups are conventional in the field of peptide synthesis, and can be generally described as chemical moieties capable of protecting the peptide derivative from reacting with other functional groups. Various protective groups are available commercially, and examples thereof can be found in U.S. Pat. No. 5,493,007 which is hereby incorporated by reference. Typical examples of suitable protective groups include acetyl, fluorenylmethyloxycarbonyl (FMOC), t-butyloxycarbonyl (BOC), benzyloxycarbonyl (CBZ), etc. In addition, Table 1 provides both the three letter and one letter abbreviations for amino acids.
TABLE 1 NATURAL AMINO ACIDS AND THEIR ABBREVIATIONS 3-letter 1-letter Name abbreviation abbreviation Alanine Ala A Arginine Arg R Asparagine Asn N Aspartic acid Asp D Cysteine Cys C Glutamic acid Glu E Glutamine Gln Q Glycine Gly G Histidine His H Isoleucine Lle I Leucine Leu L Lysine Lys K Methionine Met M Phenylalanine Phe F Proline Pro P Serine Ser S Threonine Thr T Tryptophan Trp W Tyrosine Tyr Y Valine Val V
[0018] The present C34 derivatives may be administered in vivo such that conjugation with blood components occurs in vivo, or they may be first conjugated to blood components in vitro and the resulting conjugated derivative administered in vivo.
[0019] The present invention takes advantage of the properties of existing anti-viral and antifusogenic peptides. The viruses that may be inhibited by the peptides include, but are not limited to all strains of viruses listed, e.g., in U.S. Pat. No. 6,013,263 and U.S. Pat. No. 6,017,536 at Tables V-VII and IX-XIV therein. These viruses include, e.g., human retroviruses, including HIV-1, HIV-2, and human T-lympocyte viruses (HTLV-I and HTLV-II), and non-human retroviruses, including bovine leukosis virus, feline sarcoma virus, feline leukemia virus, simian immunodeficiency virus (SIV), simian sarcoma virus, simian leukemia, and sheep progress pneumonia virus. Non-retroviral viruses may also be inhibited by the present C34 derivatives, including human respiratory syncytial virus (RSV), canine distemper virus, Newcastle Disease virus, human parainfluenza virus (HPIV), influenza viruses, measles viruses (MeV), Epstein-Barr viruses, hepatitis B viruses, and simian Mason-Pfizer viruses. Non-enveloped viruses may also be inhibited by the present C34 derivatives, and include, but are not limited to, picomaviruses such as polio viruses, hepatitis A virus, enteroviruses, echoviruses, coxsackie viruses, papovaviruses such as papilloma virus, parvoviruses, adenoviruses, and reoviruses.
[0020] The focus of the present invention is to modify the C34 peptide sequence to confer to this peptide improved bio-availability, extended half-life and better distribution through selective conjugation of the peptide onto a protein carrier without substantially modifying the peptide's anti-viral properties. The carrier of choice (but not limited to) for this invention would be albumin conjugated through its free thiol.
[0021] The present C34 derivatives are designed to specifically react with thiol groups on mobile blood proteins. Such reaction is established by covalent bonding of the peptide modified with a maleimide link to a thiol group on a mobile blood protein such as serum albumin or IgG.
[0022] Thiol groups being less abundant in vivo than, for example, amino groups, the maleimide-modified C34 peptide of the present invention, will covalently bond to fewer proteins. For example, in albumin (the most abundant blood protein) there is only a single thiol group. Thus, a C34-maleimide-albumin conjugate will tend to comprise approximately a 1:1 molar ratio of C34 peptide to albumin. In addition to albumin, IgG molecules (class U) also have free thiols. Since IgG molecules and serum albumin make up the majority of the soluble protein in blood they also make up the majority of the free thiol groups in blood that are available to covalently bond to the C34 peptide derivative.
[0023] Further, even among free thiol-containing blood proteins, including IgGs, specific labeling with a maleimide leads to the preferential formation of a C34-maleimide-albumin conjugate due to the unique characteristics of albumin itself. The single free thiol group of albumin, highly conserved among species, is located at amino acid residue 34 (Cys 34 ). It has been demonstrated recently that the Cys 34 of albumin has increased reactivity relative to free thiols on other free thiol-containing proteins. This is due in part to the very low pK value of 5.5 for the Cys 34 of albumin. This is much lower than typical pK values for cysteine residues in general, which are typically about 8. Due to this low pK, under normal physiological conditions Cys 34 of albumin is predominantly in the ionized form, which dramatically increases its reactivity. In addition to the low pK value of Cys 34 , another factor which enhances the reactivity of Cys 34 is its location, which is in a hydrophobic pocket close to the surface of one loop of region V of albumin. This location makes Cys 34 very available to ligands of all kinds, and is an important factor in Cys 34, s biological role as free radical trap and free thiol scavenger. These properties make Cys 34 highly reactive with maleimide-C34, and the reaction rate acceleration can be as much as 1000-fold relative to rates of reaction of maleimide-C34 with other free-thiol containing proteins.
[0024] Another advantage of C34-maleimide-albumin conjugates is the reproducibility associated with the 1:1 loading of C34 to albumin specifically at Cys 34 . Other techniques, such as glutaraldehyde, DCC, EDC and other chemical activations of, e.g, free amines, lack this selectivity. For example, albumin contains 52 lysine residues, 25-30 of which are located on the surface of albumin and therefore accessible for conjugation. Activating these lysine residues, or alternatively modifying C34 to couple through these lysine residues, results in a heterogenous population of conjugates. Even if 1:1 molar ratios of C34 to albumin are employed, the yield will consist of multiple conjugation products, some containing 0, 1, 2 or more C34 per albumin, and each having C34 randomly coupled at any one or more of the 25-30 available lysine sites. Given the numerous possible combinations, characterization of the exact composition and nature of each conjugate batch becomes difficult, and batch-to-batch reproducibility is all but impossible, making such conjugates less desirable as a therapeutic. Additionally, while it would seem that conjugation through lysine residues of albumin would at least have the advantage of delivering more therapeutic agent per albumin molecule, studies have shown that a 1:1 ratio of therapeutic agent to albumin is preferred. In an article by Stehle, et al., “The Loading Rate Determines Tumor Targeting properties of Methotrexate-Albumin Conjugates in Rats,” Anti - Cancer Drugs , Vol. 8, pp. 677-685 (1988), incorporated herein in its entirety, the authors report that a 1:1 ratio of the anti-cancer methotrexate to albumin conjugated via glutaraldehyde gave the most promising results. These conjugates were preferentially taken up by tumor cells, whereas conjugates bearing 5:1 to 20:1 methotrexate molecules had altered HPLC profiles and were quickly taken up by the liver in vivo. It is postulated that at these higher ratios, conformational changes to albumin diminish its effectiveness as a therapeutic carrier.
[0025] Through controlled administration of the present C34 derivatives in vivo, one can control the specific labeling of albumin and IgG in vivo. In typical administrations, 80-90% of the administered C34 derivatives will label albumin and less than 5% will label IgG. Trace labeling of free thiols such as glutathione will also occur. Such specific labeling is preferred for in vivo use as it permits an accurate calculation of the estimated half-life of C34.
[0026] In addition to providing controlled specific in vivo labeling, the present C34 derivatives can provide specific labeling of serum albumin and IgG ex vivo. Such ex vivo labeling involves the addition of the C34 derivatives to blood, serum or saline solution containing serum albumin and/or IgG. Once conjugation has occurred ex vivo with the C34 derivative, the blood, serum or saline solution can be readministered to the patient's blood for in vivo treatment, or lyophilized.
[0027] The present C34 derivatives may be synthesized by standard methods of solid phase peptide chemistry well known to any one of ordinary skill in the art. For example, the peptide may be synthesized by solid phase chemistry techniques following the procedures described by Steward et al. in Solid Phase Peptide Synthesis, 2nd Ed., Pierce Chemical Company, Rockford, Ill., (1984) using a Rainin PTI Symphony synthesizer. Similarly, peptides fragments may be synthesized and subsequently combined or linked together to form the C34 peptide sequence (segment condensation).
[0028] For solid phase peptide synthesis, a summary of the many techniques may be found in Stewart et al. in “ Solid Phase Peptide Synthesis ”, W. H. Freeman Co. (San Francisco), 1963 and Meienhofer, Hormonal Proteins and Peptides, 1973, 2 46. For classical solution synthesis, see for example Schroder et al. in “ The Peptides ”, volume 1, Acacemic Press (New York). In general, such method comprise the sequential addition of one or more amino acids or suitably protected amino acids to a growing peptide chain on a polymer. Normally, either the amino or carboxyl group of the first amino acid is protected by a suitable protecting group. The protected and/or derivatized amino acid is then either attached to an inert solid support or utilized in solution by adding the next amino acid in the sequence having the complimentary (amino or carboxyl) group suitably protected and under conditions suitable for forming the amide linkage. The protecting group is then removed from this newly added amino acid residue and the next amino acid (suitably protected) is added, and so forth.
[0029] After all the desired amino acids have been linked in the proper sequence, any remaining protecting groups (and any solid support) are cleaved sequentially or concurrently to afford the final peptide. By simple modification of this general procedure, it is possible to add more than one amino acid at a time to a growing chain, for example, by coupling (under conditions which do not racemize chiral centers) a protected tripeptide with a properly protected dipeptide to form, after deprotection, a pentapeptide.
[0030] A particularly preferred method of preparing the present C34 derivatives involves solid phase peptide synthesis wherein the amino acid α-N-terminal is protected by an acid or base sensitive group. Such protecting groups should have the properties of being stable to the conditions of peptide linkage formation while being readily removable without destruction of the growing peptide chain or racemization of any of the chiral centers contained therein. Examples of N -protecting groups and carboxy-protecting groups are disclosed in Greene, “Protective Groups In Organic Synthesis,” (John Wiley & Sons, New York pp. 152-186 (1981)), which is hereby incorporated by reference. Examples of N -protecting groups comprise, without limitation, loweralkanoyl groups such as formyl, acetyl (“Ac”), propionyl, pivaloyl, t-butylacetyl and the like; other acyl groups include 2-chloroacetyl, 2-bromoacetyl, trifluoroacetyl, trichloroacetyl, phthalyl, o-nitrophenoxy-acetyl, -chlorobutyryl, benzoyl, 4-chlorobenzoyl, 4-bromobenzoyl, 4-nitrobenzoyl and the like; sulfonyl groups such as benzenesulfonyl, p-toluenesulfonyl, o-nitrophenylsulfonyl, 2,2,5,7,8-pentamethylchroman-6-sulfonyl (pmc), and the like; carbamate forming groups such as t-amyloxycarbonyl, benzyloxycarbonyl, p-chlorobenzyloxycarbonyl, p-methoxy-benzyloxycarbonyl, p-nitrobenzyloxycarbonyl, 2-nitrobenzyloxycarbonyl, p-bromoenzyloxycarbonyl, 3,4-dimethoxybenzyloxycarbonyl, 3,5-dimethoxybenzyloxycarbonyl, 2,4-dimethoxybenzyloxycarbonyl, 4-ethoxybenzyloxycarbonyl, 2-nitro-4,5-dimethoxy-benzyloxycarbonyl, 3,4,5-trimethoxybenzyloxycarbonyl, 1-(p-biphenylyl)-1-methylthoxycarbonyl, α,α-dimethyl-3,5-dimethoxybenzyloxycarbonyl, benzhydryloxycarbonyl, t-butyloxycarbonyl (boc), diisopropylmethoxycarbonyl, isopropyloxycarbonyl, ethoxycarbonyl, methoxycarbonyl, allyloxycarbonyl, 2,2,2,-trichloroethoxycarbonyl, phenoxy-carbonyl, 4-nitrophenoxycarbonyl, fluorenyl-9-methoxycarbonyl, isobornyloxycarbonyl, cyclopentyloxycarbonyl, adamantyloxycarbonyl, cyclohexyloxycarbonyl, phenylthiocarbonyl and the like; arylalkyl groups such as benzyl, biphenylisopropyloxycarbonyl, triphenylmethyl, benzyloxymethyl, 9-fluorenylmethyloxycarbonyl (Fmoc) and the like and silyl groups such as trimethylsilyl and the like. Preferred α- N -protecting group are o-nitrophenylsulfenyl; 9-fluorenylmethyl oxycarbonyl; t-butyloxycarbonyl (boc), isobornyloxycarbonyl; 3,5-dimethoxybenzyloxycarbonyl; t-amyloxycarbonyl; 2-cyano-t-butyloxycarbonyl, and the like, 9-fluorenyl-methyloxycarbonyl (Fmoc) being more preferred, while preferred side chain N -protecting groups comprise 2,2,5,7,8-penta-methylchroman-6-sulfonyl (pmc), nitro, p-toluenesulfonyl, 4-methoxybenzene-sulfonyl, Cbz, Boc, and adamantyloxycarbonyl for side chain amino groups like lysine and arginine; benzyl, o-bromobenzyloxycarbonyl, 2,6-dichlorobenzyl, isopropyl, t-butyl (t-Bu), cyclohexyl, cyclopenyl and acetyl (Ac) for tyrosine; t-butyl, benzyl and tetrahydropyranyl for serine; trityl, benzyl, Cbz, p-toluenesulfonyl and 2,4-dinitrophenyl for histidine; formyl for tryptophan; benzyl and t-butyl for aspartic acid and glutamic acid; and triphenylmethyl (trityl) for cysteine.
[0031] A carboxy-protecting group conventionally refers to a carboxylic acid protecting ester or amide group. Such carboxy protecting groups are well known to those skilled in the art, having been extensively used in the protection of carboxyl groups in the penicillin and cephalosporin fields as described in U.S. Pat. No. 3,840,556 and U.S. Pat. No. 3,719,667, the disclosures of which are hereby incorporated herein by reference. Representative carboxy protecting groups comprise, without limitation, C 1 -C 8 loweralkyl; arylalkyl such as phenethyl or benzyl and substituted derivatives thereof such as alkoxybenzyl or nitrobenzyl groups; arylalkenyl such as phenylethenyl; aryl and substituted derivatives thereof such as 5-indanyl; dialkylaminoalkyl such as dimethylaminoethyl; alkanoyloxyalkyl groups such as acetoxymethyl, butyryloxymethyl, valeryloxymethyl, isobutyryloxymethyl, isovaleryloxymethyl, 1-(propionyloxy)-1-ethyl, 1-(pivaloyloxyl)-1-ethyl, 1-methyl-1-(propionyloxy)-1-ethyl, pivaloyloxymethyl, propionyloxymethyl; cycloalkanoyloxyalkyl groups such as cyclopropylcarbonyloxymethyl, cyclobutylcarbonyloxymethyl, cyclo-pentylcarbonyloxymethyl, cyclohexylcarbonyloxymethyl; aroyloxyalkyl such as benzoyloxymethyl, benzoyloxyethyl; arylalkylcarbonyloxyalkyl such as benzylcarbonyloxymethyl, 2-benzylcarbonyloxyethyl; alkoxycarbonylalkyl or cycloalkyloxycarbonyl-alkyl such as methoxycarbonylmethyl, cyclohexyloxycarbonylmethyl, 1-methoxyarbonyl-1-ethyl; alkoxycarbonyloxyalkyl or cycloalkyloxycarbonyloxyalkyl such as methoxycarbonyloxymethyl, t-butyloxycarbonyloxymethyl, 1-ethoxycarbonyloxy-1-ethyl, 1-cyclohexyloxycarbonyloxy-1-ethyl; aryloxycarbonyloxyalkyl such as 2-(phenoxycarbonyloxy)ethyl, 2-(5-indanyloxycarbonyloxy)-ethyl; alkoxyalkylcarbonyl-oxyalkyl such as 2-(1-methoxy-2-methylpropan-2-oyloxy)-ethyl; arylalkyloxycarbonyl-oxyalkyl such as 2-(benzyloxycarbonyloxy)ethyl; arylalkenyloxycarbonyloxyalkyl such as 2-(3-phenylpropen-2-yloxycarbonyloxy)ethyl; alkoxycarbonylaminoalkyl such as t-butyloxycarbonylaminomethyl; alkylaminocarbonyl-aminoalkyl such as methylamino-carbonylaminomethyl; alkanoylaminoalkyl such as acetylaminomethyl; heterocyclic-carbonyloxyalkyl such as 4-methylpiperazinyl-carbonyloxymethyl; dialkylamino-carbonylalkyl such as dimethylaminocarbonylmethyl, diethylaminocarbonylmethyl; (5-(loweralkyl)-2-oxo-1,3-dioxolen-4-yl)alkyl such as (5-t-butyl-2-oxo-1,3-dioxolen-4-yl)methyl; and (5-phenyl-2-oxo-1,3-dioxolen-4-yl)alkyl such as (5-phenyl-2-oxo-1,3-dioxolen-4-yl)methyl. Representative amide carboxy protecting groups comprise, without limitation, aminocarbonyl and loweralkylaminocarbonyl groups. Of the above carboxy-protecting groups, loweralkyl, cycloalkyl or arylalkyl ester, for example, methyl ester, ethyl ester, propyl ester, isopropyl ester, butyl ester, sec-butyl ester, isobutyl ester, amyl ester, isoamyl ester, octyl ester, cyclohexyl ester, phenylethyl ester and the like or an alkanoyloxyalkyl, cycloalkanoyloxyalkyl, aroyloxyalkyl or an arylalkylcarbonyloxyalkyl ester are preferred. Preferred amide carboxy protecting groups are loweralkylamino-carbonyl groups.
[0032] In the solid phase peptide synthesis method, the α-C-terminal amino acid is attached to a suitable solid support or resin. Suitable solid supports useful for the above synthesis are those materials that are inert to the reagents and reaction conditions of the stepwise condensation-deprotection reactions, as well as being insoluble in the media used. The preferred solid support for synthesis of α-C-terminal carboxy peptides is 4-hydroxymethylphenoxyacetyl-4′-methylbenzyhydrylamine resin (HMP resin). The preferred solid support for α-C-terminal amide peptides is an Fmoc-protected Ramage resin, manufactured and sold by Bachem Inc., California.
[0033] At the end of the solid phase synthesis, the peptide is removed from the resin and deprotected, either in successive operations or in a single operation. Removal of the peptide and deprotection can be accomplished conventionally in a single operation by treating the resin-bound polypeptide with a cleavage reagent comprising thioanisole, triisopropyl silane, phenol, and trifluoroacetic acid. In cases wherein the α-C-terminal of the peptide is an alkylamide, the resin is cleaved by aminolysis with an alkylamine. Alternatively, the peptide may be removed by transesterification, e.g. with methanol, followed by aminolysis or by direct transamidation. The protected peptide may be purified at this point or taken to the next step directly. The removal of the side chain protecting groups is accomplished using the cleavage mixture described above. The fully deprotected peptide can be purified by a sequence of chromatographic steps employing any or all of the following types: ion exchange on a weakly basic resin (acetate form); hydrophobic adsorption chromatography on underivatized polystyrene-divinylbenzene (such as Amberlite XAD™); silica gel adsorption chromatography, ion exchange chromatography on carboxymethylcellulose; partition chromatography, e.g. on Sephadex G25™, LH-20™ or countercurrent distribution; high performance liquid chromatography (HPLC), especially reverse-phase HPLC on octyl- or phenyl/hexylsilyl-silica bonded phase column packing. Anyone of ordinary skill in the art will be able to determine easily what would be the preferred chromatographic steps or sequences required to obtain acceptable purification of the C34 peptide.
[0034] Molecular weights of these peptides are determined using Electrospray mass spectroscopy.
[0035] The present C34 derivatives may be used alone or in combination to optimize their therapeutic effects. They can be administered in a physiologically acceptable medium, e.g. deionized water, phosphate buffered saline (PBS), saline, aqueous ethanol or other alcohol, plasma, proteinaceous solutions, mannitol, aqueous glucose, alcohol, vegetable oil, or the like. Other additives which may be included include buffers, where the media are generally buffered at a pH in the range of about 5 to 10, where the buffer will generally range in concentration from about 50 to 250 mM, salt, where the concentration of salt will generally range from about 5 to 500 mM, physiologically acceptable stabilizers, and the like. The compositions may be lyophilized for convenient storage and transport.
[0036] The C34 derivatives may be administered parenterally, such as intravascularly (IV), intraarterially (IA), intramuscularly (IM), subcutaneously (SC), or the like. Administration may in appropriate situations be by transfusion. In some instances, where reaction of the functional group is relatively slow, administration may be oral, nasal, rectal, transdermal or aerosol, where the nature of the conjugate allows for transfer to the vascular system. Usually a single injection will be employed although more than one injection may be used, if desired. The peptide derivative may be administered by any convenient means, including syringe, trocar, catheter, or the like. The particular manner of administration will vary depending upon the amount to be administered, whether a single bolus or continuous administration, or the like. Preferably, the administration will be intravascularly, where the site of introduction is not critical to this invention, preferably at a site where there is rapid blood flow, e.g., intravenously, peripheral or central vein. Other routes may find use where the administration is coupled with slow release techniques or a protective matrix. The intent is that the C34 derivative be effectively distributed in the blood, so as to be able to react with the blood components. The concentration of the conjugate will vary widely, generally ranging from about 1 pg/ml to 50 mg/ml. The total administered intravascularly will generally be in the range of about 0.1 mg/ml to about 10 mg/ml, more usually about 1 mg/ml to about 5 mg/ml.
[0037] By bonding to long-lived components of the blood, such as immunoglobulin, serum albumin, red blood cells and platelets, a number of advantages ensue. The activity of the C34 derivatives is extended for days to weeks. Only one administration need to be given during this period of time. Greater specificity can be achieved, since the active compound will be primarily bound to large molecules, where it is less likely to be taken up intracellularly to interfere with other physiological processes.
[0038] The formation of the covalent bond between the blood component may occur in vivo or ex vivo. For ex vivo covalent bond formation, the C34 derivative is added to blood serum or a saline solution containing purified blood components such as human serum albumin or IgG, to permit covalent bond formation between the derivative and the blood component. In a preferred format, the C34 derivative is reacted with human serum albumin in saline solution. After formation of the conjugate, the latter may be administered to the subject or lyophilized.
[0039] The blood of the mammalian host may be monitored for the activity of the C34 peptide and/or presence of the C34 derivatives. By taking a blood sample from the host at different times, one may determine whether C34 peptide has become bonded to the long-lived blood components in sufficient amount to be therapeutically active and, thereafter, the level of C34 in the blood. If desired, one may also determine to which of the blood components C34 is covalently bonded. Monitoring may also take place by using assays of C34 activity, HPLC-MS or antibodies directed to C34.
[0040] The following examples are provided to illustrate preferred embodiments of the invention and shall by no means be construed as limiting its scope.
[0041] The present C34 derivatives can be administered to patients according to the methods described below and other methods known in the art. Effective therapeutic dosages of the present C34 derivatives may be determined through procedures well known by those in the art and will take into consideration any concerns over potential toxicity of C34.
[0042] The present C34 derivative can also be administered prophylactically to previously uninfected individuals. This can be advantageous in cases where an individual has been subjected to a high risk of exposure to a virus, as can occur when individual has been in contact with an infected individual where there is a high risk of viral transmission. This can be expecially advantageous where there is known cure for the virus, such as the HIV virus. As an example, prophylactic administration of a C34 derivative would be advantageous in a situation where a health care worker has been exposed to blood from an HIV-infected individual, or in other situations where an individual engaged in high-risk activities that potentially expose that individual to the HIV virus.
[0043] The invention having been fully described can be further appreciated and understood with reference to the following non-limiting examples.
[heading-0044] General
[0045] Unless stated otherwise, the synthesis of each C34 derivative was performed using an automated solid-phase procedure on a Symphony Peptide Synthesizer with manual intervention during the generation of the derivative. The synthesis was performed on Fmoc-protected Ramage amide linker resin, using Fmoc-protected amino acids. Coupling was achieved by using O-benzotriazol-1-yl-N,N,N′,N′-tetramethyl-uronium hexafluorophosphate (HBW) as activator in N,N-dimethylformamide (DMF) solution and diisopropylethylamine (IDEA) as base. The Fmoc protective group was removed using 20% piperidine/DMF. When needed, a Boc-protected amino acid was used at the N-terminus in order to generate the free N α -terminus after the peptide is cleaved from resin. All amino acids used during the synthesis possess the L-stereochemistry. Glass reaction vessels were used during the synthesis.
EXAMPLE 1
[heading-0046] Compound of Formula I
[0047] Step 1: The example describes the solid phase peptide synthesis of the compound on a 100 μmole scale. The following protected amino acids were sequentially added to resin: Fmoc-Leu-OH, Fmoc-Leu-OH, Fmoc-Glu(tBu)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Lys(Aloc)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Ser(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Ile-OH, Fmoc-Leu-OH, Fmoc-Ser(tBu)-OH, Fmoc-Thr(tBu)-OH, Fmoc-Tyr(tBu)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Ile-OH, Fmoc-Glu(tBu)-OH, Fmoc-Arg(Pbf)-OH, Fmoc-Asp(tBu)-OH, Fmoc-Trp(Boc)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Met-OH, Fmoc-Trp(Boc)-OH. They were dissolved in N,N-dimethylformamide (DMF) and, according to the sequence, activated using O-benzotriazol-1-yl-N,N,N′,N′-tetramethyl-uronium hexafluorophosphate (HBTU) and diisopropylethylamine (DIEA). Removal of the Fmoc protecting group was achieved using a solution of 20% (V/V) piperidine in N,N-dimethylformamide (DMF) for 20 minutes (step 1). The amino group of the final amino acid was acetylated using acetic acid activated using O-benzotriazol-1-yl-N,N,N′,N′-tetramethyl-uronium hexafluorophosphate (HBTU) and diisopropylethylamine (DIEA).
[0048] Step 2: The selective deprotection of the Lys (Aloc) group was performed manually and accomplished by treating the resin with a solution of 3 eq of Pd(PPh 3 ) 4 dissolved in 5 mL of C 6 H 6 CHCl 3 (1:1): 2.5% NMM (v:v): 5% AcOH (v:v) for 2 h (Step 2). The resin is then washed with CHCl 3 (6×5 mL), 20% AcOH in DCM (6×5 mL), DCM (6×5 mL), and DMF (6×5 mL).
[0049] Step 3: The synthesis was then re-automated for the addition of the Fmoc-AEEA-OH and the 3-maleimidopropionic acid (Step 3). Between every coupling, the resin was washed 3 times with N,N-dimethylformamide (DMF) and 3 times with isopropanol ( i PrOH).
[0050] Step 4: The peptide was cleaved from the resin using 85% TFA/5% triisopropyl-silane (TIPS)/5% thioanisole and 5% phenol, followed by precipitation by dry-ice cold Et 2 O (Step 4).
EXAMPLE 2
[heading-0051] Compound of Formula H
[0052] Step 1: The example describes the solid phase peptide synthesis of the compound on a 100 μmole scale. The following protected amino acids were sequentially added to resin: Fmoc-Leu-OH, Fmoc-Leu-OH, Fmoc-Glu(tBu)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Lys(Boc)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Ser(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Ile-OH, Fmoc-Leu-OH, Fmoc-Lys(Aloc)-OH, Fmoc-Thr(tBu)-OH, Fmoc-Tyr(tBu)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Ile-OH, Fmoc-Glu(tBu)-OH, Fmoc-Arg(Pbf)-OH, Fmoc-Asp(tBu)-OH, Fmoc-Trp(Boc)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Met-OH, Fmoc-Trp(Boc)-OH. They were dissolved in N,N-dimethylformamide (DMF) and, according to the sequence, activated using O-benzotriazol-1-yl-N,N,N′,N′-tetramethyl-uronium hexafluorophosphate (HBTU) and diisopropylethylamine (DIEA). Removal of the Fmoc protecting group was achieved using a solution of 20% (V/V) piperidine in N,N-dimethylformamide (DMF) for 20 minutes (step 1). The amino group of the final amino acid was acetylated using acetic acid activated using O-benzotriazol-1-yl-N,N,N′,N′-tetramethyl-uronium hexafluorophosphate (HBTU) and diisopropylethylamine (DIEA).
[0053] Step 2: The selective deprotection of the Lys (Aloc) group was performed manually and accomplished by treating the resin with a solution of 3 eq of Pd(PPh 3 ) 4 dissolved in 5 mL of C 6 H 6 CHCl 3 (1:1): 2.5% NMM (v:v): 5% AcOH (v:v) for 2 h (Step 2). The resin is then washed with CHCl 3 (6×5 mL), 20% AcOH in DCM (6×5 mL), DCM (6×5 mL), and DMF (6×5 mL).
[0054] Step 3: The synthesis was then re-automated for the addition of the Fmoc-AEEA-OH and the 3-maleimidopropionic acid (Step 3). Between every coupling, the resin was washed 3 times with N,N-dimethylformamide (DMF) and 3 times with isopropanol ( i PrOH).
[0055] Step 4: The peptide was cleaved from the resin using 85% TFA/5% TIS/5% thioanisole and 5% phenol, followed by precipitation by dry-ice cold Et 2 O (Step 4).
EXAMPLE 3
[heading-0056] Compound of Formula III
[0057] Step 1: The example describes the solid phase peptide synthesis of the compound on a 100 μmole scale. The following protected amino acids were sequentially added to resin: Fmoc-Leu-OH, Fmoc-Leu-OH, Fmoc-Glu(tBu)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Ser(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Ser(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Ile-OH, Fmoc-Leu-OH, Fmoc-Ser(tBu)-OH, Fmoc-Thr(tBu)-OH, Fmoc-Tyr(tBu)-OH, Fmoc-Lys(Aloc)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Ine-OH, Fmoc-Glu(tBu)-OH, Fmoc-Arg(Pbf)-OH, Fmoc-Asp(tBu)-OH, Fmoc-Trp(Boc)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Met-OH, Fmoc-Trp(Boc)-OH. They were dissolved in N,N-dimethylformamide (DMF) and, according to the sequence, activated using O-benzotriazol-1-yl-N,N,N′,N′-tetramethyl-uronium hexafluorophosphate (HBTU) and diisopropylethylamine (DIEA). Removal of the Fmoc protecting group was achieved using a solution of 20% (V/V) piperidine in N,N-dimethylformamide (DMF) for 20 minutes (step 1). The amino group of the final amino acid was acetylated using acetic acid activated using O-benzotriazol-1-yl-N,N, 1, N-tetramethyl-uronium hexafluorophosphate (HBTU) and diisopropylethylamine (DIEA).
[0058] Step 2: The selective deprotection of the Lys (Aloc) group was performed manually and accomplished by treating the resin with a solution of 3 eq of Pd(PPh 3 ) 4 dissolved in 5 mL of C 6 H 6 CHCl 3 (1:1): 2.5% NMM (v:v): 5% AcOH (v:v) for 2 h (Step 2). The resin is then washed with CHCl 3 (6×5 mL), 20% AcOH in DCM (6×5 mL), DCM (6×5 mL), and DMF (6×5 mL).
[0059] Step 3: The synthesis was then re-automated for the addition of the Fmoc-AEEA-OH and the 3-maleimidopropionic acid (Step 3). Between every coupling, the resin was washed 3 times with N,N-dimethylformamide (DMF) and 3 times with isopropanol (iPrOH).
[0060] Step 4: The peptide was cleaved from the resin using 85% TFA/5% TIS/5% thioanisole and 5% phenol, followed by precipitation by dry-ice cold Et 2 O (Step 4).
EXAMPLE 4
[heading-0061] Compound of Formula IV
[0062] Step 1: The example describes the solid phase peptide synthesis of the compound on a 100 μmole scale. The following protected amino acids were sequentially added to resin: Fmoc-Leu-OH, Fmoc-Leu-OH Fmoc-Glu(tBu)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Ser(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Ser(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Ile-OH, Fmoc-Leu-OH, Fmoc-Ser(tBu)-OH, Fmoc-Thr(tBu)-OH, Fmoc-Tyr(tBu)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Lys(Aloc)-OH, Fmoc-Ile-OH, Fmoc-Glu(tBu)-OH, Fmoc-Arg(Pbf)-OH, Fmoc-Asp(tBu)-OH, Fmoc-Trp(Boc)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Met-OH, Fmoc-Trp(Boc)-OH. They were dissolved in N,N-dimethylformamide (DMF) and, according to the sequence, activated using O-benzotriazol-1-yl-N,N,N′,N′-tetramethyl-uronium hexafluorophosphate (HBTU) and diisopropylethylamine (DIEA). Removal of the Fmoc protecting group was achieved using a solution of 20% (V/V) piperidine in N,N-dimethylformamide (DMF) for 20 minutes (step 1). The amino group of the final amino acid was acetylated using acetic acid activated using O-benzotriazol-1-yl-N,N,N′,N′-tetramethyl-uronium hexafluorophosphate (HBTU) and diisopropylethylamine (DIEA).
[0063] Step 2: The selective deprotection of the Lys (Aloc) group was performed manually and accomplished by treating the resin with a solution of 3 eq of Pd(PPh 3 ) 4 dissolved in 5 mL of C 6 H 6 CHCl 3 (1:1): 2.5% NMM (v:v): 5% AcOH (v:v) for 2 h (Step 2). The resin is then washed with CHCl 3 (6×5 mL), 20% AcOH in DCM (6×5 mL), DCM (6×5 mL), and DMF (6×5 mL).
[0064] Step 3: The synthesis was then re-automated for the addition of the Fmoc-AEEA-OH and the 3-maleimidopropionic acid (Step 3). Between every coupling, the resin was washed 3 times with N,N-dimethylformamide (DMF) and 3 times with isopropanol ( i PrOH).
[0065] Step 4: The peptide was cleaved from the resin using 85% TFA/5% TIS/5% thioanisole and 5% phenol, followed by precipitation by dry-ice cold Et 2 O (Step 4).
EXAMPLE 5
[heading-0066] Compound of Formula V
[0067] Step 1: The example describes the solid phase peptide synthesis of the compound on a 100 μmole scale. The following protected amino acids were sequentially added to resin: Fmoc-Lys(Aloc)-OH, Fmoc-Leu-OH, Fmoc-Leu-OH, Fmoc-Glu(tBu)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Ser(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Ser(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Ile-OH, Fmoc-Leu-OH, Fmoc-Ser(tBu)-OH, Fmoc-Thr(tBu)-OH, Fmoc-Tyr(tBu)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Ile-OH, Fmoc-Glu(tBu)-OH, Fmoc-Arg(Pbf)-OH, Fmoc-Asp(tBu)-OH, Fmoc-Trp(Boc)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Met-OH, Fmoc-Trp(Boc)-OH. They were dissolved in N,N-dimethylformamide (DMF) and, according to the sequence, activated using O-benzotriazol-1-yl-N,N, N′,N′-tetramethyl-uronium hexafluorophosphate (HBTU) and diisopropylethylamine (DIEA). Removal of the Fmoc protecting group was achieved using a solution of 20% (V/V) piperidine in N,N-dimethylformamide (DMF) for 20 minutes (step 1). The amino group of the final amino acid was acetylated using acetic acid activated using O-benzotriazol-1-yl-N,N,N′,N′-tetramethyl-uronium hexafluorophosphate (HBTU) and diisopropylethyl-amine (DIEA).
[0068] Step 2: The selective deprotection of the Lys (Aloc) group was performed manually and accomplished by treating the resin with a solution of 3 eq of Pd(PPh 3 ) 4 dissolved in 5 mL of C 6 H 6 CHCl 3 (1:1): 2.5% NMM (v:v): 5% AcOH (v:v) for 2 h (Step 2). The resin is then washed with CHCl 3 (6×5 mL), 20% AcOH in DCM (6×5 mL), DCM (6×5 mL), and DMF (6×5 mL).
[0069] Step 3: The synthesis was then re-automated for the addition of the 3-maleimido-propionic acid (Step 3). Between every coupling, the resin was washed 3 times with N,N-dimethylformamide (DMF) and 3 times with isopropanol ( i PrOH).
[0070] Step 4: The peptide was cleaved from the resin using 85% TFA/5% TIS/5% thioanisole and 5% phenol, followed by precipitation by dry-ice cold Et 2 O (Step 4).
EXAMPLE 6
[heading-0071] Compound of Formula VI
[0072] Step 1: The example describes the solid phase peptide synthesis of the compound on a 100 μmole scale. The following protected amino acids were sequentially added to resin: Fmoc-Lys(Aloc)-OH, Fmoc-Leu-OH, Fmoc-Leu-OH, Fmoc-Glu(tBu)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Ser(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Ser(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Ile-OH, Fmoc-Leu-OH, Fmoc-Ser(tBu)-OH, Fmoc-Thr(tBu)-OH, Fmoc-Tyr(tBu)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Ile-OH, Fmoc-Glu(tBu)-OH, Fmoc-Arg(Pbf)-OH, Fmoc-Asp(tBu)-OH, Fmoc-Trp(Boc)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Met-OH, Fmoc-Trp(Boc)-OH. They were dissolved in N,N-dimethylformamide (DMF) and, according to the sequence, activated using O-benzotriazol-1-yl-N,N,N′,N′-tetramethyl-uronium hexafluorophosphate (HBTU) and diisopropylethylamine (DIEA). Removal of the Fmoc protecting group was achieved using a solution of 20% (V/V) piperidine in N,N-dimethylformamide (DMF) for 20 minutes (step 1). The amino group of the final amino acid was acetylated using acetic acid activated using O-benzotriazol-1-yl-N,N, N,N′-tetramethyl-uronium hexafluorophosphate (HBTU) and diisopropylethyl-amine (DIEA).
[0073] Step 2: The selective deprotection of the Lys (Aloc) group was performed manually and accomplished by treating the resin with a solution of 3 eq of Pd(PPh 3 ) 4 dissolved in 5 mL of C 6 H 6 CHCl 3 (1:1): 2.5% NMM (v:v): 5% AcOH (v:v) for 2 h (Step 2). The resin is then washed with CHCl 3 (6×5 mL), 20% AcOH in DCM (6×5 mL), DCM (6×5 mL), and DMF (6×5 mL).
[0074] Step 3: The synthesis was then re-automated for the addition of the Fmoc-AEEA-OH and the 3-maleimidopropionic acid (Step 3). Between every coupling, the resin was washed 3 times with N,N-dimethylformamide (DMF) and 3 times with isopropanol ( i PrOH).
[0075] Step 4: The peptide was cleaved from the resin using 85% TFA/5% TIS/5% thioanisole and 5% phenol, followed by precipitation by dry-ice cold Et 2 O (Step 4).
EXAMPLE 7
[heading-0076] Compound of Formula VII
[0077] Step 1: The example describes the solid phase peptide synthesis of the compound on a 100 μmole scale. The following protected amino acids were sequentially added to resin: Fmoc-Leu-OH, Fmoc-Leu-OH, Fmoc-Glu(tBu)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Ser(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Ser(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Ile-OH, Fmoc-Leu-OH, Fmoc-Ser(tBu)-OH, Fmoc-Thr(tBu)-OH, Fmoc-Tyr(tBu)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Ile-OH, Fmoc-Glu(tBu)-OH, Fmoc-Arg(Pbf)-OH, Fmoc-Asp(tBu)-OH, Fmoc-Trp(Boc)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Met-OH, Fmoc-Trp(Boc)-OH. They were dissolved in N,N-dimethylformamide (DMF) and, according to the sequence, activated using O-benzotriazol-1-yl-N,N,N′,N′-tetramethyl-uronium hexafluorophosphate (HBTU) and diisopropylethylamine (DIEA). Removal of the Fmoc protecting group was achieved using a solution of 20% (V/V) piperidine in N,N-dimethylformamide (DMF) for 20 minutes (step 1). The amino group of the final amino acid was acetylated using acetic acid activated using O-benzotriazol-1-yl-N,N,N′,N′-tetramethyl-uronium hexafluorophosphate (HBTU) and diisopropylethylamine (DIEA).
[0078] Step 2: The synthesis was continued for the addition of the 3-maleimidopropionic acid (Step 2). Between every coupling, the resin was washed 3 times with N,N-dimethylformamide (DMF) and 3 times with isopropanol ( i PrOH).
[0079] Step 3: The peptide was cleaved from the resin using 85% TFA/5% TIS/5% thioanisole and 5% phenol, followed by precipitation by dry-ice cold Et 2 O (Step 3).
EXAMPLE 8
[heading-0080] Compound of Formula VIII
[0081] Step 1: The example describes the solid phase peptide synthesis of the compound on a 100 μmole scale. The following protected amino acids were sequentially added to resin: Fmoc-Leu-OH, Fmoc-Leu-OH, Fmoc-Glu(tBu)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Ser(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Gln(Trt)-OH, Fmoc-Ser(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Ile-OH, Fmoc-Leu-OH, Fmoc-Ser(tBu)-OH, Fmoc-Thr(tBu)-OH, Fmoc-Tyr(tBu)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Asn(Trt)-OH, Fmoc-Ile-OH, Fmoc-Glu(tBu)-OH, Fmoc-Arg(Pbf)-OH, Fmoc-Asp(tBu)-OH, Fmoc-Trp(Boc)-OH, Fmoc-Glu(tBu)-OH, Fmoc-Met-OH, Fmoc-Trp(Boc)-OH. They were dissolved in N,N-dimethylformamide (DMF) and, according to the sequence, activated using O-benzotriazol-1-yl-N,N,N′,N′-tetramethyl-uronium hexafluorophosphate (HBTU) and diisopropylethylamine (DIEA). Removal of the Fmoc protecting group was achieved using a solution of 20% (V/V) piperidine in N,N-dimethylformamide (DMF) for 20 minutes (step 1). The amino group of the final amino acid was acetylated using acetic acid activated using O-benzotriazol-1-yl-N,N,N′,N′-tetramethyl-uronium hexafluorophosphate (HBTU) and diisopropylethylamine (DIEA).
[0082] Step 2: The synthesis was continued for the addition of the FMOC-AEEA-OH and the 3-maleimidopropionic acid (Step 2). Between every coupling, the resin was washed 3 times with N,N-dimethylformamide (DMF) and 3 times with isopropanol ( i PrOH).
[0083] Step 3: The peptide was cleaved from the resin using 85% TFA/5% TIS/5% thioanisole and 5% phenol, followed by precipitation by dry-ice cold Et 2 O (Step 3).
[heading-0084] Cellular Anti-HIV Assay (MTT Assay)
[0085] The antiviral activity was determined as described in Journal of Virological Methods, 1988, 20, 309-321. Briefly, various concentrations of the test compound were brought into each well of a flat-bottom microtiter plate. Subsequently, HIV strain (HIV-1 IIIB) and MT-4 cells were added to a final concentration of 200 CCID 50 /well and 30,000 cells/well, respectively. In order to determine the toxicity of the test compound, mock-infected cell cultures containing an identical compound concentration range, were incubated in parallel with the HIV-infected cell cultures. After 5 days of incubation (37° C., 5% CO 2 ), the viability of the cells was determined by the tetrazolium colorimetric MTT method. The results of both assays appear in Table 2 below.
TABLE 2 Antiviral assay Compound Comment IC50 (μM) Native C34 — 0.0064 Formula I quenched 0.0063 HSA conjugate 0.1149 Formula II quenched 0.0052 HSA conjugate 0.0200 Formula III quenched 0.0077 HSA conjugate 0.0232 Formula IV quenched 0.0048 HSA conjugate 0.0207 Formula V quenched 0.0072 HSA conjugate 0.439 Formula VI quenched 0.0047 HSA conjugate 0.0253 Formula VII quenched 0.3171 HSA conjugate 0.6602 Formula VIII quenched 0.0015 HSA conjugate 0.0175
[0086] While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modifications, and this application is intended to cover any variations, uses or adaptations of the invention following, in general, the principles of the invention, and including such departures from the present description as come within known or customary practice within the art to which the invention pertains, and as may be applied to the essential features hereinbefore set forth, and as follows in the scope of the appended claims.
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The present invention relates to C34 peptide derivatives that are inhibitors of viral infection and/or exhibit antifusogenic properties. In particular, this invention relates to C34 derivatives having inhibiting activity against human immunodeficiency virus (HIV), respiratory syncytial virus (RSV), human parainfluenza virus (HPV), measles virus (MeV), and simian immunodeficiency virus (SIV) with long duration of action for the treatment of the respective viral infections.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority of Korean Patent Application No. 10-2011-0007510 filed on Jan. 25, 2011, which is incorporated by reference in their entirety herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an active array antenna apparatus capable of controlling a radio frequency (RF) polarization in real time, and more particularly, to a general antenna apparatus capable of environmentally and temporally controlling polarization resources necessary for wireless communication in order to improve communication quality and increase communication capacity.
[0004] 2. Related Art
[0005] A wireless terrestrial/satellite communication system generally transmits/receives data information through antennas using a predetermined frequency. Here, as an important element for transmitting and receiving signals in the wireless terrestrial/satellite communication system, antennas are present at an end of the wireless terrestrial/satellite communication system. These antennas should be configured to efficiently transmit and receive electromagnetic waves. Therefore, the research and development of the antenna has been actively conducted.
[0006] A significantly number of antennas are present. However, as a generally used high frequency antenna, there are a dipole antenna, a monopole antenna, a patch antenna, a horn antenna, a parabolic antenna, a helical antenna, a slot antenna, and the like. These antenna are applied and used in various forms according to a communication distance and a service area.
[0007] As necessary resources of the wireless terrestrial/satellite communication system, there are frequency, polarization, space, and direction. In the present and the future, a frequency resource, which is the most important resource for wireless communication, has been exhausted due to an increase in kinds of wireless communication services. In addition, a multiple input multiple output (MIMO) communication technology has been necessarily demanded due to an increase in bandwidth of a service. An object of this MIMO communication technology is to increase communication capacity by performing independent multi-channel transmission using multiple antennas. However, most satellite communication/mobile communication terminal or relay/base station antennas for MIMO communication have currently used the defined fixed polarization. In this antenna system structure using the fixed polarization, it is expected that service quality is deteriorated to an interference problem between services, or the like, caused by an increase in a service and an increase in a bandwidth in the future. In order to overcome this problem, an antenna technology of improving service quality and increasing service capacity by temporally variably controlling the polarization of the antenna so as to be appropriate for wireless environment and system requirement had been demanded.
[0008] In the future, due to saturation (depletion) of the wireless communication, elastic application/utilization of new radio resources such as a polarization, a space, a direction, or the like, has been absolutely required.
SUMMARY OF THE INVENTION
[0009] The present invention provides a general active array antenna apparatus capable of environmentally and temporally controlling an RF polarization of a wireless communication antenna apparatus in order to improve quality of wireless communication services and increase communication capacity thereof in the future.
[0010] In an aspect, a transmission antenna apparatus is provided. The transmission antenna apparatus includes: a signal distributing unit distributing a plurality of input signals to generate independent signals; a channel inputting unit inputting each of the independent signals to a corresponding channel; a multi channel unit including a plurality of channels to which the independent signals are input; and a dual polarization antenna unit generating and transmitting a dual polarization, wherein the multi channel unit adjusts phases and/or amplitudes of the independent signals for each of the channels to which the independent signals are input and intersects and combines the phase and/or amplitude adjusted independent signals with respect to the plurality of input signals to generate a plurality of combined independent signals, and wherein the dual polarization antenna unit transmits each of the plurality of combined independent signals input from the multi channel unit as orthogonal components of the dual polarization.
[0011] The adjustment of the phases and/or the amplitudes of the independent signals for each of the channels may be temporally controlled.
[0012] The dual polarization antenna unit may include a plurality of dual polarization antenna elements, wherein the dual polarization antenna element has an orthogonal intersecting structure or an orthogonal intersecting dipole structure and simultaneously generates a plurality of independent orthogonal polarizations based on the structures.
[0013] The plurality of input signals may be two different input signals, the signal distributing unit may distribute two independent signals from each of the two different input signals, the multi channel unit may attenuate and remove one of independent signals configuring the combined independent signals, for each of the two different input signal, and the dual polarization antenna unit may transmit two combined independent signals of which one is attenuated and removed as each of orthogonal components of the orthogonal polarizations.
[0014] The signal distributing unit may receive two input signals to distribute each of two independent signals, the multi channel unit may attenuate and remove one of two independent signals configuring the combined independent signals, and the dual polarization antenna unit may transmit two combined independent signals of which one is attenuated and removed as each of orthogonal components of the orthogonal polarizations.
[0015] The channel inputting unit may intersect and input independent signals distributed from the plurality of input signals with respect to each of the channels of the multi channel unit.
[0016] A weight for the phase and/or the amplitude may be added to each of the channels to which the independent signal is input to adjust the phase and/or the amplitude of the independent signal.
[0017] The transmission antenna apparatus may further include a monitoring/controlling unit provided at a separate position from the signal distributing unit, the channel inputting unit, the multi channel unit, and the dual polarization antenna unit, wherein the monitoring/controlling unit controls the adjustment of the phase and/or the amplitude of the independent signal and selects an independent signal to be attenuated and removed.
[0018] The control of the adjustment of the phase and/or the amplitude of the independent signal and the selection of the independent signal to be attenuated and removed may be performed in a base station apparatus connected to the antenna apparatus.
[0019] In another aspect, a reception antenna apparatus is provided. The reception antenna apparatus includes: a dual polarization antenna unit receiving a dual polarization signal; a multi channel unit including a plurality of channels to which each of orthogonal components of the dual polarization signal is input; a signal combining unit combining signals with each other, wherein the multi channel unit distributes independent signals having different characteristics in each of the orthogonal components to input the distributed independent signals for each of the channels and adjusts and outputs phases and/or amplitudes of the independent signals for each of the channels, and wherein the signal combining unit combines signals having the same characteristics among the independent signals output from the multi channel unit with each other.
[0020] In another aspect, a method for transmitting a signal using a dual polarization antenna is provided. The method includes: distributing each of a plurality of input signals as a plurality of independent signals; inputting each of the plurality of independent signals to a corresponding channel; adjusting phases and/or amplitudes of the independent signals for each of the channels to which the independent signals are input; intersecting and combining the phase and/or amplitude adjusted independent signals with respect to the plurality of input signals to generate combined independent signals; and inputting and transmitting each of the combined independent signals as orthogonal components of a dual polarization antenna.
[0021] The adjustment of the phases and/or the amplitudes of the independent signals may be temporally controlled.
[0022] The plurality of input signals may be two different input signals, in the distributing, two independent signals may be distributed from each of the two different input signals, in the adjusting, one of independent signals configuring the combined independent signals may be attenuated and removed for each of the two different input signal, and in the transmitting, two combined independent signals of which one is attenuated and removed may be input as each of the orthogonal components of the dual polarization antenna.
[0023] In the distributing, two independent signals may be distributed from each of two input signals, in the adjusting, one of the two independent signals configuring the combined independent signals may be attenuated and removed, and in the transmitting, two combined independent signals of which one is attenuated and removed may be input as each of the orthogonal components of the dual polarization antenna.
[0024] In the adjusting, a weight for the phase and/or the amplitude may be added to each of the channels to which the independent signal is input to adjust the phase and/or the amplitude of the independent signal.
[0025] In another aspect, a method for receiving a signal using a dual polarization antenna is provided. The method includes: receiving a dual polarization signal; distributing independent signals having different characteristics in each of the orthogonal components; inputting the distributed independent signals for each of a plurality of channels adjusting phases and/or amplitudes of the independent signals for each of the channels; and combining signals having the same characteristics among the phase and/or amplitude adjusted independent signals with each other.
[0026] In the present invention described above, the antenna, which is all kinds of antennas including two input and output terminals and capable of forming a dual polarization, includes a unit antenna element, an array antenna, or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a diagram schematically showing a configuration of a passive array antenna apparatus used for a base station antenna according to the related art.
[0028] FIG. 2 is a diagram schematically describing that different polarizations are transmitted through real time scheduling in a polarization control active array antenna apparatus according to the present invention.
[0029] FIG. 3 is a diagram schematically showing an example of a configuration of a real time RF polarization control active array antenna apparatus according to an exemplary embodiment of the present invention.
[0030] FIG. 4 is a diagram schematically showing a configuration of a real time RF polarization control active array antenna apparatus and an example of a configuration of an interface for the real time RF polarization control active array antenna apparatus according to the exemplary embodiment of the present invention.
[0031] FIG. 5 is a diagram schematically showing a configuration of an active array to antenna element in the real time RF polarization control active array antenna apparatus according to the exemplary embodiment of the present invention.
[0032] FIG. 6 is a diagram schematically showing an example of a configuration of a multi active channel unit.
[0033] FIG. 7 is a diagram schematically showing a coaxial wiring relationship of a polarization reconstruction combining unit according to the exemplary embodiment of the present invention and an example of a configuration of a power distributing/combining unit.
[0034] FIG. 8 is a diagram schematically showing a configuration of a baseband/modem polarization control active array antenna apparatus.
[0035] FIG. 9 is a flow chart schematically showing an operation of a system including the real time RF polarization control active array antenna apparatus according to the exemplary embodiment of the present invention in a transmission mode.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0036] The present invention relates to an active array antenna apparatus for controlling an RF polarization in real time and a method for transmitting and receiving a signal using the same. In the active array antenna apparatus for controlling an RF polarization in real time according to an exemplary embodiment of the present invention, each antenna element has an active array antenna element form and also has an antenna structure capable of generating an orthogonal dual polarization. In addition, each antenna element includes two input or output terminals, and signals input or output through two terminals may have independent controlled amplitudes and phases. Here, the amplitude and phase control of two orthogonal component signals may be performed by an analog or digital polarization control apparatus.
[0037] The polarization control apparatus may include an analog active part, a digital signal processing unit, or the like, therein according to a configuration of an antenna system. The polarization control apparatus is connected to an end orthogonal dual polarization antenna, and may be controlled by or communicate with an antenna main controlling unit performing a polarization control.
[0038] Hereinafter, the present invention will be described with reference to the accompanying drawings. In describing the present invention, a description for portions obvious to those skilled in the art will be omitted in order not to obscure the gist of the present invention. In addition, the same reference numerals will be used to describe the same components through the accompanying drawing for convenience of explanation and understanding.
[0039] It is to be noted that each of terms described below is used only in order to help the understanding of the present invention and each manufacturing company or study group may use different terms for the same use.
[0040] In addition, it is noted that each component of the antenna system described in the present description may be applied to all of transmission and reception and uplink transmission and downlink transmission.
[0041] FIG. 1 is a diagram schematically showing a configuration of a passive array antenna apparatus used for a base station antenna according to the related art.
[0042] The passive array antenna apparatus includes a passive array antenna 100 , a remote head unit (RRH) 140 , a donor unit 150 , and a baseband base station apparatus 160 . The passive array antenna 100 includes a plurality of passive antenna array elements 110 and a feed circuit 120 combining or distributing power for the plurality of passive antenna array elements 110 . The remote head unit 140 includes high output amplification, low noise amplification, frequency conversion, and digital to optical signal conversion devices. The passive array antenna 100 and the remote head unit 140 may be connected to each other by a simple coaxial cable. The donor unit 150 connected to the base station apparatus 160 and the remote head unit 140 may be connected to each other by an optical cable.
[0043] The antenna apparatus according to the related art does not include a real time polarization conversion function and a beam forming/beam scan function and has low antenna efficiency and low system power efficiency due to feed loss of the feed circuit 120 .
[0044] FIG. 2 is a diagram schematically describing that different polarizations are transmitted through real time scheduling in a polarization control active array antenna apparatus according to the present invention. Referring to FIG. 2 , a real time RF polarization control active array antenna apparatus proposed in the present invention provides a function of performing transmission and reception while changing the polarization according to real time scheduling, unlike the antenna apparatus according to the related art. For example, a linear polarization 1 (P LP1 ) may be generated during Δt 1 , a linear polarization 2 (P LP2 ) may be generated during Δt 2 , and a circular polarization 1 (P CP1 ) may be generated during Δt 3 , from the array antenna apparatus.
[0045] FIG. 3 is a diagram schematically showing an example of a configuration of a real time RF polarization control active array antenna apparatus according to an exemplary embodiment of the present invention. The real time RF polarization control active array antenna apparatus includes an active array antenna apparatus 3000 , a monitoring and controlling unit 3800 , a donor unit 150 , and a baseband base station apparatus 160 . The active array antenna apparatus 3000 includes a plurality of active antenna array elements 3100 , a multi active channel unit 3200 providing functions of a remote head unit, that is, a transmission high output amplification function, a reception low noise amplification function, and a function capable of an amplitude and a phase of active channels, and an uplink and downlink frequency conversion and digital to optical signal conversion device (not shown). The active array antenna apparatus 3100 and the donor unit 150 may be connected to each other by an optical cable.
[0046] The real time RF polarization control active array antenna apparatus according to the exemplary embodiment of the present invention may provide a real time polarization conversion function and a three dimensional beam forming/three dimensional beam scan function, and also provide significantly high antenna efficiency and high system power efficiency since it has an active feed structure.
[0047] Hereinafter, a configuration of the active array antenna apparatus 3000 will be described in detail. Here, for convenience of explanation, a time division duplex (TDD) type WiMAX (or Wibro) system will be described as an example of a system according to the exemplary embodiment of the present invention.
[0048] FIG. 4 is a diagram schematically showing a configuration of a real time RF polarization control active array antenna apparatus 3000 and an example of a configuration of an interface for the real time RF polarization control active array antenna apparatus 3000 according to the exemplary embodiment of the present invention.
[0049] The donor unit 150 and the baseband base station apparatus 160 may be installed inside a house, and the active array antenna apparatus 3000 except for the monitoring/controlling unit 3800 may be installed outside the house.
[0050] The real time RF polarization control active array antenna apparatus 3000 includes an active array antenna element 3100 , a multi active channel unit 3200 , a polarization reconstruction combining unit 3300 , a power distributing/combining unit 3400 , an antenna controlling unit 3500 , a frequency converting/digital to optical converting unit 3600 , and a power supplying unit 3700 . Here, the monitoring/controlling unit 3800 may be installed inside the home so as to be independently interfaced with the donor unit 150 .
[0051] The active array antenna element 3100 may include N 1 horizontal array elements and N 2 vertical array elements. The N 1 horizontal array elements may provide horizontal beam forming and beam scan functions, and the N 2 vertical array elements may provide vertical beam forming and beam scan functions. Here, for convenience of explanation, a structure in which eight antenna elements are arranged in each of two layers, for example, a case in which two horizontal array elements and eight vertical array elements are arranged will be described as an example of the present invention.
[0052] FIG. 5 is a diagram schematically showing a configuration of an active array antenna element 3100 in the real time RF polarization control active array antenna apparatus 3000 according to the exemplary embodiment of the present invention.
[0053] Referring to FIG. 5 , left vertical array antenna elements 3110 include eight antenna elements, and right vertical array antenna elements 3120 also include eight antenna elements. The left vertical array antenna elements 3110 and the right vertical array antenna elements 3120 may be disposed, having an interval of d x therebetween. An array interval between the vertical array antenna elements may be determined according to unique characteristics of an applied antenna element and have an influence on horizontal beam forming and beam scan characteristics.
[0054] Each antenna element may have a structure of orthogonal intersecting antenna elements DE 1 and DE 2 or a structure of orthogonal intersecting dipole elements. For example, the antenna element may have two input terminals I 1 and I 2 so as to provide two orthogonal components E x and E y . Therefore, in the case of allowing each antenna element to correspond to users receiving a communication service through the RF polarization control active array antenna according to the exemplary embodiment of the present invention, it is possible to perform a polarization control based on each user.
[0055] Two independent signals are combined with each other and input to each input terminal. For example, a signal M 11 +M 21 may be input to the input terminal 1 I 1 , and a signal M 12 +M 22 may be input to the input terminal 2 I 2 . Here, signals M 11 and M 12 are coherent signals branched from an input signal M 1 and each having an amplitude and a phase that may be mutually controlled. In addition, signals M 21 and M 22 are also coherent signals branched from an input signal M 2 and each having an amplitude and a phase that may be mutually controlled.
[0056] Two independent signals are combined with each other by a multi active channel unit 3200 to be described below.
[0057] FIG. 6 is a diagram schematically showing an example of a configuration of a multi active channel unit 3200 . The multi active channel unit 3200 includes two layers and includes eight multi active channel sub units arranged in each of the two layers, that is, a total of sixteen multi active channel sub units 3210 to 3217 and 3220 to 3227 . Each of the multi active channel sub units includes four active channels corresponding to four input signals M 11 , M 12 , M 21 , and M 22 and outputs two signals M 11 +M 21 and M 12 +M 22 corresponding to the inputs I 1 and I 2 of each antenna element.
[0058] In a transmission mode, each of the multi active channel sub units 3210 to 3217 and 3220 to 3227 has an output interfaced with the antenna element of the antenna element arrays 3110 and 3120 and an input interfaced with the polarization reconstruction coaxial wiring combining unit 3300 . In a reception mode, each of the multi active channel sub units 3210 to 3217 and 3220 to 3227 has an input interfaced with the antenna element of the antenna element arrays 3110 and 3120 and an output interfaced with the polarization reconstruction coaxial wiring combining unit 3300 .
[0059] Each of the multi active channel sub units 3210 to 3217 and 3220 to 3227 includes two end filters BPF 1 and BPF 2 , four RF channel switches SW 1 to SW 4 , two transmission high output amplifiers HPA 1 and HPA 2 , two low noise amplifiers LNA 1 and LNA 2 , two power distributers/combiners PDC 1 and PDC 2 , and vector signal controlling units 3210 a and 3220 a.
[0060] The vector signal controlling units 3210 a and 3220 a include four digital phase shifters PS 1 to PS 4 and fourth digital power attenuators ATT 1 to ATT 4 .
[0061] Here, the end filters BPF 1 and BPF 2 serve to suppress out-of-band signals.
[0062] The four RF channel switches SW 1 to SW 4 may be simultaneously synchronized and selected so as to provide a transmission and reception channel selection function. Here, a synchronization control signal (T-sync signal) is provided from the base station apparatus.
[0063] The transmission high output amplifiers HPA 1 and HPA 2 provide a function of high-output amplifying a transmission signal at the time of a transmission channel mode. In addition, at the time of a reception channel mode, power of the transmission high output amplifiers is blocked, thereby making it possible to protect the reception low noise amplifiers LNA 1 and LNA 2 . Here, the high output amplifiers may also be blocked through the RF channel switches SW 1 to SW 4 .
[0064] The reception low noise amplifiers LNA 1 and LNA 2 provide a function of low-noise amplifying a reception signal at the time of the reception channel mode. In addition, at the time of the transmission channel mode, power of the low noise amplifiers is blocked, thereby making it possible to protect the low noise amplifiers from the high output signal leaked and input from the high output amplifiers. Here, the low noise amplifiers may also be blocked through the RF channel switches SW 1 to SW 4 .
[0065] The power distributers/combiners PDC 1 and PDC 2 provide a function of combining two transmitted independent input signals M 11 and M 21 with each other at the time of the transmission channel mode. The power distributers/combiners PDC 1 and PDC 2 provide a function of distributing two received independent input signals M 11 and M 21 at the time of the reception channel mode.
[0066] The vector signal controlling units 3210 a and 3220 a may include four digital phase shifters PS 1 to PS 4 and fourth digital power attenuators ATT 1 to ATT 4 .
[0067] The four digital phase shifters PS 1 to PS 4 may adjust phases of the respective active channels. Here, the digital phase shifters adjust the phases of the respective channels with respect to the input signal to allow two orthogonal component signals transmitted to the antenna element to have a phase difference of 90 degrees, thereby making it possible to generate a circular polarization.
[0068] The four digital power attenuators ATT 1 to ATT 4 may adjust amplitudes of the respective active channels. Here, channels for signals to be transmitted among channels to which signals are input may also be selected through the digital power attenuators. For example, attenuation is maximally applied to one of signals input to each channel to remove or minimize a corresponding signal, thereby making it possible to select a desired channel among the channels to which the signals are input.
[0069] The adjustment of the amplitudes and/or the phases through the vector signal controlling units 3210 and 3220 a is performed by the antenna controlling unit 3500 . The amplitude and/or the phase of the active channel is controlled through the antenna controlling unit 3500 , thereby making it possible to perform real time polarization reconstruction, beam forming and beam scan, initial phase compensation, and the like. The antenna controlling unit 3500 receives various control signals from the monitoring/controlling unit 3800 to transfer a control command to the multi active channel unit 3200 . The monitoring controlling unit 3800 may be configured separately from the antenna apparatus 3000 , and a user/manager may control parameters on transmission of the antenna apparatus through the monitoring/controlling unit 3800 as described below.
[0070] FIG. 7 is a diagram schematically showing a coaxial wiring relationship of a polarization reconstruction combining unit according to the exemplary embodiment of the present invention and an example of a configuration of a power distributing/combining unit.
[0071] An intermediate portion of FIG. 7 shows a coaxial wiring relationship of the polarization reconstruction combining unit 3300 . Referring to FIG. 7 , the polarization reconstruction combining unit 3300 provides a function of replacing an RF wiring in order to reconstruct two signals and transmission and reception polarizations. For example, referring to FIG. 7 , the polarization reconstruction combining unit 3300 allows two independent RF signals M 11 and M 21 to be input to two left channels configuring the multi active channel sub unit 3210 and allows two independent RF signals M 12 and M 22 to be input to two right channels configuring the multi active channel sub unit 3210 .
[0072] A lower end portion of FIG. 7 shows an internal configuration of the power distributing/combining unit 3400 .
[0073] Referring to FIG. 7 , the power distributing/combining unit 3400 includes two 1-8 way power distributers/combiners 3420 and 3421 and sixteen 2-8 way power distributers/combiners 3410 to 3471 . The power distributing/combining unit 3400 distributes power of two independent input signals to output each 32 (a total of 64) signal, at the time of the transmission channel mode. Similarly, the power distributing/combining unit 3400 distributes power of each 32 (a total of 64) input signal to output two independent signals, at the time of the reception channel mode.
[0074] Hereinafter, again referring to FIG. 4 , the real time RF polarization control active array antenna apparatus 3000 according to the exemplary embodiment of the present invention will be additionally described.
[0075] The antenna controlling unit 3500 of FIG. 4 receives various control signals from the monitoring/controlling unit 3800 to transfer a control command to the multi active channel unit 3200 . Here, as the control signals input from the monitoring/controlling unit 3800 , there are an amplitude and/or phase control signal, a power turn on/off control signal, a beam forming and beam scan control signal, a polarization control signal, and the like.
[0076] The antenna controlling unit 3500 may also collect status information of each of the 16 multi active channel sub units 3210 to 3217 to 3220 to 3227 to transfer the status information to the monitoring/controlling unit 3800 and may transfer a synchronization control (T Sync) signal received from the frequency converting/digital to optical converting units 3600 to each of the 16 multi active channel sub units 3210 to 3217 and 3220 to 3227 . Here, the antenna controlling unit 3500 , the multi active channel unit 3200 , and the monitoring/controlling unit 3800 may communicate with each other in, for example, a RS232C serial communication (38, 400 bps, half duplex) scheme.
[0077] The frequency converting/digital to optical converting unit 3600 includes two frequency converting units 3610 and 3620 , a local oscillator 3630 synchronized with an external reference frequency (for example, 10 MHz) (for example, a phase locked loop (PLL) type local oscillator), and a digital to optical converter 3640 . The frequency converting/digital to optical converting unit 3600 performs digital to optical interfacing with the donor unit 150 and provides a frequency conversion function and a function of converting a digital optical signal into an RF signal and/or amplifying and transmitting the digital optical signal. The digital to optical converter 3640 separates the independent signals, for example, M 1 and M 2 , received from the donor unit and supplies each of the separated signals to the frequency converting units 3610 and 3620 .
[0078] The power supplying unit 3700 of FIG. 4 converts alternate current (AC) power into direct current (DC) power to supply the DC power to each active unit, for example, the antenna controlling unit 3500 , the frequency converting/digital to optical converting unit 3600 , the multi active channel unit 3200 , and the like. The power supplying unit 3700 supplies power to each channel configuring the sub units of the multi active channel unit 3200 , thereby making it possible to increase power efficiency.
[0079] The monitoring/controlling unit 3800 of FIG. 4 may be installed inside the home, separately from the antenna apparatus 3000 , and communicate with the donor unit 150 through a universal serial bus (USB) terminal in the RS232C serial communication (38, 400 bps, half duplex) scheme. In addition, the monitoring/controlling unit 3800 may passively control the synchronization control (T Sync) with respect to an uplink and a downlink.
[0080] The monitoring/controlling unit 3800 may communicate with the antenna controlling unit 3500 in the RS232C serial communication (38, 400 bps, half duplex) scheme. Therefore, the monitoring/controlling unit 3800 may provide a function of controlling the amplitude and/or the phase control, a function of controlling the power turn on/off, a function of controlling the beam forming and/or beam scan, a function of controlling the polarization reconstruction, a function of collecting the status information (a power level, a temperature, or the like) of each 16 sub unit, and a function of setting a monitor, a TDD guide offset, a TDD receive-to-transmit transition gap (TDD RTG), a TDD transmit-to-receive transition gap (TDD TTG), or the like, of the multi active channel unit 3200 .
[0081] In contrast with the donor unit of the base station system according to the related art, the donor unit 150 has a modified firmware so that it is interfaced with the monitoring/controlling unit 3800 .
[0082] FIG. 8 is a diagram schematically showing a configuration of a baseband/modem polarization control active array antenna apparatus according to another exemplary embodiment of the present invention.
[0083] In the exemplary embodiment of FIG. 8 , the distributing/combining function of the power distributing/combining unit 3400 , the function of the polarization reconstruction combining unit 3300 , and the functions of the digital power attenuators ATT 1 to ATT 4 and the digital phase shifters PS 1 to PS 4 of the multi active channel sub units 3210 to 3217 and 3220 to 3227 in the exemplary embodiment of FIGS. 4 to 7 may be performed in a baseband/modem unit 8000 positioned at the donor unit or the baseband base station apparatus. Therefore, in the exemplary embodiment of FIG. 8 , an active array antenna apparatus 7000 performs a function required for transmitting and receiving signals in addition to the above-mentioned functions.
[0084] The baseband/modem unit 8000 includes a demultiplexer (DEMUX) unit 8100 distributing digital signals in terms of transmission, a vector signal controlling unit 8200 control amplitudes and phases of the distributed digital signals, and a multiplex (MUX) unit 8300 combining the amplitude and/or phase controlled digital signals with each other. Two independent input data M 1 data and M 2 data pass through the vector signal controlling unit 8200 and are then combined with each other.
[0085] Next, the combined signals pass through the active array antenna apparatus 7000 and are then input to a single orthogonal dual polarization antenna element 3110 in order to simultaneously generate two independent orthogonal polarizations. Here, the two dual polarizations may be generated by controlling weighting factors (complex factors controlling the amplitude and the phase) W 11 , W 12 , W 21 , and W 22 .
[0086] In addition, in order to obtain an array gain, at the time of use of the array antenna, the input signals may be distributed and used by the number of array antennas in the active array antenna apparatus 7000 or the baseband/modem unit 8000 .
[0087] FIG. 9 is a flow chart schematically showing an operation of a system including the real time RF polarization control active array antenna apparatus according to the exemplary embodiment of the present invention in a transmission mode.
[0088] A plurality of independent signals M 1 and M 2 are input from a base station to an antenna apparatus (S 910 ). The independent signals input to the antenna apparatus is subjected to optical to digital conversion and is subjected to sync control and frequency conversion if needed.
[0089] The independent signals M 1 and M 2 are distributed as each element independent signal (S 920 ).
[0090] Each of the independent signals M 1 and M 2 is distributed as a plurality of independent signals M 11 and M 12 , and M 21 and M 22 . The independent signals M 11 and M 12 are first and second independent signals distributed from the independent signal M 1 . The independent signals M 21 and M 22 are first and second independent signals distributed from the independent signal M 2 .
[0091] The distributed independent signals are input to each of the channels (S 930 ). Each of the channels corresponds to each of the independent signals in a one-to-one scheme, and each of the independent signals may be input to each of the channels.
[0092] Amplitudes and/or phases of the independent signals passing through each channel are adjusted (S 940 ). The amplitudes and/or the phases of the independent signals may be controlled for each channel.
[0093] In order to control the amplitudes and/or the phases of each of the independent signals, a attenuator and a phase shifter may be used for each channel. In addition, in order to control the amplitudes and/or the phases of each of the independent signals, each of the weighting factors W 11 , W 12 , W 21 , and W 22 may be added to each of the independent signals. Here, the weighting factors, which are complex factors, adjust the amplitudes and the phases of each of the independent signals.
[0094] The amplitude and phase controlled independent signals are combined with different independent signals to form a dual polarization (S 950 ). A single independent signal is combined with a different kind of independent signal as represented by Equation. 1.
[0000] E 1= M 11′+ M 21′
[0000] E 2= M 12′+ M 22′ [Equation 1]
[0095] Where M 11 ′, M 12 ′, M 21 ′, and M 22 ′ indicate phase and/or amplitude controlled independent signals, and E 1 and E 2 indicate orthogonal component signals (polarization signals) input to each intersecting structure in a single antenna element having an orthogonal intersecting structure or an orthogonal intersecting dipole structure.
[0096] Here, when the M 1 and the M 2 are the same signal, the antenna apparatus according to the exemplary embodiment of the present invention transmits the same signal.
[0097] Here, when the M 1 and the M 2 are the different signals, the antenna apparatus according to the exemplary embodiment of the present invention is a MIMO system and may obtain a transmission diversity effect. For example, when the M 21 ′ and M 12 ′ are removed through the attenuator, a single antenna may transmit two independent signals orthogonal to each other. Even in the case in which the M 1 and the M 2 are the different signals, only signals on one sides such as M 11 and M 12 or M 21 and M 22 are removed, thereby making it possible to selectively transmit only the same signal.
[0098] Two polarizations E 1 and E 2 are transmitted through the antenna element (S 960 ).
[0099] The present invention may also be applied to a system including a real time RF polarization control active array antenna apparatus in a reception mode.
[0100] In the case of the system the real time RF polarization control active array antenna apparatus in the reception mode, operations in the transmission mode described in FIG. 9 are reversely applied to received polarization signals, thereby making it possible to obtain the independent signals.
[0101] Although the TDD type WiMAX (or Wibro) system has been described as an example of the system according to the exemplary embodiment of the present invention for convenience of explanation, the present invention is not limited thereto. That is, the spirit of the present invention may be applied to various systems. For example, the spirit of the present invention may also be applied to a FDD type WiMAX (or Wibro) system by excluding the switches SW 1 to SW 4 in the exemplary embodiment of FIG. 6 and may also be applied to a long term evolution (LTE) system.
[0102] In contents described in the present specification, work performed in a communication network may be performed during a process of controlling the communication network and transmitting data in a system (for example, a server, a base station, or the like) managing the communication network or be performed in a terminal coupled to the communication network.
[0103] With the antenna apparatus according to the exemplary embodiments of the present invention, the polarization control adapted for a real time or long term wireless communication environment change is performed, polarization characteristics of the antenna are provided for each of wireless communication environment adaptation sector user groups, thereby making it possible to improve communication service quality and increase communication capacity.
[0104] In addition, according to the exemplary embodiments of the present invention, a wireless electric wave may be efficiently and optimally operated and utilized so as to be adapted for the future various services and complex wireless environment. In addition, a technology in which a wireless communication environment adaptation real time polarization control technology and a MIMO signal processing technology are combined with each other in order to transmit data at a high speed may be widely applied to the next generation mobile communication base station/relay array antenna system.
[0105] Further, in the present invention, “comprising” a specific configuration will be understood that additional configuration may also be included in the embodiments or the scope of the technical idea of the present invention.
[0106] In the above-mentioned exemplary system, although the methods have described based on a flow chart as a series of steps or blocks, the present invention is not limited to a sequence of steps but any step may be generated in a different sequence or simultaneously from or with other steps as described above. Further, it may be appreciated by those skilled in the art that steps shown in a flow chart is non-exclusive and therefore, include other steps or deletes one or more steps of a flow chart without having an effect on the scope of the present invention.
[0107] The above-mentioned embodiments include examples of various aspects. Although all possible combinations showing various aspects are not described, it may be appreciated by those skilled in the art that other combinations may be made. Therefore, the present invention should be construed as including all other substitutions, alterations and modifications belong to the following claims.
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The present invention relates to a general active array antenna apparatus capable of environmentally and temporally controlling radio frequency (RF) polarization resource necessary for wireless communication in order to improve communication quality and increase communication capacity. The antenna according to the present invention has a form of an active array antenna element, wherein each active array antenna element has a structure in which it may generate orthogonal dual polarizations and includes two input terminals and output terminals. An end orthogonal dual polarization antenna is connected to a polarization control apparatus that may process analog or digital signals, and the polarization control apparatus is controlled by or communicate with an antenna main controlling apparatus performing a polarization control algorithm. Ultimately, an object of this antenna apparatus is to improve communication quality and increase communication capacity.
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Genus and species of plant claimed: Distylium racemosum×Distylium myricoides.
Variety denomination: ‘PIIDIST-IV’.
BACKGROUND OF THE INVENTION
The present invention relates to a new and distinct cultivar of Distylium plant, botanically known as Distylium hybrid, a member of the Hamamelidaceae, and hereinafter referred to by the cultivar name ‘PIIDIST-IV’.
‘PIIDIST-IV’ originated in 2010 as an open-pollinated seedling from seed collected from a Distylium racemosum seedling selection (unnamed and unpatented) growing in Watkinsville, Ga. The Distylium racemosum was growing in close proximity to several Distylium myricoides and Distylium hybrid plants. Subsequent DNA analysis of ‘PIIDIST-IV’ has confirmed its hybrid status between Distylium racemosum and Distylium myricoides. ‘PIIDIST-IV’ was selected by the inventor in a cultivated environment in Watkinsville, Ga.
Asexual reproduction of ‘PIIDIST-IV’ by stem cuttings since 2011 has shown that all the unique features of ‘PIIDIST-IV’, as herein described, are stable and reproduced true-to-type through successive generations of such asexual propagation.
SUMMARY OF THE INVENTION
Plants of the new cultivar ‘PIIDIST-IV’ have not been observed under all possible environmental conditions. The phenotype may vary somewhat with changes in light, temperature, soil and rainfall without, however, any variance in genotype.
The following traits have been repeatedly observed and are determined to be unique characteristics of ‘PIIDIST-IV’. These characteristics in combination distinguish ‘PIIDIST-IV’ as a new and distinct cultivar:
1. Compact, upright growth habit; 3. Reddish new growth; 3. Lustrous, leathery, dark green mature foliage; 4. Resistance to insects and disease; and 5. Tolerance of wet and dry soil conditions.
‘PIIDIST-IV’ differs from the female parent, Distylium racemosum, primarily in growth habit and foliage color. ‘PIIDIST-IV’ has a smaller, compact, upright growth habit, whereas the female parent has a larger, less compact, upright-spreading growth habit. ‘PIIDIST-IV’ has darker reddish new growth, whereas the female parent has lighter orange-red new growth.
‘PIIDIST-IV’ can be compared to ‘PIIDIST-IV’ (U.S. Plant Pat. No. 24,410), but differs in the following characteristics. ‘PIIDIST-IV’ has a compact, upright growth habit and reddish new growth, whereas ‘PIIDIST-IV’ has a less compact, upright-spreading growth habit and yellow-green new growth.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying color photographs illustrate the foliage characteristics and the overall appearance of ‘PIIDIST-IV’, showing the colors as true as it is reasonably possible to obtain in color reproductions of this type. Colors in the photographs may differ slightly from the color values cited in the detailed botanical description which accurately describe the colors of ‘PIIDIST-IV’.
FIG. 1 illustrates the overall appearance and growth habit of ‘PIIDIST-IV’.
FIG. 2 illustrates a close-up view of the new growth and mature foliage of ‘PIIDIST-IV’.
DETAILED DESCRIPTION
In the following description, color references are made to The Royal Horticultural Society Colour Chart, 2007 Edition, except where general terms of ordinary dictionary significance are used. The plant used for the description was approximately 4-years-old and was grown in the ground in Watkinsville, Ga.
Botanical classification: Distylium hybrid ‘PIIDIST-IV’. Parentage: female parent: Distylium racemosum seedling selection (unnamed and unpatented), male parent: unknown (open-pollinated). Propagation: stem cuttings. Time to initiate roots in summer: about 5 weeks at 32° C.
Plant description: Broadleaf, evergreen, flowering shrub; multi-stemmed; compact, upright growth habit. Freely branching; removal of the terminal bud enhances lateral branch development.
Root description.— Medium, well-branched. Plant size.— The original plant, now about four-years-old in the ground, is about 170 cm high from the soil level to the top of the foliage and about 145 cm wide. First year stems .—Having a diameter of about 2.5 mm. Shape: round. Fine pubescence on young stems, becoming glabrous with maturity. Approximately 10 lenticels per 1 cm of stem length. Lenticels are about 0.5 mm in diameter and N199B in color. First year stem color.— 176B on new growth, changing to 146C, and finally maturing to 199A. Second year and older stems .—Have a diameter of about 4 mm or more. Shape: round. Second year and older stem color.— 199A. Stem strength.— Flexible when young, less flexible once mature. Internode length.— About 1.8 cm. Trunk diameter.— About 5.7 cm at the soil line. Color: N199A. Bark does not exfoliate, covered with lenticels about 1 mm in diameter and N199B in color. Approximately 25 lenticels per 1 cm of stem length.
Vegetative bud description:
Arrangement.— Alternate. Shape.— Ovoid with fused, finely pubescent bud scales. Size.— About 4 mm in length and about 2 mm in width. Color.— 199A.
Foliage description:
Arrangement.— Alternate, simple. Length.— About 5.7 cm. Width.— About 2.3 cm. Shape.— Narrow-oblong to obovate. Apex.— Obtuse. Base.— Broadly tapering to rounded. Margin.— Entire, often undulate. Texture ( upper and lower surfaces ).—Lustrous, thick, leathery. Venation pattern.— Pinnate. Venation color ( upper surface ).—Midrib color is 146C and secondary vein color is 147A. Venation color ( lower surface ).—Midrib color is N144D and secondary vein color is N137B. Color of emerging foliage ( upper surface ).—183A. Color of emerging foliage ( lower surface ).—147C. Color of mature foliage ( upper surface ).—147A. Color of mature foliage ( lower surface ).—146B. Petiole length .—About 5 mm. Petiole diameter .—About 1.5 mm. Petiole color ( upper and lower surfaces ).—146B. Finely pubescent.
Flower description: The original plant, now four-years-old, has not flowered to date. Fruit: The original plant, now four-years-old, has not produced fruit to date. Disease/pest resistance: Plants of the new Distylium grown in the nursery and garden have exhibited resistance to pathogens and pests common in these environments. ‘PIIDIST-IV’ is cold hardy in USDA Hardiness Zones 7-9.
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A new and distinct cultivar of Distylium plant named ‘PIIDIST-IV’, characterized by its compact, upright growth habit, reddish new growth, lustrous, leathery, dark green mature foliage, resistance to insects and disease, and tolerance of wet and dry soil conditions.
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CROSS REFERENCE TO RELATED APPLICATION
This application is based upon provisional application Serial No. 60/065,617, filed Nov. 18, 1997.
BACKGROUND OF THE INVENTION
Casement windows include a sash hinged to a frame or jamb so that by rotation of the handle the window could be moved to an open position or a closed position. Various structures have been suggested to attempt to provide a firm locking of the sash to the frame. Problems exist, however, regarding the window sagging while in the locked as well as the open condition.
SUMMARY OF THE INVENTION
An object of this invention is to provide a sag prevention and correcting system for windows, particularly casement windows.
A further object of this invention is to provide such a sag prevention system which operates in connection with the locking arrangement.
In accordance with this invention the sag prevention system is used with a locking arrangement wherein the sash includes at least one and preferably a pair of spaced keepers of a multi-point locking system. The frame has a tie bar arrangement with a roller for each keeper. When the window is rotated to its closed condition the handle for the tie bar arrangement is moved to slide the rollers upwardly for engagement with the keepers. In accordance with the invention a lifting block is located adjacent one of the keepers to be disposed directly above its roller when the window is in the locked condition. The lifting block may be integral with the keeper or may be a separate member. Any sagging is prevented by the lifting block contacting the roller.
THE DRAWINGS
FIG. 1 is a front elevational view of a casement window in the locked condition in accordance with this invention;
FIG. 2 is a fragmental front elevational view of the casement window in the unlocked condition;
FIG. 3 is a fragmental side elevational view of the window shown in FIG. 2;
FIG. 4 is a fragmental front elevational view of a casement window in the locked condition;
FIG. 5 is a fragmental side elevational view of the window shown in FIG. 4;
FIG. 6 is a fragmental side elevational view of a modified form of keeper/lifting block arrangement in accordance with this invention;
FIG. 7 is a fragmental end elevational view of a tie bar having a cylindrical roller;
FIG. 8 is a fragmental and elevational view of a tie bar having a shouldered roller and a keeper with a flange;
FIG. 9 is a fragmental front elevational view showing a casement window in its unlocked condition having a modified form of link structure;
FIG. 10 is a fragmental side elevational view of the arrangement shown in FIG. 9;
FIG. 11 is a fragmental side elevational view showing yet another form of vertical adjustment mechanism in accordance with this invention;
FIG. 12 is a fragmental end elevational view of the arrangement shown in FIG. 11;
FIG. 13 is a fragmental side elevational view showing still yet another form of vertical adjustment mechanism in accordance with this invention;
FIG. 14 is a fragmental end elevational view of the arrangement shown in FIG. 13;
FIG. 15 is a fragmental side elevational view of yet another form of vertical adjustment mechanism in accordance with this invention;
FIG. 16 is an enlarged fragmental end view showing a vertical adjustment mechanism for the link in accordance with this invention; and
FIG. 17 is a front elevational view of a gauge used for locating the lifting block in the window of FIGS. 1 - 5 .
DETAILED DESCRIPTION
FIG. 1 illustrates a casement window 10 which includes a frame or jamb 12 and a sash 14 which extends around the window pane itself. Sash 14 is hinged to frame 12 by hinge arms at the bottom area 16 of the window assembly so that the window can be moved to an open position or a closed position. The rotation is controlled by handle 18 in a known manner and its details are not critical to an understanding of this invention.
FIGS. 2-5 illustrate the details of the invention wherein a sag prevention system is incorporated with locking members of a known multi-point locking system on the sash and frame. Reference is made to U.S. Pat. Nos. 5,074,075, 5,118,145 and 5,448,857, the details of which are incorporated herein by reference thereto with regard to the known multi-point locking system with which the invention may be adapted. The invention thus has the advantage of requiring only minor structural additions to the known locking system.
As shown in FIGS. 2-3 the various components are in their unlocked condition. FIG. 2 illustrates a tie bar 20 having a pair of spaced rollers or abutment members 22 which may be frusto-conically shaped, as shown in FIG. 2 or may have other types of shapes such as shown in FIGS. 7 and 8. It is to be understood that while the members 22 are referred to as rollers, it is not necessary in the broad practice of the invention that the members 22 actually rotate. What is important is that the members 22 present an abutment surface as later described. Members 22 may be considered first abutment members. The tie bar 20 is mounted to the frame 12 . A pair of second abutment members keepers 24 , 26 is mounted to the sash, as shown in FIG. 3 . Keeper 24 has an inclined cam edge 28 and a vertical guide surface or straight guide edge 30 . Keeper 26 has an inclined cam edge 32 and a straight guide edge 34 . In accordance with this invention a lifting block 36 is disposed outwardly from the upper end of straight edge 34 . Although only one lifting block 36 is illustrated in FIG. 3, it is to be understood that the invention may be practiced with a lifting block for each roller as illustrated in phantom in FIG. 5 by the reference numeral 36 A. Similarly, while a pair of rollers and keepers are illustrated, the invention may be broadly practiced with only a single roller and keeper.
Tie bar 20 is mounted to a link 38 which in turn is mounted to a pivotable handle 40 . When handle 40 is in the up position the tie bar is in its unlocked condition where the rollers 22 are spaced from the keepers 24 , 26 . When handle 40 is rotated downwardly the tie bar is shifted upwardly and the rollers contact the keepers, as shown in FIGS. 4-5.
The sequential contacting of the keepers takes place by the lower roller 22 first contacting and rolling against inclined cam edge 32 of lower keeper 26 . When the lower roller reaches the junction with straight guide edge 34 upper roller 22 begins to contact inclined cam edge 28 of upper keeper 24 . Similarly, where abutment member 22 is a roller, the roller may but need not rotate. In continued upper movement of the rollers, the lower roller 22 rides against straight guide edge 34 while upper roller 22 rides against inclined edge 28 and ultimately straight guide edge 30 . When the rollers are both located at the straight edges the window sash is pulled tightly against the weather seals of the frame.
Thus, as described above, each keeper is in the path of movement of the vertically moving roller 22 so that when the rollers 22 contact the inclined and straight edges of each keeper, a locking results.
In accordance with this invention lifting block 36 is mounted outwardly of straight edge 34 generally in line with or more accurately across the path of movement of lower roller 22 . Lifting block 36 is illustrated in FIGS. 3 and 5 as being integral with keeper 26 and extending outwardly from guide edge 34 . It is to be understood, however, that the invention may be practiced where the lifting block is a separate element mounted adjacent to and upwardly from keeper 26 .
FIGS. 4-5 show the condition of the components in the fully locked position. As shown therein, lower roller 22 is located directly below lifting block 36 when upper roller 22 is along straight guide edge 30 of upper keeper 24 . In the fully locked condition roller 22 would be at the lower edge 44 of block 36 . If there should be any tendency for the sash to sag, such tendency is prevented by lower roller 22 acting as an abutment against edge 44 for lifting block 36 thereby preventing downward movement or sagging of the sash, or lifting the sash if it has sagged while in the open position.
Preferably, lifting block 36 is located at lower keeper 26 . The invention, however, may also be practiced by having the lifting block at the upper keeper 24 located directly above the upper roller 22 when the handle 40 is moved to its down position as shown in FIGS. 4-5. The invention may also be practiced by having a lifting block for each keeper, particularly when used with a heavy sash. The preferred practice of the invention is illustrated where there is a single lifting block located at the lower keeper 26 and where the sash is not particularly heavy.
As noted, the lifting block 36 may be integral with keeper 26 or may be a separate member located directly above the lower roller 22 . Not only does lifting block 36 prevent sagging and support the sash in its locked position, but also the lifting block corrects minor sag while the sash is in its open position.
The invention may be practiced by having one or both keepers or lifting block 36 vertically adjustable in its location on sash 14 . FIG. 3, for example, illustrates a pair of slots 27 to be formed in keeper 26 so that the keeper 26 could be slidably moved up or down and then locked in position by the illustrated screws or fasteners.
Any other suitable structure may be used to permit the vertical adjustability of the keepers and/or lifting block. FIG. 6, for example, illustrates the lifting block 36 to include the same type of slot/fastener arrangement so as to be independently movable with respect to keeper 26 . FIG. 6, further illustrates a variation of the invention where the contact surface 35 of lifting block 36 is arcuate to receive cylindrical roller 22 A. The cylindrical roller is also shown in FIG. 7 .
FIG. 8 shows a variation of the invention where one of the keepers such as keeper 24 has a flange 25 for contacting roller 22 B which is in the form of a cylinder having an outwardly extending shoulder 23 which rides against flange 25 .
Where lifting block 36 is not integral with keeper 26 the two pieces could have mating teeth or cams engaged with each other to effect vertical movement of one piece with respect to the other. Where vertical adjusting structure is used care should be taken to take into account the weight of the window as it might affect the efficiency of performance of the vertical adjusting structure.
FIGS. 9-10 show a variation of the invention wherein the link 38 A associated with handle 40 is connected to tie bar 20 by a fork structure 100 wherein the fork arms or prongs 101 are disposed on each side of a pin 102 fixed on tie bar 20 .
FIGS. 11-12 illustrate a further vertical adjustment mechanism which may be used in accordance with this invention. As shown therein, the pin 102 A is eccentrically mounted or may be of elliptical form so that upon rotation of the pin the forked end of link 38 A is moved up or down. For example, as shown in FIG. 12, the eccentrically mounted pin 103 is secured to tie bar 20 with a cam disk 105 disposed between link 38 A and tie bar 20 . Rotation of eccentric pin 103 affects the precise location of link 38 at its area of mounting to tie bar 20 . A known mechanism commonly referred to as TORX would provide this type of adjustment.
FIGS. 13-14 illustrate yet another form of vertical adjustment mechanism wherein a hexagonal cam disk 105 A is mounted to pin 103 so that rotation of pin 103 causes pin 102 disposed between the fork arms of link 38 A to move the arms upwardly or downwardly. Such adjustment may be easily achieved by using a conventional adjustment wrench W.
FIG. 15 illustrates yet another manner of adjustment wherein the link 38 B is made of two parts 39 A and 39 B which are connected together by a suitable fastener 41 extending through elongated slot 43 thereby controlling the degree of overlap of link parts 39 A and 39 B.
FIG. 16 illustrates yet another form of adjustment where link 20 A is provided with teeth 31 for engagement with complementary teeth 33 on link 38 C. A suitable threaded fastener 29 and nut 29 B may be manipulated to move the mating teeth 31 , 33 into and out of engagement with each other.
FIG. 17 illustrates a gauge 42 which may be used for properly positioning the lifting block and more particularly its lower edge 44 on the sash. As shown therein gauge 42 is of two piece construction for locating the bottom keeper lifter on casement windows with multi-point locking systems. A pair of sliding members 46 , 48 comprise gauge 42 . Each member includes a slot 50 into which pins 52 , 52 of the other member are slidably mounted. The members 46 , 48 can be locked together in any suitable manner once the proper height adjustment can be achieved.
Lower member 48 includes a lower surface 54 which would be placed on the bottom hinge track of frame 12 . A side wall 56 is dimensioned to correspond to the stack height of the hinge and spacers, if used. Such height might, for example, be {fraction (7/16)} inches. Surface 58 would be set in the bottom sash arm mounting surface. A cutout 60 avoids contact with weld flash. For example, the cut out 60 includes a relief notch 59 with a recess 61 to accommodate any weld flash at the corner of the window frame F, shown in phantom. Surface 62 of upper member 46 would correspond to the top tangent surface of the bottom roller in the locked position. This would also correspond to the lower edge 44 or 35 of lifting block 36 . A similar surface 64 in line with surface 62 is provided also to correspond to the tangible surface of the bottom roller. Either of the surfaces 62 , 64 could be used for determining where the lifting block 36 should be located with regard to its lower surface.
Thus, in use the surface 54 would be placed on the bottom hinge track. Members 46 , 48 would be slidably adjusted so that surface 62 or 64 would be tangent to the bottom roller 22 in the locked position. Members 46 , 48 would then be locked to fix this distance. Surface 58 would be set in the bottom hinge sash arm mounting surfaces. By the proper placement and selection of the various surfaces in gauge 42 , accurate placement of the lifting block 36 can be assured.
The above procedure allows for the proper placement and location of the lifting block 36 with respect to roller 22 . If it is more desirable to adjust the location of the roller in order to obtain the proper alignment and positioning with respect to the lifting block 36 the following procedure can be used. Surface 58 of gauge 42 would be set in the bottom hinge sash arm surface. Slide members 46 , 48 would be selectively adjusted so that surface 62 or 64 would correspond to the location of surface 44 or 35 of lifting block 36 . Members 46 , 48 would then be locked to fix this distance. Surface 54 would be placed on the bottom hinge track surface. Roller 22 would then be adjusted so that roller 22 would be tangent to surface 62 or 64 . This adjustment of the location of roller 22 could be made by using the various techniques shown in FIGS. 11-14 and/or 17 .
Gauge 42 is useful not only in retrofitting existing windows to add a separate lifting block, but could also be used in original manufactured windows to be sure of proper location of the roller and the lifting block whether the lifting block is integral with the lower keeper or is a separate member.
It is to be understood that the invention may be practiced in manners other than specifically shown and described. For example, the tie bar may be mounted to either the sash or the frame with the fixed abutment member mounted on the other of the sash or the frame. The tie bar may have the roller as its movable abutment member, as described, or the keeper may be mounted on the tie bar and be an abutment member with the roller or abutment member on the other of the sash or the frame. Where the keeper is mounted on the tie bar, the keeper may be considered as a second abutment member and the roller would be a first abutment member. In these variations the lifting block would be disposed across the path of movement of the movable or second abutment member so as to be contacted by the second abutment member when the window assembly is in its locked position to minimize sag and to correct for sag.
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A casement window utilizes a multi-locking system having a pair of spaced keepers and a tie bar with a corresponding pair of rollers. In the locking action the rollers ride against the inclined and straight vertical surfaces of the keepers. A lifting block is located immediately above the lower roller when the locking system is in its locked condition. The lifting block prevents sagging and supports the sash in the locked condition. The provision of a lifting block in combination with the known multi-point locking system takes advantage of the locking system components to prevent sagging.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a Section 365(c) continuation of International Application No. PCT/EP2005/006540 filed 17 Jun. 2005, which in turn claims the priority of DE Application 10 2004 031 177.3 filed Jun. 29, 2004, each of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to 25 not previously described genes of B. licheniformis and gene products derived therefrom which are involved in the formation of odorous substances in five different metabolic pathways, and to biotechnological production methods which are improved inasmuch as, on the basis of the identification of these genes, the formation of these odorous substances can be reduced.
The present invention is in the area of biotechnology, in particular the preparation of valuable products by fermentation of microorganisms able to form the valuable products of interest. This includes for example the preparation of low molecular weight compounds, for instance of dietary supplements or pharmaceutically relevant compounds, or of proteins for which, because of their diversity, there is in turn a large area of industrial use. In the first case, the metabolic properties of the relevant microorganisms are utilized and/or modified to prepare the valuable products; in the second case, cells which express the genes of the proteins of interest are employed. In both cases, genetically modified organisms (GMO) are mostly involved.
There is an extensive prior art on the fermentation of microorganisms, especially on the industrial scale; it extends from the optimization of the relevant strains in relation to the formation rate and the nutrient utilization via the technical design of the fermenters and up to the isolation of the valuable products from the relevant cells themselves and/or the fermentation medium. Both genetic and microbiological, and process engineering and biochemical approaches are applied thereto. The aim of the present invention is to improve this process in relation to a common property of the microorganisms employed, which impairs the actual fermentation step, specifically at the level of the genetic properties of the strains employed.
For industrial biotechnological production, the relevant microorganisms are cultured in fermenters which are designed appropriate for their metabolic properties. During the culturing, they metabolize the provided substrate and normally form, besides the actual product, a large number of other substances in which there is usually no interest and/or which may lead to unwanted side effects.
These include odorous and/or poisonous substances which are a nuisance and/or harmful and are discharged even during the fermentation via the exit air and/or are only incompletely removed during the subsequent working up of the valuable product and thus impair the quality of the product. The concomitant odorous and/or poisonous substances are thus deleterious firstly for the production process, meaning the staff involved and the surroundings of the plant. Secondly, failure to reach a desired quality (specification) of the product may lead to it being unavailable for the intended area of use (for example food production), which means a considerable economic disadvantage. Conversely, reducing the formation of odorous and/or poisonous substances could increase occupational and environmental safety and open up additional areas of use and markets for sales of the product.
Odors frequently found during fermentation of microorganisms are caused by small organic molecules from the classes of volatile, branched and unbranched fatty acids, alcohols and diamines. These include isovaleric acid, 2-methylbutyric acid, isobutyric acid from the class of branched fatty acids, butyric acid, propionic acid (unbranched fatty acids), butanol (alcohol), cadaverine and putrescine (diamines).
Some of these volatile substances are additionally toxic for humans and animals, for example cadaverine and putrescine, which are also known as ptomaines. They can therefore be defined not only as odorous substances but also, depending on the concentration and the exposure time for the relevant organism, as poisonous substances.
Efforts are being made even at present to remove such compounds subsequently from fermentation products. For this purpose, usual working up of the valuable products formed comprises, besides steps to remove cell detritus and high molecular weight compounds, also additional process steps which are referred to as deodorizing. To these are ordinarily added filtrations, precipitation steps and/or chromatography steps, each of which also contribute to a certain extent to the deodorizing. Nevertheless, all these steps carried out for removal lead to a purity which is only inadequate according to the above-mentioned criteria.
The exit air from the fermenter is likewise checked in order to minimize the pollution during the production process.
It would nevertheless be desirable to combat odors causally where possible, i.e. to prevent the relevant substances being produced at all. It would thus be possible firstly to keep the number of subsequent purification and working-up steps small, which appears to be advantageous because they represent in each case a physicochemical stress on the desired product, and reduce the yield. Overall, therefore, a better product quality would be obtained. Secondly, the production conditions would be improved per se, and the systems for filtering the fermenter exit air could be kept simpler. Such a combating of odors causally would, if the properties of the microorganism itself were to be changed thereby, also increase its tolerability for further operations on this microorganism.
SUMMARY OF THE INVENTION
The object was thus to reduce the formation of unpleasant odors and/or poisonous compounds which occurs during the fermentation of microorganisms, especially Gram-positive bacteria of the species Bacillus , and is attributable to the same. It was intended preferably that this take place at the genetic level in order to obtain odorous and/or poisonous substance-depleted microorganisms. In partial problems, this means identifying metabolic pathways relevant thereto, finding genes which code for proteins and/or enzymes which catalyze reactions lying on these pathways and are suitable as possible starting points for solving the problem, and, via identification of the relevant nucleotide sequences, acquiring tools for the desired genetic modification and providing corresponding applications.
To solve this problem, the following five metabolic pathways have been identified:
(1) the metabolic pathway for synthesizing isovaleric acid (as part of leucine catabolism), (2) the metabolic pathway for synthesizing 2-methylbutyric acid and/or isobutyric acid (as part of valine and/or isoleucine catabolism), (3) the metabolic pathway for synthesizing butanol and/or butyric acid (as part of butyric acid metabolism), (4) the metabolic pathway for synthesizing propionic acid (as part of propionate metabolism) and (5) the metabolic pathway for synthesizing cadaverine and/or putrescine (as parts of lysine and/or arginine catabolism).
The following genes which code for proteins and/or enzymes which catalyze reactions lying on these pathways and are suitable as starting points for biotechnological production processes of the invention were then found; the non-consecutive numbering in some cases is based in each case on the complete description hereinafter of the respective metabolic pathways; in addition, some of them are involved in more than one of these pathways:
on the metabolic pathway for synthesizing isovaleric acid and as part of leucine catabolism: (1) L-leucine dehydrogenase (E.C. 1.4.1.9), (2) 3-methyl-2-oxobutanoate dehydrogenase or 2-oxoglutarate dehydrogenase E1 (E.C. 1.2.4.2), (3) enzyme for hydrolyzing isovaleryl-CoA to isovaleric acid and coenzyme A, (4) acyl-CoA dehydrogenase (E.C. 1.3.99.-), (5) methylcrotonyl carboxylase, (6) 3-methylglutaconyl-CoA hydratase and (7) enoyl-CoA hydratase (E.C. 4.2.1.17);
on the metabolic pathway for synthesizing 2-methylbutyric acid and/or isobutyric acid and as part of valine and/or isoleucine catabolism:
(1) branched-chain amino acid aminotransferase (E.C. 2.6.1.42), (2) 3-methyl-2-oxobutanoate dehydrogenase or 2-oxoglutarate dehydrogenase E1 (E.C. 1.2.4.2), (3) enzyme for hydrolyzing 2-methylbutyryl-CoA to 2-methylbutyric acid or isobutyryl-CoA to isobutyric acid and coenzyme A, (4) acyl-CoA dehydrogenase (E.C. 1.3.99.-), (5) enoyl-CoA hydratase (protein) (E.C. 4.2.1.17), (6) 3-hydroxy-acyl-CoA dehydrogenase (E.C. 1.1.1.35), (7) acetyl-CoA acyltransferase, (8) enoyl-(3-hydroxyisobutyryl)-CoA hydrolase protein and (9) 3-hydroxyisobutyrate dehydrogenase (E.C. 1.1.1.31) or oxidoreductase (E.C. 1.1.-.-);
on the metabolic pathway for synthesizing butanol and/or butyric acid and as part of butyric acid metabolism:
(1) 3-hydroxybutyryl-CoA dehydrogenase (E.C. 1.1.1.157), (2) 3-hydroxybutyryl-CoA dehydratase (E.C. 4.2.1.55), (3) butyryl-CoA dehydrogenase (E.C. 1.3.99.25), (4) phosphate butyryltransferase (E.C. 2.3.1.19), (5) butyrate kinase (E.C. 2.7.2.7), (6) butyraldehyde dehydrogenase and (8) NADH-dependent butanol dehydrogenase A (E.C. 1.1.1.-);
on the metabolic pathway for synthesizing propionic acid and as part of propionate metabolism:
(1) succinate-propionate CoA-transferase, (2) acetate-CoA ligase or synthetase or propionate-CoA ligase or synthetase (E.C. 6.2.1.1) and (3) acetate-CoA ligase or synthetase or propionate-CoA ligase or synthetase (E.C. 6.2.1.1); and
on the metabolic pathway for synthesizing cadaverine and/or putrescine and as parts of lysine and/or arginine catabolism:
(1) lysine decarboxylase (E.C. 4.1.1.18) and/or arginine decarboxylase (E.C. 4.1.1.19), (2) agmatinase (E.C. 3.5.1.11) and (3) ornithine decarboxylase (E.C. 4.1.1.17).
Finally, nucleotide and amino acid sequences coding for these proteins/enzymes were completely determined by sequencing relevant genes in B. licheniformis DSM 13, and thus made available for the desired modification of the microorganisms of interest. They are compiled in the sequence listing for the present application. These involve the following nucleic acids (odd numbers) and amino acid sequences derived therefrom for enzymes or proteins as parts of those enzymes which consist of a plurality of subunits (even numbers below in each case):
putative branched-chain amino acid aminotransferase (E.C. 2.6.1.42), defined by SEQ ID NO. 1 and 2, putative branched-chain amino acid aminotransferase (E.C. 2.6.1.42) defined by SEQ ID NO. 3 and 4, lysine and/or arginine decarboxylase (protein SpeA; E.C. 4.1.1.18 or E.C. 4.1.1.19) defined by SEQ ID NO. 5 (speA gene) and 6, NADH-dependent butanol dehydrogenase A (protein YugJ; E.C. 1.1.1.-) defined by SEQ ID NO. 7 (yugJ gene) and 8, butyryl-CoA dehydrogenase (E.C. 1.3.99.25) or acyl-CoA dehydrogenase (E.C. 1.3.99.-) defined by SEQ ID NO. 9 and 10, butyryl-CoA dehydrogenase (E.C. 1.3.99.25) or acyl-CoA dehydrogenase (E.C. 1.3.99.-) defined by SEQ ID NO. 11 and 12, 3-hydroxybutyryl-CoA dehydrogenase (E.C. 1.1.1.157) defined by SEQ ID NO. 13 and 14, putative enoyl-CoA hydratase protein (E.C. 4.2.1.17) defined by SEQ ID NO. 15 and 16, probable enoyl-(3-hydroxyisobutyryl)-CoA hydrolase protein defined by SEQ ID NO. 17 and 18, probable enoyl-CoA hydratase (protein EchA8; E.C. 4.2.1.17) defined by SEQ ID NO. 19 (echA8 gene) and 20, acyl-CoA dehydrogenase (E.C. 1.3.99.-) defined by SEQ ID NO. 21 and 22, acetate-CoA ligase or propionate-CoA ligase (or synthetase; protein AcsA; E.C. 6.2.1.1) defined by SEQ ID NO. 23 (acsA gene) and 24, 3-hydroxybutyryl-CoA dehydratase (protein YngF; E.C. 4.2.1.55) defined by SEQ ID No. 25 (yngF gene) and 26, butyryl-CoA dehydrogenase (protein YusJ; E.C. 1.3.99.25) or acyl-CoA dehydrogenase (E.C. 1.3.99.-) defined by SEQ ID NO. 27 (yusJ gene) and 28, 3-hydroxyisobutyrate dehydrogenase (protein YkwC; E.C. 1.1.1.31) or oxidoreductase (E.C. 1.1.-.-) defined by SEQ ID NO. 29 (ykwC gene) and 30, probable phosphate butyryltransferase (E.C. 2.3.1.19) defined by SEQ ID NO. 31 and 32, probable butyrate kinase (E.C. 2.7.2.7) defined by SEQ ID NO. 33 and 34, acetate-CoA ligase or synthetase or propionate-CoA ligase or synthetase (protein AcsA; E.C. 6.2.1.1) defined by SEQ ID NO. 35 (acsA gene) and 36, acetate-CoA ligase or propionate-CoA ligase (protein Ytcl; E.C. 6.2.1.1) defined by SEQ ID NO. 37 (ytcl gene) and 38, lysine and/or arginine decarboxylase (protein speA; E.C. 4.1.1.18 or E.C. 4.1.1.19) defined by SEQ ID NO. 39 (speA gene) and 40, probable enoyl-CoA hydratase (E.C. 4.2.1.17) defined by SEQ ID NO. 41 (ysiB gene) and 42, similar to 3-hydroxy-acyl-CoA dehydrogenase (E.C. 1.1.1.35) defined by SEQ ID NO. 43 and 44, 3-methyl-2-oxobutanoate dehydrogenase or 2-oxoglutarate dehydrogenase E1 (E.C. 1.2.4.2) defined by SEQ ID NO. 45 and 46, probable acetate-CoA ligase or propionate-CoA ligase (protein YhfL; E.C. 6.2.1.1) or acid-CoA ligase (E.C. 6.2.1.-) defined by SEQ ID NO. 47 (yhfL gene) and 48 or agmatinase (E.C. 3.5.1.11) defined by SEQ ID NO. 49 (ywhG gene) and 50.
All of them are made available by the present application.
The stated problem is thus solved in the same way in principle by all 25 nucleic acids of SEQ ID NO. 1, 3, 5, 7, 9, 11, 13, 15, 17, 19, 21, 23, 25, 27, 29, 31, 33, 35, 37, 39, 41, 43, 45, 47 and 49 which are indicated in the sequence listing and are obtainable from B. licheniformis DSM 13, including an in each case corresponding homology region which is defined hereinafter and which effects a delimitation from the sequences described in the prior art. It is likewise solved by the gene products derived therefrom of SEQ ID NO. 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48 and 50, once again including a corresponding homology region defined hereinafter. The respective most similar nucleic acid and amino acid sequences described in the prior art are compiled in Example 2 (Table 1) with reference to the relevant database entries. The homology regions claimed in each case have been defined on the basis of this information. Solutions according to the invention of the stated problem are preferably in each case those nucleic acids and proteins which actually originate from microorganisms.
Which of these genes is preferred must be ascertained experimentally taking account of the individual strain to be cultured (and possibly different gene activities) and the respective metabolic situation (for example (over)supply of certain C or N sources) in the individual case. For this it is necessary for a series of several mutants, which are to be produced in the same way in principle, of the various relevant genes to be generated in parallel and cultured under conditions which are otherwise identical.
Further solutions are represented by fermentation processes in which one or more of the metabolic pathways for synthesizing (1) isovaleric acid (as part of leucine catabolism), (2) 2-methylbutyric acid and/or isobutyric acid (as part of valine and/or isoleucine catabolism), (3) butanol and/or butyric acid (as part of butyric acid metabolism), (4) propionic acid (as part of propionate metabolism) and/or (5) cadaverine and/or putrescine (as parts of lysine and/or arginine catabolism) are functionally inactivated, preferably via the abovementioned enzymes/proteins which are active on these pathways, and particularly preferably via the nucleotide sequences provided according to the invention. The latter can be used in a manner known per se and established in the prior art, for example for producing knock-out constructs and for introducing them via vectors in the host cells so that gene disruption takes place.
Further solutions are represented by appropriately modified microorganisms in particular relevant to industrial production, all fermentation processes in which these are employed, and among these especially those used to produce valuable products.
In addition, these gene products are available on the basis of the present invention for reaction mixtures or processes according to their respective biochemical properties, by which is meant in particular the synthesis of (1) isovaleric acid, (2) 2-methylbutyric acid and/or isobutyric acid, (3) butanol and/or butyric acid, (4) propionic acid and/or (5) cadaverine and/or putrescine.
The present invention enables, at least as far as these important metabolic pathways are concerned, causal combating of odors. This is because it is possible by switching off the identified metabolic pathways via the proteins involved with the aid of the nucleic acids coding for these proteins to substantially prevent the relevant substances being produced at all. It is thus possible firstly to keep the number of subsequent purification and working-up steps small, which is advantageous because they represent in each case a physicochemical stress on the desired product and reduce the yield; the product quality is thus overall improved. Secondly, the production conditions are improved per se, and the systems for filtration of the fermenter exit air can be kept simpler. This causal combating of odors acts, because it operates at the genetic level, on the properties of the respective microorganism itself, thus increasing its tolerability of further operations on this microorganism.
In particular, industrial fermentation is improved thereby, which ought also to lead to a reduction of the costs of the fermentation products.
In addition, the identified genes and gene products are thus available for diverse applications, for example for chemical and/or at least partly biocatalyzed synthesis of the relevant compounds.
As described in the examples of the present application, it was possible by sequencing the genomic DNA of the B. licheniformis DSM 13, the reference strain obtainable from the Deutschen Sammlung von Mikroorganismen and Zellkulturen GmbH, Mascheroder Weg 1b, 38124 Brunswick, to identify said 25 novel genes for this species. These are ones which code for enzymes or enzyme subunits which are involved in the reactions described herein for synthesizing odorous substances.
The most similar genes and relevant proteins in each case which are known in this connection in the prior art show the sequence homologies indicated in Example 2 (Table 1) of the present application. The range of protection covered in each case by the present application is defined thereby. Accordingly, all the following nucleic acids and proteins represent in principle equivalent embodiments of the present invention:
nucleic acid coding for a gene product (putative branched-chain amino acid aminotransferase; E.C. 2.6.1.42) involved in the synthesis of 2-methylbutyric acid and/or isobutyric acid and having a nucleotide sequence which shows at least 67% identity and with increasing preference at least 70%, 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 1, gene product (putative branched-chain amino acid aminotransferase; E.C. 2.6.1.42) involved in the synthesis of 2-methylbutyric acid and/or isobutyric acid and having an amino acid sequence which shows at least 73% identity and with increasing preference at least 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 2; nucleic acid coding for a gene product (putative branched-chain amino acid aminotransferase; E.C. 2.6.1.42) involved in the synthesis of 2-methylbutyric acid and/or isobutyric acid and having a nucleotide sequence which shows at least 78% identity and with increasing preference at least 80%, 85%, 90%, 92%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 3; gene product (putative branched-chain amino acid aminotransferase; E.C. 2.6.1.42) involved in the synthesis of 2-methylbutyric acid and/or isobutyric acid and having an amino acid sequence which shows at least 83% identity and with increasing preference at least 85%, 87.5% 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 4; nucleic acid speA coding for a gene product (lysine and/or arginine decarboxylase; E.C. 4.1.1.18 or 4.1.1.19) involved in the synthesis of cadaverine and/or putrescine and having a nucleotide sequence which shows at least 78% identity and with increasing preference at least 80%, 85%, 90%, 92%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 5; gene product SpeA (lysine and/or arginine decarboxylase; E.C. 4.1.1.18 or E.C. 4.1.1.19) involved in the synthesis of cadaverine and/or putrescine and having an amino acid sequence which shows at least 89% identity and with increasing preference at least 90%, 92%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 6; nucleic acid yugJ coding for a gene product (NADH-dependent butanol dehydrogenase A; E.C. 1.1.1.-) involved in the synthesis of butanol and/or butyric acid and having a nucleotide sequence which shows at least 81% identity and with increasing preference at least 85%, 90%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 7; gene product YugJ (NADH-dependent butanol dehydrogenase A; E.C. 1.1.1.-) involved in the synthesis of butanol and/or butyric acid and having an amino acid sequence which shows at least 93% identity and with increasing preference at least 94%, 95%, 96%, 97%, 98%, 98.5%, 99%, 99.5% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 8; nucleic acid coding for a gene product (acyl-CoA dehydrogenase; E.C. 1.3.99.-) involved in the synthesis of isovaleric acid, 2-methylbutyric acid, isobutyric acid, butanol and/or butyric acid and having a nucleotide sequence which shows at least 79% identity and with increasing preference at least 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 9; gene product (acyl-CoA dehydrogenase; E.C. 1.3.99.-) involved in the synthesis of isovaleric acid, 2-methylbutyric acid, isobutyric acid or butanol and/or butyric acid and having an amino acid sequence which shows at least 86% identity and with increasing preference at least 87.5%, 90%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 10; nucleic acid coding for a gene product (acyl-CoA dehydrogenase; E.C. 1.3.99.-) involved in the synthesis of isovaleric acid, 2-methylbutyric acid, isobutyric acid, butanol and/or butyric acid and having a nucleotide sequence which shows at least 64% identity and with increasing preference at least 65%, 70%, 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 11; gene product (acyl-CoA dehydrogenase; E.C. 1.3.99.-) involved in the synthesis of isovaleric acid, 2-methylbutyric acid, isobutyric acid, butanol and/or butyric acid and having an amino acid sequence which shows at least 67% identity and with increasing preference at least 70%, 75%, 80%, 85%, 87.5%, 90%, 92%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 12; nucleic acid coding for a gene product (3-hydroxybutyryl-CoA dehydrogenase; E.C. 1.1.1.157) involved in the synthesis of butanol and/or butyric acid and having a nucleotide sequence which shows at least 67% identity and with increasing preference at least 70%, 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 13; gene product (3-hydroxybutyryl-CoA dehydrogenase; E.C. 1.1.1.157) involved in the synthesis of butanol and/or butyric acid and having an amino acid sequence which shows at least 69% identity and with increasing preference at least 70%, 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 14; nucleic acid coding for a gene product (putative enoyl-CoA hydratase protein; E.C. 4.2.1.17) involved in the synthesis of isovaleric acid, 2-methylbutyric acid and/or isobutyric acid and having a nucleotide sequence which shows at least 65% identity and with increasing preference at least 70%, 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 15; gene product (putative enoyl-CoA hydratase protein; E.C. 4.2.1.17) involved in the synthesis of isovaleric acid, 2-methylbutyric acid and/or isobutyric acid and having an amino acid sequence which shows at least 62% identity and with increasing preference at least 65%, 70%, 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 16; nucleic acid coding for a gene product (probable enoyl-(3-hydroxyisobutyryl)-coenzyme A hydrolase protein) involved in the synthesis of isovaleric acid, 2-methylbutyric acid and/or isobutyric acid and having a nucleotide sequence which shows at least 66% identity and with increasing preference at least 70%, 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 17; gene product (probable enoyl-(3-hydroxyisobutyryl)-coenzyme A hydrolase protein) involved in the synthesis of isovaleric acid, 2-methylbutyric acid and/or isobutyric acid and having an amino acid sequence which shows at least 66% identity and with increasing preference at least 70%, 75%, 80%, 85%, 87.5%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 18; nucleic acid echA8 coding for a gene product (probable enoyl-CoA hydratase; E.C. 4.2.1.17) involved in the synthesis of isovaleric acid, 2-methylbutyric acid and/or isobutyric acid and having a nucleotide sequence which shows at least 48% identity and with increasing preference at least 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 19; gene product EchA8 (probable enoyl-CoA hydratase; E.C. 4.2.1.17) involved in the sythesis of isovaleric acid, 2-methylbutyric acid and/or isobutyric acid and having an amino acid sequence which shows at least 52% identity and with increasing preference at least 55%, 60%, 70%, 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 20; nucleic acid coding for a gene product (acyl-CoA dehydrogenase; E.C. 1.3.99.-) involved in the synthesis of isovaleric acid, 2-methylbutyric acid and/or isobutyric acid and having a nucleotide sequence which shows at least 54% identity and with increasing preference at least 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 21; gene product (acyl-CoA dehydrogenase) involved in the synthesis of isovaleric acid, 2-methylbutyric acid and/or isobutyric acid and having an amino acid sequence which shows at least 65% identity and with increasing preference at least 70%, 75%, 80%, 85%, 87.5%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 22; nucleic acid acsA coding for a gene product (acetyl-coenzyme A synthetase; E.C. 6.2.1.1) involved in the synthesis of propionic acid and having a nucleotide sequence which shows at least 67% identity and with increasing preference at least 70%, 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 23; gene product AscA (acetyl-coenzyme A synthetase; E.C. 6.2.1.1) involved in the synthesis of propionic acid and having an amino acid sequence which shows at least 65% identity and with increasing preference at least 70%, 75%, 80%, 85%, 87.5%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 24; nucleic acid yngF coding for a gene product (3-hydroxybutyryl-CoA dehydratase; E.C. 4.2.1.55) involved in the synthesis of butanol and/or butyric acid and having a nucleotide sequence which shows at least 68% identity and with increasing preference at least 70%, 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 25; gene product YngF (3-hydroxybutyryl-CoA dehydratase; E.C. 4.2.1.55) involved in the synthesis of butanol and/or butyric acid and having an amino acid sequence which shows at least 69% identity and with increasing preference at least 70%, 75%, 80%, 85%, 87.5%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 26; nucleic acid yusJ coding for a gene product (acyl-CoA dehydrogenase; E.C. 1.3.99.-) involved in the synthesis of isovaleric acid, 2-methylbutyric acid, isobutyric acid, butanol and/or butyric acid and having a nucleotide sequence which shows at least 77% identity and with increasing preference at least 80%, 85%, 90%, 92%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 27; gene product YusJ (acyl-CoA dehydrogenase; E.C. 1.3.99.-) involved in the synthesis of isovaleric acid, 2-methylbutyric acid, isobutyric acid, butanol and/or butyric acid and having an amino acid sequence which shows at least 86% identity and with increasing preference at least 87.5%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 28; nucleic acid ykwC coding for a gene product (hypothetical oxidoreductase; E.C. 1.1.-.-) involved in the synthesis of 2-methylbutyric acid and/or isobutyric acid and having a nucleotide sequence which shows at least 77% identity and with increasing preference at least 80%, 85%, 90%, 92%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 29; gene product YkwC (hypothetical oxidoreductase; E.C. 1.1.-.-) involved in the synthesis of 2-methylbutyric acid and/or isobutyric acid and having an amino acid sequence which shows at least 85% identity and with increasing preference at least 87.5%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 30; nucleic acid coding for a gene product (probable phosphate butyryltransferase; E.C. 2.3.1.19) involved in the synthesis of butanol and/or butyric acid and having a nucleotide sequence which shows at least 51% identity and with increasing preference at least 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 31; gene product (probable phosphate butyryltransferase; E.C. 2.3.1.19) involved in the synthesis of butanol and/or butyric acid and having an amino acid sequence which shows at least 69% identity and with increasing preference at least 70%, 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 32; nucleic acid coding for a gene product (probable butyrate kinase; E.C. 2.7.2.7) involved in the synthesis of butanol and/or butyric acid and having a nucleotide sequence which shows at least 77% identity and with increasing preference at least 80%, 85%, 90%, 92%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 33; gene product (probable butyrate kinase; E.C. 2.7.2.7) involved in the synthesis of butanol and/or butyric acid and having an amino acid sequence which shows at least 84% identity and with increasing preference at least 85%, 87.5%, 90%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 34; nucleic acid acsA coding for a gene product (acetyl-coenzyme A synthetase; E.C. 6.2.1.1) involved in the synthesis of propionic acid and having a nucleotide sequence which shows at least 79% identity and with increasing preference at least 80%, 85%, 90%, 92%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 35; gene product AcsA (acetyl-coenzyme A synthetase: E.C. 6.2.1.1) involved in the synthesis of propionic acid and having an amino acid sequence which shows at least 85% identity and with increasing preference at least 87.5%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 36; nucleic acid ytcl coding for a gene product (acetate-CoA ligase; E.C. 6.2.1.1) involved in the synthesis of propionic acid and having a nucleotide sequence which shows at least 74% identity and with increasing preference at least 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 37; gene product Ytcl (acetate-CoA ligase; E.C. 6.2.1.1) involved in the synthesis of propionic acid and having an amino acid sequence which shows at least 77% identity and with increasing preference at least 80%, 85%, 87.5%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 38; nucleic acid speA coding for a gene product (lysine and/or arginine decarboxylase; E.C. 4.1.1.18 or E.C. 4.1.1.19) involved in the synthesis of cadaverine and/or putrescine and having a nucleotide sequence which shows at least 68% identity and with increasing preference at least 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 39; gene product SpeA (lysine and/or arginine decarboxylase; E.C. 4.1.1.18 or E.C. 4.1.1.19) involved in the synthesis of cadaverine and/or putrescine and having an amino acid sequence which shows at least 66% identity and with increasing preference at least 70%, 75%, 80%, 85%, 87.5%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 40; nucleic acid ysiB coding for a gene product (probable enoyl-CoA hydratrase; E.C. 4.2.1.17) involved in the synthesis of isovaleric acid, 2-methylbutyric acid and/or isobutyric acid and having a nucleotide sequence which shows at least 75% identity and with increasing preference at least 80%, 85%, 90%, 92%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 41; gene product YsiB (probable enoyl-CoA hydratrase; E.C. 4.2.1.17) involved in the synthesis of isovaleric acid, 2-methylbutyric acid and/or isobutyric acid and having an amino acid sequence which shows at least 77% identity and with increasing preference at least 80%, 85%, 87.5%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 42; nucleic acid coding for a gene product (similar to 3-hydroxyacyl-CoA dehydrogenase; E.C. 1.1.1.35) involved in the synthesis of 2-methylbutyric acid and having a nucleotide sequence which shows at least 76% identity and with increasing preference at least 80%, 85%, 90%, 92%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 43; gene product (similar to 3-hydroxyacyl-CoA dehydrogenase) involved in the synthesis of 2-methylbutyric acid and having an amino acid sequence which shows at least 80% identity and with increasing preference at least 85%, 87.5%, 90%, 92%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 44; nucleic acid coding for a gene product (2-oxoglutarate dehydrogenase E1 component; E.C. 1.2.4.2) involved in the synthesis of isovaleric acid, 2-methylbutyric acid and/or isobutyric acid and having a nucleotide sequence which shows at least 80% identity and with increasing preference at least 80%, 85%, 90%, 92%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 45; gene product (2-oxoglutarate dehydrogenase E1 component; E.C. 1.2.4.2) involved in the synthesis of isovaleric acid, 2-methylbutyric acid and/or isobutyric acid and having an amino acid sequence which shows at least 82% identity and with increasing preference at least 85%, 87.5%, 90%, 92%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 46; nucleic acid yhfL coding for a gene product (probable acid-CoA ligase; E.C. 6.2.1.-) involved in the synthesis of propionic acid and having a nucleotide sequence which shows at least 67% identity and with increasing preference at least 70%, 75%, 80%, 85%, 90%, 92%, 94%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 47; gene product YhfL (probable acid-CoA ligase; E.C. 6.2.1.-) involved in the synthesis of propionic acid and having an amino acid sequence which shows at least 76% identity and with increasing preference at least 80%, 85%, 90%, 92%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 48; nucleic acid ywhG coding for a gene product (agmatinase; E.C. 3.5.1.11) involved in the synthesis of cadaverine and/or putrescine and having a nucleotide sequence which shows at least 85% identity and with increasing preference at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99% and particularly preferably 100% identity to the nucleotide sequence indicated in SEQ ID NO. 49; gene product YwhG (agmatinase; E.C. 3.5.1.11) involved in the synthesis of cadaverine and/or putrescine and having an amino acid sequence which shows at least 97% identity and with increasing preference at least 97.5%, 98%, 98.5%, 99%, 99.5% and particularly preferably 100% identity to the amino acid sequence indicated in SEQ ID NO. 50.
In connection with the present application, an expression of the form “at least X %” means “X % to 100%, including the extreme values X and 100 and all integral and non-integral percentages in between”.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 : Metabolic pathway for the formation of isovaleric acid. Explanations: see text
FIG. 2 : Metabolic pathway for the formation of 2-methylbutyric acid and/or isobutyric acid; aspect of the formation of 2-methylbutyric acid. Explanations: see text
FIG. 3 : Metabolic pathway for the formation of 2-methylbutyric acid and/or isobutyric acid; aspect of the formation of isobutyric acid. Explanations: see text
FIG. 4 : Metabolic pathway for the formation of butanol and/or butyric acid. Explanations: see text
FIG. 5 : Metabolic pathway for the formation of propionic acid. Explanations: see text
FIG. 6 : Metabolic pathway for the formation of cadaverine and/or putrescine; aspect of the formation of cadaverine. Explanations: see text
FIG. 7 : Metabolic pathway for the formation of cadaverine and/or putrescine; aspect of the formation of putrescine. Explanations: see text
DETAILED DESCRIPTION
The designations of the respective enzymes are governed by the specific reactions catalyzed by them, as are depicted for example in FIGS. 1 to 7 . (Detailed explanations of the figures and of the relevant metabolic pathways following hereinafter.) Thus, it is also possible for a single enzyme to be able to catalyze two reactions which are chemically virtually identical but are assigned to different pathways on the basis of the respective substrate. This may also be associated with a different enzyme classification (E.C. numbers) according to IUBMB. The enzyme designation is governed according to the invention according to the respective specific reaction. This is because the specific function which is implemented in the course of the present invention or is to be switched off where appropriate is also associated therewith.
For illustration, reference may be made by way of example to the enzyme which is indicated in SEQ ID NO. 18 and with which such a deviation is in fact located on the same metabolic pathway defined according to the invention. According to the relevant statement in SEQ ID NO. 17, this is a “probable enoyl-(3-hydroxyisobutyryl)-coenzyme A hydrolase protein”. At the time of the application, the IUBMB has not yet allocated an E.C. number for this reaction, which is why reference can be made for definition of the relevant enzymic activity only to reaction (6.) in FIG. 3 . On the same metabolic pathway for synthesizing 2-methylbutyric acid and/or isobutyric acid (as part of valine and/or isoleucine catabolism) there is also a reaction which is catalyzed by an enoyl-CoA hydratase, reaction (3.) in FIG. 3 ; the situation is likewise for reaction (7.) in FIG. 1 . A plurality of enzymes with E.C. class 4.2.1.17 are in each case suitable for this, for example those shown in SEQ ID NO. 16, 20 and 42 (see below), but also the enzyme according to SEQ ID NO. 18. In the course of this specific reaction, the enzyme according to SEQ ID NO. 18 is thus to be regarded as enoyl-CoA hydratase and assigned to E.C. class 4.2.1.17.
These genes and gene products can now be synthesized artificially by methods known per se, and without the need to reproduce the sequencing described in Example 1, in a targeted manner on the basis of these sequences.
As a further alternative thereto, it is possible to obtain the relevant genes from a Bacillus strain, in particular the strain B. licheniformis DSM 13 which is obtainable from the DSMZ, via PCR, it being possible to use the respective border sequences listed in the sequence listing for synthesizing primers. On use of other strains, the genes homologous thereto are obtained in each case, and the success of the PCR should increase with the closeness of the relationship of the selected strains to B. licheniformis DSM 13, because an increasing agreement in sequence also within the primer binding regions should be associated therewith.
As an alternative thereto, the nucleic acids indicated in the sequence listing can also be employed as DNA probes in order to detect the respective homologous genes in preparations of genomic DNA from other species. The procedure for this is known per se; as is the isolation of the genes obtained in this way, their cloning, their expression and obtaining of the relevant proteins. Consideration is given in this connection in particular to operating steps like those described for B. licheniformis itself in Example 1.
The existence of the relevant proteins in a strain of interest is detected in the first place by a chemical detection of whether the relevant odorous substances are formed. It is then possible for the enzymic activities presumed therefor to be ascertained in suitable detection reactions. This takes place for example by the starting compound relevant to the reaction in question being incubated with a cell extract. When the relevant enzymic activity is present, the products following in the relevant metabolic pathway should accumulate and, if all the subsequent enzymes are present, result in the odorous substance.
As detection at the level of molecular biology it is possible to synthesize proteins on the basis of the amino acid sequences shown in the present sequence listing, and to form antibodies against them. These can then be used for example in Western blots for detecting the homologous protein in cell extracts of the host cells of interest.
Among the nucleic acids mentioned herein and coding for a gene product of the invention involved in the synthesis of isovaleric acid, 2-methylbutyric acid, isobutyric acid, butanol, butyric acid, propionic acid, cadaverine and/or putrescine and defined as above on the basis of SEQ ID NO. 1, 3, 5, 7, 9, 11, 13, 15, 17, 19, 21, 23, 25, 27, 29, 31, 33, 35, 37, 39, 41, 43, 45, 47 or 49, preference is given in each case to that present naturally in a microorganism, preferably a bacterium, particularly preferably a Gram-positive bacterium, among these preferably one of the genus Bacillus , among these particularly preferably one of the species B. licheniformis and among these very particularly preferably B. licheniformis DSM13.
It is thus possible as just described comparatively easy in relation to neosynthesis for the relevant nucleic acids to be obtained from natural species, especially microorganisms. Among these, increasing preference is given in view of the stated problem to those which can be fermented and which can in fact be employed in industrial fermentations. These include in particular representatives of the genera Staphylococcus, Corynebacterium and Bacillus . Mention should be made among these for example of S. carnosus and C. glutamicum , and B. subtilis, B. licheniformis, B. amyloliquefaciens, B. agaradherens, B. lentus, B. globigii and B. alkalophilus . Most preference is given to B. licheniformis DSM 13 because it was possible to obtain therefrom exactly the sequences listed in the sequence listing.
These explanations apply in the same way to the relevant proteins.
Thus, among the gene products mentioned herein and involved in the synthesis of isovaleric acid, 2-methylbutyric acid, isobutyric acid, butanol, butyric acid, propionic acid, cadaverine and/or putrescine and defined on the basis of SEQ ID NO. 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48 or 50, preference is given in each case to those naturally formed by a microorganism, preferably by a bacterium, particularly preferably by a Gram-positive bacterium, among these preferably by one of the genus Bacillus , among these particularly preferably by one of the species B. licheniforms and among these very particularly preferably by B. licheniforms DSM 13.
The metabolic pathway utilized in Gram-positive bacteria of the genus Bacillus for synthesizing isovaleric acid as part of leucine catabolism is depicted in FIG. 1 . It ultimately represents an interface between the citrate cycle and/or fatty acid metabolism and pyruvate metabolism as far as the synthesis of leucine.
The enzymes involved in the reactions shown in FIG. 1 are, as mentioned above, the following, where the relevant number designates the respective reaction step indicated in the figure:
(1.) L-leucine dehydrogenase (E.C. 1.4.1.9), (2.) 3-methyl-2-oxobutanoate dehydrogenase or 2-oxoglutarate dehydrogenase E1 (E.C. 1.2.4.2), (3.) enzyme for hydrolyzing isovaleryl-CoA to isovaleric acid and coenzyme A (where non-enzymatic hydrolysis is also possible), (4.) acyl-CoA dehydrogenase (E.C. 1.3.99.-), (5.) methylcrotonyl carboxylase, (6.) 3-methylglutaconyl-CoA hydratase and (7.) enoyl-CoA hydratase (E.C. 4.2.1.17).
Solutions of the stated problem and thus independent embodiments of the present invention are thus represented by all processes for fermenting a microorganism in which at least one of the genes on a metabolic pathway for synthesizing isovaleric acid (as part of leucine catabolism) is functionally inactivated.
The advantages previously explained are associated with this solution.
Preference is given in this connection to any process of this type in which the microorganism now forms only 50% of the amount naturally formed under the same conditions, preferably now only 10%, particularly preferably no isovaleric acid.
These percentages (and all subsequent corresponding data for the further metabolic pathways) mean, in analogy to the statement made above for the sequence homology, once again all intermediate integral or fractional percentages in correspondingly preferred gradation. To determine these values, cells of an untreated strain and of a treated strain are fermented under conditions which are otherwise identical and, during the fermentation, the rate of formation of the unwanted odorous substance is suitably ascertained in a manner known per se. Since the strains are otherwise identical, the differences in the formation of this substance are attributable to the different gene activities. In this connection, any reduction in the formation of the odorous substance is desired according to the invention. Values comparable in percentage terms are obtained by taking samples (for instance from the exit air) from both fermentations and determining the content of the respective substance by analytical methods known per se. It is preferred to determine this value at the transition to the stationary phase of growth, because this time can usually be identified unambiguously and, at the same time, is normally associated with the highest metabolic rate.
Account is taken thereby of the generally high flexibility of microorganisms in relation to their metabolism. Thus, it is conceivable for inactivation of one gene to be partly compensated by enhancement of the activity of another gene and/or protein which is possibly not quite as effective in vivo. However, increasing preference is given to inactivation of the said pathway as extensively as possible. It is possible for this to test in the individual case the inactivation of various genes for the effectiveness according to the invention thereof and to select those with the strongest effect. It is additionally possible to combine a plurality of inactivations together.
Preference is given to a process according to the invention in which at least one of the following enzymes is functionally inactivated:
(1.) L-leucine dehydrogenase (E.C. 1.4.1.9), (2.) 3-methyl-2-oxobutanoate dehydrogenase or 2-oxoglutarate dehydrogenase E1 (E.C. 1.2.4.2), (3.) enzyme for hydrolyzing isovaleryl-CoA to isovaleric acid and coenzyme A, (4.) acyl-CoA dehydrogenase (E.C. 1.3.99.-), (5.) methylcrotonyl carboxylase, (6.) 3-methylglutaconyl-CoA hydratase and (7.) enoyl-CoA hydratase (protein) (E.C. 4.2.1.17).
This is because, as depicted in FIG. 1 , these activities may be connected with the metabolic pathway under consideration here.
As already stated above and described in the examples of the present application, it was possible by sequencing the genomic DNA of B. licheniformis DSM 13 to identify several of the genes coding for enzymes located on this pathway, or for subunits thereof. The genes involved are the following (the preceding number designates in each case the reaction in which the relevant enzyme is involved):
(2.) 3-methyl-2-oxobutanoate dehydrogenase or 2-oxoglutarate dehydrogenase E1 (E.C. 1.2.4.2) defined by SEQ ID NO. 45, (4.) a subunit of acyl-CoA dehydrogenase (E.C. 1.3.99.-) defined by SEQ ID NO. 9, 11, 21 or 27 (yusJ gene), and (7.) enoyl-CoA hydratase (protein) (E.C. 4.2.1.17) defined by SEQ ID NO. 15, 17, 19 (echA8 gene) or 41 (ysiB gene).
The amino acid sequences derived therefrom are indicated in SEQ ID NO. 46, 10, 12, 22, 28, 16, 18, 20 and 42, respectively. It was thus possible to identify these specific gene products in the course of the present invention as involved in this metabolic pathway for synthesizing isovaleric acid
(as part of leucine catabolism).
A process of the invention which is therefore preferred is one where the functionally inactivated enzyme is the homolog, which is naturally active in the relevant microorganism, to one of the following proteins from B. licheniformis DSM13:
(2.) 3-methyl-2-oxobutanoate dehydrogenase or 2-oxoglutarate dehydrogenase E1 (E.C. 1.2.4.2) defined by SEQ ID NO. 46, (4.) a subunit of acyl-CoA dehydrogenase (E.C. 1.3.99.-) defined by SEQ ID NO. 10, 12, 22 or 28, and (7.) enoyl-CoA hydratase (protein) (E.C. 4.2.1.17) defined by SEQ ID NO. 16, 18, 20 or 42.
A preferred process of the invention is one where the enzyme is functionally inactivated at the genetic level, preferably by inactivation of a gene which corresponds to the nucleic acid which codes for one of the following proteins from B. licheniformis DSM 13:
(2.) 3-methyl-2-oxobutanoate dehydrogenase or 2-oxoglutarate dehydrogenase E1 (E.C. 1.2.4.2) defined by SEQ ID NO. 45, (4.) a subunit of acyl-CoA dehydrogenase (E.C. 1.3.99.-) defined by SEQ ID NO. 9, 11, 21 or 27 (yusJ gene), and (7.) enoyl-CoA hydratase (protein) (E.C. 4.2.1.17) defined by SEQ ID NO. 15, 17, 19 (echA8 gene) or 41 (ysiB gene).
This is because, in accordance with the stated problem, it was preferably intended to find a causal solution, meaning one applying at the level of molecular biology. This is available with the stated nucleotide sequences. Example 3 explains how corresponding deletions can be undertaken; further statements concerning this are given hereinafter because they apply in principle to all described metabolic pathways.
A preferred process of the invention is thus one where, for inactivation at the genetic level, one of the nucleic acids of the invention within the region designated above homologous to
(2.) SEQ ID NO. 45, (4.) 9, 11, 21 or 27 and (7.) 15, 17, 19 or 41
has been used, preferably one, particularly preferably two parts in each case one of these sequences which in each case comprise at least 70 connected positions.
This can be detected for example by a molecular biological investigation (such as, for example, restriction, sequencing) of the gene region modified by the mutagenesis.
A further embodiment of the present invention is represented by the use of a gene which corresponds to the nucleic acid which codes for one of the following proteins of B. licheniformis DSM 13 for functional inactivation of a metabolic pathway for synthesizing isovaleric acid (as part of leucine catabolism) at the genetic level in a microorganism:
(2.) 3-methyl-2-oxobutanoate dehydrogenase or 2-oxoglutarate dehydrogenase E1 (E.C. 1.2.4.2) defined by SEQ ID NO. 45, (4.) a subunit of acyl-CoA dehydrogenase (E.C. 1.3.99.-) defined by SEQ ID NO. 9, 11, 21 or 27 (yusJ gene), and (7.) enoyl-CoA hydratase (protein) (E.C. 4.2.1.17) defined by SEQ ID NO. 15, 17, 19 (echA8 gene) or 41 (ysiB gene).
The same statements as previously made about the corresponding processes apply in principle to such uses.
Accordingly, a preferred use according to the invention of nucleic acids of the invention is within the region of homology designated above to
(2.) SEQ ID NO. 45, (4.) 9, 11, 21 or 27 and (7.) 15, 17, 19 or 41 for functional inactivation, preferably of one, particularly preferably of two parts in each case of one of these sequences, where these parts in each case comprise at least 70 connected positions.
Further embodiments based on these fermentation processes and uses are detailed hereinafter because they can be applied in principle to all the metabolic pathways described within the scope of the present invention.
The metabolic pathway utilized in Gram-positive bacteria of the genus Bacillus for synthesizing 2-methylbutyric acid as part of isoleucine catabolism is depicted in FIG. 2 ; the corresponding pathway proceeding via the same enzymes in principle for synthesizing isobutyric acid as part of valine catabolism is evident from FIG. 3 . This aspect, which is regarded in connection with the present application as a single pathway, of bacterial metabolism ultimately represents, like the pathway considered previously too, an interface between the citrate cycle and/or fatty acid metabolism and pyruvate metabolism as far as the synthesis of the two amino acids isoleucine and valine.
As already mentioned, the following enzymes are involved in the reactions shown in FIGS. 2 and 3 , in each case the relevant numbers of the reaction steps indicated in the figures being indicated:
(1.) branched-chain amino acid aminotransferase (E.C. 2.6.1.42; reaction 1 in FIGS. 2 and 3 ), (2.) 3-methyl-2-oxobutanoate dehydrogenase or 2-oxoglutarate dehydrogenase E1 (E.C. 1.2.4.2; reaction 2 in FIGS. 2 and 3 ), (3.) enzyme for hydrolyzing 2-methylbutyryl-CoA to 2-methylbutyric acid (reaction 3 in FIG. 2 ) or isobutyryl-CoA to isobutyric acid and coenzyme A (reaction 3 in FIG. 3 ; a non-enzymatic hydrolysis also being possible in both cases), (4.) acyl-CoA dehydrogenase (E.C. 1.3.99.-; reaction 4 in FIGS. 2 and 3 ), (5.) enoyl-CoA hydratase (protein) (E.C. 4.2.1.17; reaction 5 in FIGS. 2 and 3 ), (6.) 3-hydroxy-acyl-CoA dehydrogenase (E.C. 1.1.1.35) (reaction 6 in FIG. 2 ), (7.) acetyl-CoA acyltransferase (reaction step 7 in FIG. 2 ), (8.) enoyl-(3-hydroxyisobutyryl)-CoA hydrolase protein (step 6 in FIG. 3 ) and (9.) 3-hydroxyisobutyrate dehydrogenase (E.C. 1.1.1.31) or oxidoreductase (E.C. 1.1.-.-; step 7 in FIG. 3 ).
Solutions of the stated problem and thus independent embodiments of the present invention are thus represented by all processes for fermenting a microorganism in which at least one of the genes on a metabolic pathway for synthesizing 2-methylbutyric acid and/or isobutyric acid (as part of valine and/or isoleucine catabolism) is functionally inactivated.
The advantages already explained are associated with this solution.
Preference is given in this connection to any process of this type in which the microorganism now forms only 50% of the amount formed naturally under the same conditions, preferably now only 10%, particularly preferably no 2-methylbutyric acid and/or isobutyric acid.
Account is thereby taken, as explained above for the first metabolic pathway described, of the generally high flexibility of microorganisms in relation to their metabolism.
A preferred process of the invention is one in which at least one of the following enzymes is functionally inactivated:
(1.) branched-chain amino acid aminotransferase (E.C. 2.6.1.42), (2.) 3-methyl-2-oxobutanoate dehydrogenase or 2-oxoglutarate dehydrogenase E1 (E.C. 1.2.4.2), (3.) enzyme for hydrolyzing 2-methylbutyryl-CoA to 2-methylbutyric acid or isobutyryl-CoA to isobutyric acid and coenzyme A, (4.) acyl-CoA dehydrogenase (E.C. 1.3.99.-), (5.) enoyl-CoA hydratase (protein) (E.C. 4.2.1.17), (6.) 3-hydroxy-acyl-CoA dehydrogenase (E.C. 1.1.1.35), (7.) acetyl-CoA acyltransferase, (8.) enoyl-(3-hydroxyisobutyryl)-CoA hydrolase protein and (9.) 3-hydroxyisobutyrate dehydrogenase (E.C. 1.1.1.31) or oxidoreductase (E.C. 1.1.-.-).
This is because, as depicted in FIGS. 2 and 3 , these activities may be associated with the metabolic pathway considered.
As stated previously and described in the examples of the present application, it was possible by sequencing the genomic DNA of B. licheniformis DSM 13 to identify several of the genes which code for enzymes located on this pathway, or for subunits thereof. These involve the following genes (the preceding number designates in each case the reaction in which the relevant enzyme is involved):
(1.) branched-chain amino acid aminotransferase (E.C. 2.6.1.42) defined by SEQ ID NO. 1 or 3, (2.) 3-methyl-2-oxobutanoate dehydrogenase or 2-oxoglutarate dehydrogenase E1 (E.C. 1.2.4.2) defined by SEQ ID NO. 45, (4.) acyl-CoA dehydrogenase (E.C. 1.3.99.-) defined by SEQ ID NO. 9, 11, 21 or 27 (yusJ gene), (5.) enoyl-CoA hydratase (protein) (E.C. 4.2.1.17) defined by SEQ ID NO. 15, 17, 19 (echA8 gene) or 41 (ysiB gene), (6.) 3-hydroxy-acyl-CoA dehydrogenase (E.C. 1.1.1.35) defined by SEQ ID NO. 43, (8.) enoyl-(3-hydroxyisobutyryl)-CoA hydrolase protein defined by SEQ ID NO. 17 and (9.) 3-hydroxyisobutyrate dehydrogenase (E.C. 1.1.1.31) or oxidoreductase (E.C. 1.1.-.-) defined by SEQ ID NO. 29 (ykwC gene).
The amino acid sequences derived therefrom are indicated in SEQ ID NO. 2, 4, 46, 10, 12, 22, 28, 16, 18, 20, 42, 44, 18 and 30. It was thus possible in the course of the present invention to identify the specific gene products as involved in this metabolic pathway for synthesizing 2-methylbutyric acid and/or isobutyric acid (as part of valine and/or isoleucine catabolism).
A preferred process of the invention is therefore one where the functionally inactivated enzyme is the homolog, naturally active in the relevant microorganism, to one of the following proteins from B. licheniformis DSM 13:
(1.) branched-chain amino acid aminotransferase (E.C. 2.6.1.42) defined by SEQ ID NO. 2 or 4, (2.) 3-methyl-2-oxobutanoate dehydrogenase or 2-oxoglutarate dehydrogenase E1 (E.C. 1.2.4.2) defined by SEQ ID NO. 46, (4.) acyl-CoA dehydrogenase (E.C. 1.3.99.-) defined by SEQ ID NO. 10, 12, 22 or 28, (5.) enoyl-CoA hydratase (protein) (E.C. 4.2.1.17) defined by SEQ ID NO. 16, 18, 20 or 42, (6.) 3-hydroxy-acyl-CoA dehydrogenase (E.C. 1.1.1.35) defined by SEQ ID NO. 44, (8.) enoyl-(3-hydroxyisobutyryl)-CoA hydrolase protein defined by SEQ ID NO. 18 and (9.) 3-hydroxyisobutyrate dehydrogenase (E.C. 1.1.1.31) or oxidoreductase (E.C. 1.1.-.-) defined by SEQ ID NO. 30.
A preferred process of the invention is one where the enzyme is functionally inactivated at the genetic level, preferably by inactivation of a gene which corresponds to the nucleic acid which codes for one of the following proteins of B. licheniformis DSM 13:
(1.) branched-chain amino acid aminotransferase (E.C. 2.6.1.42) defined by SEQ ID NO. 1 or 3, (2.) 3-methyl-2-oxobutanoate dehydrogenase or 2-oxoglutarate dehydrogenase E1 (E.C. 1.2.4.2) defined by SEQ ID NO. 45, (4.) acyl-CoA dehydrogenase (E.C. 1.3.99.-) defined by SEQ ID NO. 9, 11, 21 or 27 (yusJ gene), (5.) enoyl-CoA hydratase (protein) (E.C. 4.2.1.17) defined by SEQ ID NO. 15, 17, 19 (echA8 gene) or 41 (ysiB gene), (6.) 3-hydroxy-acyl-CoA dehydrogenase (E.C. 1.1.1.35) defined by SEQ ID NO. 43, (8.) enoyl-(3-hydroxyisobutyryl)-CoA hydrolase protein defined by SEQ ID NO. 17 and (9.) 3-hydroxyisobutyrate dehydrogenase (E.C. 1.1.1.31) or oxidoreductase (E.C. 1.1.-.-) defined by SEQ ID NO. 29 (ykwC gene).
This is because, in accordance with the stated problem, the intention was preferably to find a causal solution, meaning one applying at the level of molecular biology. Example 3 explains how corresponding deletions can be undertaken; further statements concerning this are given hereinafter.
A preferred process of the invention is thus one where, for inactivation at the genetic level, one of the nucleic acids of the invention within the region designated above and homologous to
(1.) SEQ ID NO. 1 or 3, (2.) 45, (4.) 9, 11, 21 or 27, (5.) 15, 17, 19 or 41, (6.) 43, (8.) 17 and (9.) 29
has been used, preferably one, particularly preferably two parts in each case of one of these sequences which in each case comprise at least 70 connected positions.
A further embodiment of the present invention is represented by the use of a gene which corresponds to the nucleic acid which codes for one of the following proteins of B. licheniformis DSM 13 for functional inactivation of a metabolic pathway for synthesizing isovaleric acid (as part of leucine catabolism) at the genetic level in a microorganism:
(1.) branched-chain amino acid aminotransferase (E.C. 2.6.1.42) defined by SEQ ID NO. 1 or 3, (2.) 3-methyl-2-oxobutanoate dehydrogenase or 2-oxoglutarate dehydrogenase E1 (E.C. 1.2.4.2) defined by SEQ ID NO. 45, (4.) acyl-CoA dehydrogenase (E.C. 1.3.99.-) defined by SEQ ID NO. 9, 11, 21 or 27 (yusJ gene), (5.) enoyl-CoA hydratase (protein) (E.C. 4.2.1.17) defined by SEQ ID NO. 15, 17, 19 (echA8 gene) or 41 (ysiB gene), (6.) 3-hydroxy-acyl-CoA dehydrogenase (E.C. 1.1.1.35) defined by SEQ ID NO. 43, (8.) enoyl-(3-hydroxyisobutyryl)-CoA hydrolase protein defined by SEQ ID NO. 17 and (9.) 3-hydroxyisobutyrate dehydrogenase (E.C. 1.1.1.31) or oxidoreductase (E.C. 1.1.-.-) defined by SEQ ID NO. 29 (ykwC gene).
The same as previously stated concerning the corresponding processes applies in principle to such uses.
Accordingly, a preferred use according to the invention is of nucleic acids of the invention within the regions designated above and homologous to
(1.) SEQ ID NO. 1 or 3, (2.) 45, (4.) 9, 11, 21 or 27, (5.) 15, 17, 19 r 41, (6.) 43, (8.) 17 and (9.) 29
for functional inactivation, preferably of one, particularly preferably of two parts in each case of one of these sequences, where these parts comprise in each case at least 70 connected positions.
Further embodiments based on these fermentation processes and uses are detailed hereinafter.
The metabolic pathway utilized in Gram-positive bacteria of the genus Bacillus for synthesizing butanol and/or butyric acid as part of butyric acid metabolism is depicted in FIG. 4 . This metabolic pathway is ultimately derived from fatty acid metabolism.
As previously mentioned, the following enzymes are involved in the reactions shown in FIG. 4 , the relevant number designating the respective reaction step indicated in the figure:
(1.) 3-hydroxybutyryl-CoA dehydrogenase (E.C. 1.1.1.157), (2.) 3-hydroxybutyryl-CoA dehydrogenase (E.C. 4.2.1.55), (3.) butyryl-CoA dehydrogenase (E.C. 1.3.99.25), (4.) phosphate butyryltransferase (E.C. 2.3.1.19), (5.) butyrate kinase (E.C. 2.7.2.7), (6.) butyraldehyde dehydrogenase and (8.) NADH-dependent butanol dehydrogenase A (E.C. 1.1.1.-).
Reaction (7.) normally takes place by non-enzymatic oxidation by atmospheric oxygen.
Solutions of the stated problem and thus independent embodiments of the present invention are thus represented by all processes for fermenting a microorganism in which at least one of the genes on a metabolic pathway for synthesizing butanol and/or butyric acid (as part of butyric acid metabolism) is functionally inactivated.
The advantages already explained are associated with this solution.
Preference is given in this connection to any process of this type in which the microorganism now forms only 50% of the amount naturally formed under the same conditions, preferably now only 10%, particularly preferably no butanol or no butyric acid.
This takes account, as explained above for the first metabolic pathway described, of the generally high flexibility of microorganisms in relation to their metabolism.
A preferred process of the invention is one in which at least one of the following enzymes is functionally inactivated:
(1.) 3-hydroxybutyryl-CoA dehydrogenase (E.C. 1.1.1.157), (2.) 3-hydroxybutyryl-CoA dehydratase (E.C. 4.2.1.55), (3.) butyryl-CoA dehydrogenase (E.C. 1.3.99.25), (4.) phosphate butyryltransferase (E.C. 2.3.1.19), (5.) butyrate kinase (E.C. 2.7.2.7), (6.) butyraldehyde dehydrogenase and (8.) NADH-dependent butanol dehydrogenase A (E.C. 1.1.1.-).
This is because, as depicted in FIG. 4 , these activities can be associated with the metabolic pathway under consideration here.
As stated above and described in the examples of the present application, it was possible by sequencing the genomic DNA of B. licheniformis DSM 13 to identify several of the genes which code for enzymes located on this pathway, or for subunits thereof. These are the following genes (the preceding number designates in each case the reaction in which the relevant enzyme is involved):
(1.) 3-hydroxybutyryl-CoA dehydrogenase (E.C. 1.1.1.157) defined by SEQ ID NO. 13, (2.) 3-hydroxybutyryl-CoA dehydratase (E.C. 4.2.1.55) defined by SEQ ID NO. 25 (yngF gene), (3.) butyryl-CoA dehydrogenase (E.C. 1.3.99.25) defined by SEQ ID NO. 9, 11 or 27 (yusJ gene), (4.) phosphate butyryltransferase (E.C. 2.3.1.19) defined by SEQ ID NO. 31, (5.) butyrate kinase (E.C. 2.7.2.7) defined by SEQ ID NO. 33 and (8.) NADH-dependent butanol dehydrogenase A (E.C. 1.1.1.-) defined by SEQ ID NO. 7 (yugJ gene).
The amino acid sequences derived therefrom are indicated in SEQ ID NO. 14, 26, 10, 12, 28, 32, 34 and 8. It was thus possible in the course of the present invention to identify these specific gene products as involved in this metabolic pathway for synthesizing butanol and/or butyric acid (as part of butyric acid metabolism).
A preferred process of the invention is therefore one where the functionally inactivated enzyme is the homolog, which is naturally active in the relevant microorganism, to one of the following proteins from B. licheniformis DSM 13:
(1.) 3-hydroxybutyryl-CoA dehydrogenase (E.C. 1.1.1.157) defined by SEQ ID NO. 14, (2.) 3-hydroxybutyryl-CoA dehydratase (E.C. 4.2.1.55) defined by SEQ ID NO. 26, (3.) butyryl-CoA dehydrogenase (E.C. 1.3.99.25) defined by SEQ ID NO. 10, 12 or 28, (4.) phosphate butyryltransferase (E.C. 2.3.1.19) defined by SEQ ID NO. 32, (5.) butyrate kinase (E.C. 2.7.2.7) defined by SEQ ID NO. 34 and (8.) NADH-dependent butanol dehydrogenase A (E.C. 1.1.1.-) defined by SEQ ID NO. 8.
The preferred process according to the invention is one where the enzyme is functionally inactivated at the genetic level, preferably by inactivation of a gene which corresponds to the nucleic acid which codes for one of the following proteins of B. licheniformis DSM 13:
(1.) 3-hydroxybutyryl-CoA dehydrogenase (E.C. 1.1.1.157) defined by SEQ ID NO. 13, (2.) 3-hydroxybutyryl-CoA dehydratase (E.C. 4.2.1.55) defined by SEQ ID NO. 25 (yngF gene), (3.) butyryl-CoA dehydrogenase (E.C. 1.3.99.25) defined by SEQ ID NO. 9, 11 or 27 (yusJ gene), (4.) phosphate butyryltransferase (E.C. 2.3.1.19) defined by SEQ ID NO. 31, (5.) butyrate kinase (E.C. 2.7.2.7) defined by SEQ ID NO. 33 and (8.) NADH-dependent butanol dehydrogenase A (E.C. 1.1.1.-) defined by SEQ ID NO. 7 (yugJ gene).
This is because, in accordance with the stated problem, it was intended preferably to find a causal solution, meaning one applying at the level of molecular biology. Example 3 explains how corresponding deletions can be undertaken; further statements concerning this are given hereinafter.
Thus, a preferred process of the invention is one where, for inactivation at the genetic level, one of the nucleic acids of the invention within the region designated above and homologous to
(1.) SEQ ID NO. 13, (2.) 25, (3.) 9, 11 or 27, (4.) 31, (5.) 33 and (6.) 7
has been used, preferably one, particularly preferably two parts in each case of one of these sequences, which in each case comprise at least 70 connected positions.
A further embodiment of the present invention is represented by the use of a gene which corresponds to the nucleic acid which codes for one of the following proteins of B. licheniformis DSM 13 for functional inactivation of a metabolic pathway for synthesizing butanol and/or butyric acid (as part of butyric acid metabolism) at the genetic level in a microorganism:
(1.) 3-hydroxybutyryl-CoA dehydrogenase (E.C. 1.1.1.157) defined by SEQ ID NO. 13, (2.) 3-hydroxybutyryl-CoA dehydratase (E.C. 4.2.1.55) defined by SEQ ID NO. 25 (yngF gene), (3.) butyryl-CoA dehydrogenase (E.C. 1.3.99.25) defined by SEQ ID NO. 9, 11 or 27 (yusJ gene), (4.) phosphate butyryltransferase (E.C. 2.3.1.19) defined by SEQ ID NO. 31, (5.) butyrate kinase (E.C. 2.7.2.7) defined by SEQ ID NO. 33 and (8.) NADH-dependent butanol dehydrogenase A (E.C. 1.1.1.-) defined by SEQ ID NO. 7 (yugJ gene).
The same as has previously been stated concerning the corresponding processes applies in principle to such uses.
Accordingly, a preferred use according to the invention is of nucleic acids of the invention within the region designated above and homologous to
(1.) SEQ ID NO. 13, (2.) 25, (3.) 9, 11 or 27, (4.) 31, (5.) 33 and (8.) 7
for functional inactivation, preferably of one, particularly preferably of two parts in each case of one of these sequences, where these parts comprise in each case at least 70 connected positions.
Further embodiments based on these fermentation processes and uses are detailed hereinafter.
The metabolic pathway utilized in Gram-positive bacteria of the genus Bacillus for synthesizing propionic acid (as part of propionate metabolism) is depicted in FIG. 5 . This metabolic pathway ultimately represents an interface between the citrate cycle and fatty acid metabolism.
As already mentioned, the following enzymes are involved in the reactions shown in FIG. 5 , where the relevant number designates the respective reaction step indicated in the figure:
(1.) succinate-propionate CoA-transferase, (2.) acetate-CoA ligase or synthetase or propionate-CoA ligase or synthetase (E.C. 6.2.1.1) and (3.) acetate-CoA ligase or synthetase or propionate-CoA ligase or synthetase (E.C. 6.2.1.1).
Solutions of the stated problem and thus independent embodiments of the present invention are thus represented by all processes for fermenting a microorganism in which at least one of the genes on a metabolic pathway for synthesizing propionic acids (as part of propionate metabolism) is functionally inactivated.
The previously explained advantages are associated with this solution.
Preference is given in this connection to any process of this type in which the microorganism now forms only 50% of the amount naturally formed under the same conditions, preferably now only 10%, particularly preferably no propionic acid.
This takes account, as explained above for the first metabolic pathway described, of the generally high flexibility of microorganisms in relation to their metabolism.
A preferred process of the invention is one in which at least one of the following enzymes is functionally inactivated:
(1.) succinate-propionate CoA-transferase, (2.) acetate-CoA ligase or synthetase or propionate-CoA ligase or synthetase (E.C. 6.2.1.1) and (3.) acetate-CoA ligase or synthetase or propionate-CoA ligase or synthetase (E.C. 6.2.1.1).
This is because, as depicted in FIG. 5 , these activities can be connected with the metabolic pathway under consideration herein.
As already stated above and described in the examples in the present application, it was possible to identify by sequencing the genomic DNA of B. licheniformis DSM 13 several of the genes which code for enzymes located on this pathway, or for subunits thereof. These are the following genes (the preceding number designates in each case the reaction in which the relevant enzyme is involved):
acetate-CoA ligase or synthetase or propionate-CoA ligase or synthetase (E.C. 6.2.1.1) defined by SEQ ID NO. 35 (acsA gene), 37 (ytcl gene), 47 (yhfL gene) or 23 (acsA gene).
The amino acid sequences derived therefrom are indicated in SEQ ID NO. 36, 38, 48 and 24. It was thus possible to identify the specific gene products in the course of the present invention as involved in this metabolic pathway for synthesizing propionic acid (as part of propionate metabolism).
A preferred process of the invention is therefore one where the functionally inactivated enzyme is the homolog, which is naturally active in the relevant microorganism, to one of the following proteins from B. licheniformis DSM 13: acetate-CoA ligase or synthetase or propionate-CoA ligase or synthetase (E.C. 6.2.1.1) defined by SEQ ID NO. 36, 38, 48 or 24.
A preferred process of the invention is one where the enzyme is functionally inactivated at the genetic level, preferably by inactivation of a gene which corresponds to the nucleic acid which codes for one of the following proteins of B. licheniformis DSM 13: acetate-CoA ligase or synthetase or propionate-CoA ligase or synthetase (E.C. 6.2.1.1) defined by SEQ ID NO. 35 (acsA gene), 37 (ytcl gene), 47 (yhfL gene) or 23 (acsA gene).
This is because, in accordance with the stated problem, the intention was preferably to find a causal solution, meaning one applying at the level of molecular biology. Example 3 explains how corresponding deletions can be undertaken; further statements concerning this are given hereinafter.
A preferred process of the invention is thus one where, for the inactivation at the genetic level, one of the nucleic acids of the invention has been used within the region designated above and homologous to SEQ ID NO. 35, 37, 47 or 23, preferably one, particularly preferably two parts in each case of one of these sequences which comprise in each case at least 70 connected positions.
A further embodiment of the present invention is represented by the use of a gene which corresponds to the nucleic acid which codes for one of the following proteins of B. licheniformis DSM 13 for the functional inactivation of a metabolic pathway for synthesizing propionic acid (as part of propionate metabolism) at the genetic level in a microorganism: acetate-CoA ligase or synthetase or propionate-CoA ligase or synthetase (E.C. 6.2.1.1) defined by SEQ ID NO. 35 (acsA gene), 37 (ytcl gene), 47 (yhfL gene) or 23 (acsA gene).
The same as previously stated concerning the corresponding processes applies in principle to uses of this type.
Accordingly, preference is given to such a use according to the invention of nucleic acids of the invention within the region designated above and homologous to SEQ ID NO. 35, 37, 47 or 23 for functional inactivation, preferably of one, particularly preferably of two parts in each case of one of these sequences, where these parts comprise in each case at least 70 connected positions.
Further embodiments based on these fermentation processes and uses are detailed hereinafter.
The metabolic pathway utilized in Gram-positive bacteria of the genus Bacillus for synthesizing cadaverine and/or putrescine (as parts of lysine and/or arginine catabolism) is depicted in FIGS. 6 (for lysine and the cadaverine derived therefrom) and 7 (for arginine and the putrescine derived therefrom). This aspect, which is designated as a single pathway in the present application, of the bacterial metabolism is ultimately derived as side pathway from amino acid metabolism and in the second case additionally from the urea cycle.
As already mentioned, the following enzymes are involved in the reactions shown in FIGS. 6 and 7 , where the relevant number designates the respective reaction step indicated in the figures:
(1.) lysine decarboxylase (E.C. 4.1.1.18) and/or arginine decarboxylase (E.C. 4.1.1.19) (single demonstrated reaction in FIG. 6 ; step 1 in FIG. 7 ; the case where the same enzyme is able to catalyze both reactions also applies here), (2.) agmatinase (E.C. 3.5.1.11); step 2 in FIG. 7 ) and (3.) ornithine decarboxylase (E.C. 4.1.1.17; step 3 in FIG. 7 ).
Solutions of the stated problem and thus independent embodiments of the present invention are thus represented by all processes for fermenting a microorganism in which at least one of the genes on a metabolic pathway for synthesizing cadaverine and/or putrescine (as parts of lysine and/or arginine catabolism) is functionally inactivated.
The previously explained advantages are associated with this solution.
Preference is given in this connection to any process of this type in which the microorganism now forms only 50% of the amount naturally formed under the same conditions, preferably now only 10%, particularly preferably no cadaverine and/or no putrescine.
This takes account, as explained above for the first metabolic pathway described, of the generally high flexibility of microorganisms in relation to their metabolism.
A preferred process of the invention is one where at least one of the following enzymes is functionally inactivated:
(1.) lysine decarboxylase (E.C. 4.1.1.18) and/or arginine decarboxylase (E.C. 4.1.1.19), (2.) agmatinase (E.C. 3.5.1.11) and (3.) ornithine decarboxylase (E.C. 4.1.1.17).
This is because, as depicted in FIGS. 6 and 7 , these activities can be associated with the metabolic pathway under consideration here.
As stated above and described in the examples of the present application, it was possible by sequencing the genomic DNA of B. licheniformis DSM 13 to identify several of the genes coding for enzymes located on this pathway, or for subunits thereof. These are the following genes
(the preceding number designates in each case the reaction in which the relevant enzyme is involved): (1.) lysine and/or arginine decarboxylase (E.C. 4.1.1.18 or E.C. 4.1.1.19) defined by SEQ ID NO. 5 (speA gene) or 39 (speA gene) and (2.) agmatinase (E.C. 3.5.1.11) defined by SEQ ID NO. 49 (ywhG gene).
The amino acid sequences derived therefrom are indicated in SEQ ID NO. 6, 40 and 50. It was thus possible in the course of the present invention to identify these specific gene products as involved in this metabolic pathway for synthesizing cadaverine and/or putrescine (as parts of lysine and/or arginine catabolism).
A preferred process of the invention is therefore one where the functionally inactivated enzyme is the homolog, which is naturally active in the relevant microorganism, to one of the following proteins from licheniformis DSM 13:
(1.) lysine and/or arginine decarboxylase (E.C. 4.1.1.18 or E.C. 4.1.1.19) defined by SEQ ID NO. 6 or 40 and (2.) agmatinase (E.C. 3.5.1.11) defined by SEQ ID NO. 50.
A preferred process of the invention is one where the enzyme is functionally inactivated at the genetic level, preferably by inactivation of a gene which corresponds to the nucleic acid which codes for one of the following proteins of B. licheniformis DSM 13:
(1.) lysine and/or arginine decarboxylase (E.C. 4.1.1.18 or E.C. 4.1.1.19) defined by SEQ ID NO. 5 (speA gene) or 39 (speA gene) and (2.) agmatinase (E.C. 3.5.1.11) defined by SEQ ID NO. 49 (ywhG gene).
This is because, in accordance with the stated problem, the intention was preferably to find a causal solution, meaning one applying at the level of molecular biology. Example 3 explains how corresponding deletions can be undertaken; further statements concerning this are given hereinafter.
Thus, preference is given to a process of the invention where for the inactivation at the genetic level one of the nucleic acids of the invention within the region designated above and homologous to
(1.) SEQ ID NO. 5 or 39 and (2.) 49
has been used, preferably one, particularly preferably two parts in each case of one of these sequences which in each case comprise at least 70 connected positions.
A further embodiment of the present invention is represented by the use of a gene which corresponds to the nucleic acid which codes for one of the following proteins of B. licheniformis DSM 13 for functional inactivation of a metabolic pathway for synthesizing cadaverine and/or putrescine (as parts of lysine and/or arginine catabolism) at the genetic level in a microorganism:
(1.) lysine and/or arginine decarboxylase (E.C. 4.1.1.18 or E.C. 4.1.1.19) defined by SEQ ID NO. 5 (speA gene) or 39 (speA gene) and (2.) agmatinase (E.C. 3.5.1.11) defined by SEQ ID NO. 49 (ywhG gene).
The same as has previously been stated concerning corresponding processes applies in principle to such uses.
Accordingly, preference is given to a use according to the invention of nucleic acids of the invention within the region designated above and homologous to
(1.) SEQ ID NO. 5 or 39 and (2.) 49
for functional inactivation, preferably of one, particularly preferably of two parts in each case of one of these sequences, where these parts comprise in each case at least 70 connected positions.
Further embodiments based on these fermentation processes and uses are detailed hereinafter.
Embodiments which are preferred in each case of the uses described above according to the invention of the genes and/or nucleic acids on each of the described five metabolic pathways are those where the functional inactivation takes place during the fermentation of the microorganism.
This is because in accordance with the stated problem the intention was to improve the fermentation at the genetic level. On fermentation of microorganisms which have been correspondingly modified via these genes and/or nucleic acids is to be expected that the amount of the odorous and/or poisonous substances is less than with unmodified strains. This advantage, which emerges during the fermentation, is preferred according to the invention because it has advantageous effects both on the production process, meaning the fermentation process, and on the subsequent working up.
Among these, preference is given to any use of this type where (if present) with increasing preference 2, 3 or 4 of the genes mentioned for each metabolic pathway ((1.) for synthesizing isovaleric acid, (2.) for synthesizing 2-methylbutyric acid and/or isobutyric acid, (3.) for synthesizing butanol and/or butyric acid, (4) for synthesizing propionic acid and/or (5.) for synthesizing cadaverine and/or putrescine) are inactivated.
This is because, as already explained, microorganisms may in individual cases escape inactivation by activating an alternative pathway or at least enzymes with comparable reactions and thus continuing to form the relevant odorous and/or poisonous substance. This problem can be solved in particular by blocking a plurality of single reactions.
Preference is further given to any use of this type where (if present in the relevant microorganism) with increasing preference 2, 3, 4 or 5 of the metabolic pathways (1.) for synthesizing isovaleric acid, (2.) for synthesizing 2-methylbutyric acid and/or isobutyric acid, (3.) for synthesizing butanol and/or butyric acid, (4.) for synthesizing propionic acid and/or (5.) for synthesizing cadaverine and/or putrescine are blocked at least in part.
This is because firstly the inactivation of a single reaction may block a plurality of said pathways. This applies for example to butyryl-CoA dehydrogenase (E.C. 1.3.99.25) defined by SEQ ID NO. 9, 11 or 27 (yusJ gene) which occurs on the first three metabolic pathways mentioned; or to the three following enzymes or groups of enzymes which are equally involved in the two pathways mentioned first: 3-methyl-2-oxobutanoate dehydrogenase or 2-oxoglutarate dehydrogenase E1 (E.C. 1.2.4.2) defined by SEQ ID NO. 46, a subunit of acyl-CoA dehydrogenase (E.C. 1.3.99.-) defined by SEQ ID NO. 10, 12, 22 or 28, and enoyl-CoA hydratase (protein) (E.C. 4.2.1.17) defined by SEQ ID NO. 16, 18, 20 or 42. In these cases too, the enzymic activities are defined with reference to the reactions described above and indicated in the figures.
Secondly, it is possible by generally known methods of molecular biology to inactivate a plurality of genes in parallel, so that in principle all these pathways can be switched off and thus correspondingly favorable fermentation processes can be obtained.
In one alternative, all these uses of genes and/or of the described nucleic acids of the invention are ones where in each case a nucleic acid coding for an inactive protein and having a point mutation is employed.
Nucleic acids of this type can be generated by methods of point mutagenesis known per se. Such methods are described for example in relevant handbooks such as that of Fritsch, Sambrook and Maniatis “Molecular cloning: a laboratory manual”, Cold Spring Harbour Laboratory Press, New York, 1989. In addition, numerous commercial construction kits are now available therefor, for instance the QuickChange® kit from Stratagene, La Jolla, USA. The principle thereof is for oligonucleotides having single exchanges (mismatch primers) to be synthesized and hybridized with the gene in single-stranded form; subsequent DNA polymerization then affords corresponding point mutants. It is possible to use for this purpose the respective species-specific sequences of these genes. Owing to the high homologies, it is possible and particularly advantageous according to the invention to carry out this reaction on the basis of the nucleotide sequences provided in the sequence listing. These sequences can also serve to design appropriate mismatch primers for related species.
In one alternative, all these uses of genes and/or of the described nucleic acids of the invention are ones where in each case a nucleic acid with a deletion mutation or insertion mutation is employed, preferably comprising the border sequences, in each case comprising at least 70 to 150 nucleic acid positions, of the region coding for the protein.
These methods are also familiar per se to the skilled worker. It is thus possible to prevent the formation of one or more of the described gene products by the host cell by cutting out part of the relevant gene on an appropriate transformation vector via restriction endonucleases, and subsequently transforming the vector into the host of interest, where the active gene is replaced by the inactive copy via the homologous recombination which is still possible until then. In the embodiment of insertion mutation it is possible merely to introduce the intact gene interruptingly or, instead of a gene portion, another gene, for example a selection marker. Phenotypical checking of the mutation event is possible thereby in a manner known per se.
In order to enable these recombination events which are necessary in each case between the defective gene introduced into the cell and the intact gene copy which is endogenously present for example on the chromosome, it is necessary according to the current state of knowledge that in each case there is agreement in at least 70 to 150 connected nucleic acid positions, in each case in the two border sequences to the non-agreeing part, with the part lying between being immaterial. Accordingly, preferred embodiments are those including only two flanking regions with at least one of these sizes.
In an alternative embodiment of this use, nucleic acids having a total of two nucleic acid segments which in each case comprise at least 70 to 150 nucleic acid positions, and thus flank at least partly, preferably completely, the region coding for the protein, are employed. The flanking regions can in this connection be ascertained starting from the known sequences by methods known per se, for example with the aid of outwardly directed PCR primers and a preparation of genomic DNA as template (anchored PCR). This is because it is not obligatory for the segments to be protein-encoding in order to make it possible to exchange the two gene copies by homologous recombination. According to the present invention it is possible to design the primers required for this on the basis of the nucleotide sequences indicated in the sequence listing also for other species of Gram-positive bacteria and, among these, in particular for those of the genus Bacillus . As an alternative to this experimental approach it is possible to take such regions which are at least in part non-coding for many of the genes from related species, for example from B. subtilis database entries, for example the SubtiList database of the Institute Pasteur, Paris, France (http://genolist.pasteur.fr/SubtiList/genome.cgi) or the databases specified in Example 2.
The present invention is aimed in particular at providing genetically improved microorganisms for biotechnological production. Thus, every microorganism in which at least one of the genes which corresponds to the nucleic acid which codes for one of the following proteins of B. licheniformis DSM 13 is functionally inactivated represents an embodiment of the present invention:
putative branched-chain amino acid aminotransferase (E.C. 2.6.1.42) defined by SEQ ID NO. 1, putative branched-chain amino acid aminotransferase (E.C. 2.6.1.42) defined by SEQ ID NO. 3, lysine and/or arginine decarboxylase (protein SpeA; E.C. 4.1.1.18 or E.C. 4.1.1.19) defined by SEQ ID NO. 5 (speA gene), NADH-dependent butanol dehydrogenase A (protein YugJ; E.C. 1.1.1.-) defined by SEQ ID NO. 7 (yugJ gene), butyryl-CoA dehydrogenase (E.C. 1.3.99.25) or acyl-CoA dehydrogenase (E.C. 1.3.99.-) defined by SEQ ID NO. 9, butyryl-CoA dehydrogenase (E.C. 1.3.99.25) or acyl-CoA dehydrogenase (E.C. 1.3.99.-) defined by SEQ ID NO. 11, 3-hydroxybutyryl-CoA dehydrogenase (E.C. 1.1.1.157) defined by SEQ ID NO. 13, putative enoyl-CoA hydratase protein (E.C. 4.2.1.17) defined by SEQ ID NO. 15, probable enoyl-(3-hydroxyisobutyryl)-CoA hydrolase protein defined by SEQ ID NO. 17, probable enoyl-CoA hydratase (protein EchA8; E.C. 4.2.1.17) defined by SEQ ID NO. 19 (echA8 gene), acyl-CoA dehydrogenase (E.C. 1.3.99.-) defined by SEQ ID NO. 21, acetate-CoA ligase or propionate-CoA ligase (or synthetase; protein AcsA; E.C. 6.2.1.1) defined by SEQ ID NO. 23 (acsA gene), 3-hydroxybutyryl-CoA dehydratase (protein YngF; E.C. 4.2.1.55) defined by SEQ ID NO. 25 (yngF gene), butyryl-CoA dehydrogenase (protein YusJ; E.C. 1.3.99.25) or acyl-CoA dehydrogenase (E.C. 1.3.99.-) defined by SEQ ID NO. 27 (yusJ gene), 3-hydroxyisobutyrate dehydrogenase (protein YkwC; E.C. 1.1.1.31) or oxidoreductase (E.C. 1.1.-.-) defined by SEQ ID NO. 29 (ykwC gene), probable phosphate butyryltransferase (E.C. 2.3.1.19) defined by SEQ ID NO. 31, probable butyrate kinase (E.C. 2.7.2.7) defined by SEQ ID NO. 33, acetate-CoA ligase or synthetase or propionate-CoA ligase or synthetase (protein AcsA; E.C. 6.2.1.1) defined by SEQ ID NO. 35 (acsA gene), acetate-CoA ligase or propionate-CoA ligase (protein Ytcl; E.C. 6.2.1.1) defined by SEQ ID NO. 37 (ytcl gene), lysine and/or arginine decarboxylase (protein speA; E.C. 4.1.1.18 or E.C. 4.1.1.19) defined by SEQ ID NO. 39 (speA gene), probable enoyl-CoA hydratase (E.C. 4.2.1.17) defined by SEQ ID NO. 41 (ysiB gene), similar to 3-hydroxyacyl-CoA dehydrogenase (E.C. 1.1.1.35) defined by SEQ ID NO. 43, 3-methyl-2-oxobutanoate dehydrogenase or 2-oxoglutarate dehydrogenase E1 (E.C. 1.2.4.2) defined by SEQ ID NO. 45, probable acetate-CoA ligase or propionate-CoA ligase (protein YhfL; E.C. 6.2.1.1) or acid-CoA ligase (E.C. 6.2.1.-) defined by SEQ ID NO. 47 (yhfL gene) or agmatinase (E.C. 3.5.1.11) defined by SEQ ID NO. 49 (ywhG gene).
“Corresponds” means in this connection in each case a gene of the organism under consideration which codes for a gene product having the same biochemical activity as defined above in connection with the respective metabolic pathways. This is generally at the same time the gene of all those of this organism which are translated in vivo which shows the greatest homology in each case to the stated gene from B. licheniformis (usually more than 40% identity, as can be found by an alignment of the two sequences as carried out in Example 2).
Among these, in accordance with the above statements, there is increasing preference in each case for a microorganism in which 2, 3 or 4 of the genes mentioned for each metabolic pathway ((1.) for synthesizing isovaleric acid, (2.) for synthesizing 2-methylbutyric acid and/or isobutyric acid, (3.) for synthesizing butanol and/or butyric acid, (4.) for synthesizing propionic acid and/or (5.) for synthesizing cadaverine and/or putrescine) are inactivated.
In addition, in accordance with the above statements, there is increasing preference in each case for a microorganism in which 2, 3, 4 or 5 of the metabolic pathways (1.) for synthesizing isovaleric acid, (2.) for synthesizing 2-methylbutyric acid and/or isobutyric acid, (3.) for synthesizing butanol and/or butyric acid, (4.) for synthesizing propionic acid and/or (5.) for synthesizing cadaverine and/or putrescine are blocked at least in part.
In addition, among these in each case a microorganism which is a bacterium is preferred.
This is because they have particular importance for biotechnological production. On the other hand, the relevant pathways have been described for microorganisms of the genus Bacillus.
A microorganism which is preferred among these is in each case a Gram-negative bacterium, in particular one of the genera Escherichia Coli, Klebsiella, Pseudomonas or Xanthomonas , in particular strains of E. coli K12 , E. coli B or Klebsiella planticola , and very especially derivatives of the strains Escherichia coli BL21 (DE3), E. coli RV308 , E. coli DH5 α, E. coli JM109 , E. coli XL-1 or Klebsiella planticola (Rf).
This is because these are important strains for molecular biological operations on genes, for instance for cloning (see examples), and additionally important producer strains.
As alternative thereto, in each case a microorganism which is a Gram-positive bacterium is preferred, in particular one of the genera Bacillus, Staphylococcus or Corynebacterium , very especially of the species Bacillus lentus, B. licheniformis, B. amyloliquefaciens, B. subtilis, B. globigii or B. alcalophilus, Staphylococcus carnosus or Corynebacterium glutamicum , and among these very particularly preferably B. licheniformis DSM 13.
This is because these are particularly important for the biotechnological production of valuable products and proteins because they are naturally able to secrete them into the surrounding medium. On the other hand, they are increasingly related to the B. licheniformis employed for the present application, so that the working steps described and derived from the sequences disclosed in each case should proceed more successfully as the extent of relationship to B. licheniformis DSM 13 increases. It is thus to be assumed for example that a gene indicated in the sequence listing can, after point mutation, be used in a related species directly for a deletion mutation without the need to isolate the homologous gene from the strain itself for this purpose.
The present invention is aimed in particular at improving fermentation processes. Thus, every process for fermenting a microorganism of the invention described above represents an embodiment of the present invention.
These processes and the processes described above in each case in connection with an influence on one of the five metabolic pathways described are in particular processes where a valuable product is produced, in particular a low molecular weight compound or a protein.
This is because these are the essential areas of use of biotechnological production by fermentation of microorganisms.
Among these, preference is given in each case to a process where the low molecular weight compound is a natural product, a dietary supplement or a pharmaceutically relevant compound.
This is because they are important product groups for biotechnological production by fermentation of microorganisms.
Among such biotechnological processes for producing proteins by fermentation of microorganisms, preference is given in each case to a process where the protein is an enzyme, in particular one from the group of α-amylases, proteases, cellulases, lipases, oxidoreductases, peroxidases, laccases, oxidases and hemicellulases.
This is because these are important enzymes produced on the industrial scale, for example for incorporation in detergent or cleaning compositions.
In addition, the gene products provided according to the invention are available for further applications. Thus, the present invention is also implemented by any use of any gene product of the invention in a reaction mixture or process appropriate for its biochemical properties, which is defined as described above with reference to SEQ ID NO. 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48 or 50.
Among these are preferably included uses (1.) for synthesizing isovaleric acid, (2.) for synthesizing 2-methylbutyric acid and/or isobutyric acid, (3.) for synthesizing butanol and/or butyric acid, (4.) for synthesizing propionic acid and/or (5.) for synthesizing cadaverine and/or putrescine, where appropriate in suitable combination with further enzymes.
Thus, the products of the metabolic pathways described are simple organic chemical compounds for which there is certainly a need in chemistry, for example to employ them as starting materials for more complex syntheses. Preparation thereof can be considerably simplified, especially when stereochemical reactions are involved, by the use of appropriate enzymes, because they in most cases specifically form one enantiomer. The term used when such synthetic routes are undertaken in at least one reaction step by biological catalysts is biotransformation. All gene products of the invention are suitable in principle therefor.
The following examples illustrate the present invention further.
EXAMPLES
All molecular biological working steps follow standard methods as indicated for example in the handbook by Fritsch, Sambrook and Maniatis “Molecular cloning: a laboratory manual”, Cold Spring Harbour Laboratory Press, New York, 1989, or comparable relevant works. Enzymes and construction kits are employed in accordance with the respective manufacturer's instructions.
Example 1
Identification of the Nucleic Acids Shown in SEQ ID NO. 1, 3, 5, 7, 9, 11, 13, 15, 17, 19, 21, 23, 25, 27, 29, 31, 33, 35, 37, 39, 41, 43, 45, 47 and 49 from B. licheniformis DSM 13
The genomic DNA was prepared by standard methods from the strain B. licheniformis DSM 13, which is available to anyone from the Deutsche Sammiung von Mikroorganismen and Zelikulturen GmbH, Mascheroder Weg 1b, 38124 Brunswick, mechanically fractionated and fractionated by electrophoresis in a 0.8% agarose gel. For a shotgun cloning of the smaller fragments, the fragments 2 to 2.5 kb in size were eluted from the agarose gel, dephosphorylated and ligated as blunt-ended fragments into the Smal restriction cleavage site of the vector pTZ19R-Cm. This is a derivative which confers chloramphenicol resistance of the plasmid pTZ19R which is obtainable from Fermentas (St. Leon-Rot). A gene library of the smaller fragments was obtained thereby. As second shotgun cloning, the genomic fragments obtained by a partial restriction with the enzyme Saulllal were ligated into the SuperCos 1 vector system (“Cosmid Vector Kit”) from Stratagene, La Jolla, USA, resulting in a gene library over the predominantly larger fragments.
The relevant recombinant plasmids were isolated and sequenced from the bacteria E. Coli DH5α (D. Hannahan (1983): “Studies on transformation on Escherichia coli”; J. Mol. Microbiol ., volume 166, pages 557-580) obtainable by transformation with the relevant gene libraries. The dye termination method (dye terminator chemistry) was employed in this case, carried out by the automatic sequencers MegaBACE 1000/4000 (Amersham Bioscience, Piscataway, USA) and ABI Prism 377 (Applied Biosystems, Foster City, USA).
In this way, inter alia, the sequences SEQ ID NO. 1, 3, 5, 7, 9, 11, 13, 15, 17, 19, 21, 23, 25, 27, 29, 31, 33, 35, 37, 39, 41, 43, 45, 47 and 49 indicated in the sequence listing of the present application were obtained. The amino acid sequences derived therefrom are indicated—the relevant ones under the higher number in each case—under SEQ ID NO. 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48 and 50.
Example 2
Sequence Homologies
After ascertaining the DNA and amino acid sequences as in Example 1, in each case the most similar homologs disclosed to date were ascertained by searching the databases GenBank (National Center for Biotechnology Information NCBI, National Institute of Health, Bethesda, Md., USA), EMBL European Bioinformatics Institute (EBI) in Cambridge, Great Britain (http://www.ebi.ac.uk), Swiss-Prot (Geneva Bioinformatics (GeneBio) S.A., Geneva, Switzerland; http://www.genebio.com/sprot.html) and PIR (Protein Information Resource, National Biomedical Research Foundation, Georgetown University Medical Center, Washington, D.C., USA; http://www.pir.georgetown.edu). The nr (nonredundant) option was chosen in this connection.
The ascertained DNA and amino acid sequences were compared with one another via alignments in order to determine the degree of homology; the computer program used for this was Vector NTI® Suite Version 7, which is obtainable from Informax Inc., Bethesda, USA. In this case, the standard parameters of this program were used, meaning for comparison of the DNA sequences: K-tuple size: 2; Number of best Diagonals: 4; Window size: 4; Gap penalty: 5; Gap opening penalty: 15 and Gap extension penalty: 6.66. The following standard parameters applied to the comparison of the amino acid sequences: K-tuple size: 1; Number of best Diagonals: 5; Window size: 5; Gap penalty: 3; Gap opening penalty: 10 and Gap extension penalty: 0.1. The results of these sequence comparisons are compiled in Table 1 below, together with an indication of the respective enzyme names, meaning functions, E.C. numbers and the relevant metabolic pathways. The numbering of enzymes known in the prior art is the consistent nomenclature of the abovementioned databases.
TABLE 1
Genes and proteins of most similarity to the genes and proteins
respectively ascertained in Example 1.
The meanings therein are:
ID the SEQ ID NO. indicated in the sequence listing in the present application;
E.C. No. the number according to the international enzyme classification
(Enzyme Nomenclature of the IUBMB).
Name of the enzyme
(where possible of
the gene) and
Identity to the
Identity to the
additional
most closely
most closely
information where
Metabolic
related at the
related at the
ID
appropriate
E.C. No.
pathway
DNA level %
protein level %
1, 2
putative branched-
2.6.1.42
valine/isoleucine
62.40% to gb|AE017003.1|,
69% to
chain amino acid
catabolism
B. cereus ATCC
aminotransferase
aminotransferase
14579, section 6
IV from B.
of 18 of the
anthracis Ames
complete genome
(NP_655296.1)
3, 4
putative branched-
2.6.1.42
valine/isoleucine
73.80% to
79% to
chain amino acid
catabolism
emb|Z49992.1|BS
branched-chain
aminotransferase
CELABCD,
amino acid
B. subtilis genes
aminotransferase
celA, celB, celC,
from B. subtilis
celD and ywaA
168
(NP_391734.1)
5, 6
lysine and/or
4.1.1.18
cadaverine
74.00% to
85% to lysine
arginine
or
and/or
emb|X58433.1|BS
decarboxylase
decarboxylase
4.1.1.19
putrescine
CADDNA
from B. subtilis
(speA)
synthesis (lysine
B. subtilis , cad
(NP_389346;
and/or arginine
gene for lysine
A54546)
catabolism)
decarboxylase
7, 8
NADH-dependent
1.1.1.-
butyric acid
76.30% to
89% to NADH-
butanol
metabolism
emb|Z93934.1|BS
dependent
dehydrogenase A
Z93934,
butanol
(yugJ)
B. subtilis ,
dehydrogenase
genomic DNA
from B. subtilis
fragment from
168
patB to yugK
(NP_391015.1)
9, 10
acyl-CoA
1.3.99.-/
leucine
74.70% to
82% to short-
dehydrogenase
1.3.99.25
catabolism
emb|Z49782.1|BS
chain specific
(sic, i.e. more
valine/
DNA320D,
acyl-CoA
generally indicated
isoleucine
B. subtilis ,
dehydrogenase
in the sequence
catabolism,
chromosomal
from B. cereus
listing)/butyryl-
butyric acid
DNA (region 320-
ATCC 14579
CoA dehydrogenase
metabolism
321 degrees)
(NP_835003.1)
11, 12
acyl-CoA
1.3.99.-
leucine
59.30% to
63% to C-
dehydrogenase
catabolism
emb|Z49782.1|BS
terminal domain
(sic, i.e. more
DNA320D,
of acyl-CoA
generally indicated
B. subtilis ,
dehydrogenase
in the sequence
chromosomal
from B. anthracis
listing)/butyryl-
DNA (region 320-
Ames
CoA dehydrogenase.
321 degrees)
(NP_653803.1)
The first codon
ought to be
translated in vivo
as methionine
13, 14
3-hydroxyburyryl-
1.1.1.157
butyric cid
62.40% to
65% to the NAD-
CoA dehydrogenase
metabolism
gb|AE017015.1|,
binding domain
B. cereus ATCC
of 3-hydroxyacyl-
14579, section 18
CoA
of 18 of the
dehydrogenase,
complete genome
from B. anthracis
Ames
(NP_653804.1)
15, 16
putative enoyl-
4.2.1.17
leucine
61.00% to
58% to YhaR
CoA hydratase
catabolism,
emb|Y14078.1|BS
from B. subtilis
protein
valine/
Y14078,
168
isoleucine
B. subtilis , 8.7 Kb
(CAB12828.2)
catabolism
chromosomal
DNA:
downstream of
the glyB-prsA
region
17, 18
probable enoyl-
not yet allo-
leucine
61.90% to
62% to 3-
(3-hydroxy-
cated
catabolism,
gb|AE017031.1|,
hydroxy-
isobutyryl)-
valine/
B. anthracis
isobutyryl-
coenzyme A
isoleucine
Ames, section 8
coenzyme A
hydrolase protein
catabolism
of 18 of the
hydrolase from
complete genome
B. cereus ATCC
14579
(NP_832055.1;
AAP09256)
19, 20
probable enoyl-CoA
4.2.1.17
leucine
43.50% to
48% to 3-hydroxy-
hydratase (echA8).
catabolism,
gb|AC084761.2|,
butyryl-CoA
The first codon
valine/
Gallus gallus ,
dehydratase from
ought to be
isoleucine
clone WAG-69H2,
B subtilis 168
translated in vivo
catabolism
complete
(NP_390732.1)
as methionine
sequence
21, 22
actyl-CoA
1.3.99.-
leucine
49.90% to
61% to acyl-CoA
dehydrogenase
catabolism,
gb|AE015940.1|,
dehydrogenase
valine/
Clostridium tetani
from B. cereus
isoleucine
E88, section 5 of
ATCC 14579
catabolism
10 of the
(NP_832051.1)
complete genome
23, 24
acetyl-coenzyme
6.2.1.1
propionate
63.00% to
61% to acetyl-
A synthetase
metabolism
dbj|AP001511.1|,
CoA synthetase
(indicated thus in
B. halodurans ,
from B.
the sequence
genomic DNA,
halodurans
listing) or
section 5/14
(NP_242003.1)
propionate-CoA
ligase (acsA)
25, 26
3-hydroxybutyryl-
4.2.1.55
butyric acid
63.80% to
65% to
CoA dehydratase
metabolism
emb|Y13917.1|BS
hydroxybutyryl
(yngF)
Y13917,
dehydratase
B. subtilis , genes
from
ppsE, yngL,
B. subtilis
yngK, yotB, yngJ,
(AAF32340.1)
yngI, yngH, yngG
and yngF and partial genes
ppsD and yngE
27, 28
acyl-CoA
1.3.99./
leucine
72.90% to
82% of butyryl-
dehydrogenase
1.3.99.25
catabolism,
emb|Y13917.1|BS
CoA
(sic, i.e. more
valine/
Y13917,
dehydrogenase
generally,
isoleucine
B. subtilis , genes
from B. subtilis
indicated in the
catabolism,
ppsE, yngL,
168
sequence listing)/
butyric acid
yngK, yotB, yngJ,
(NP_389708.1)
butyryl-CoA
metabolism
yngI, yngH, yngG
dehydrogenase
and yngF and
(yusJ)
partial genes
ppsD and yngE
29, 30
3-hydroxy-
1.1.1.31 or 1.1.-.-
valine
72.80% to
81% to 3-
isobutyrate
catabolism
emb|AJ222587.1|
hydroxy
dehydrogenase/
BS16829KB,
isobutyrate
hypothetical
B. subtilis , 29 kB
dehydrogenase
oxidoreductase
DNA fragment
from B. subtilis
(sic, i.e. more
from the gene
168
generally,
ykwC to the gene
(NP_389279.1)
indicated in the
cse15
sequence listing)
(ykwC)
31, 32
probable phosphate
2.3.1.19
butyric acid
46.30% to
65% to
butyryl-transferase
metabolism
gb|S81735.1|S81
phosphate
735, leucine
butyryl-
dehydrogenase
transferase
from B. subtilis 168
(NP_390289.1)
33, 34
probable butyrate
2.7.2.7
butyric acid
72.50% to
80% to
kinase
metabolism
emb|Z99116.2|BS
branched-chain
UB0013,
fatty acid kinase
B. subtilis ,
from B. subtilis
complete genome
168
(section 13 of 21):
(NP_390287.1)
from 2409151 to
2613687
35, 36
acetyl-coenzyme A
6.2.1.1
propionate
74.90% to
81% to acetyl-
synthetase
metabolism
emb|Z99119.2|BS
CoA synthetase
(indicated thus in
UB0016,
from B. subtilis
the sequence
B. subtilis ,
168
listing) or
complete genome
(NP_390846.1)
propionate-CoA
(section 16 of 21):
and to acetate-
ligase (acsA)
from 3013458 to
CoA ligase from
3213379
B. subtilis
(P39062,
S39646)
37, 38
acetate-CoA ligase
6.2.1.1
propionate
70% to
73% to acetate-
(indicated thus in
metabolism
emb|Z99119.2|BS
CoA ligase from
the sequence
UB0016,
B. subtilis 168
listing) or
B. subtilis ,
(NP_390834.1,
propionate-CoA
complete genome
E69989)
ligase (ytcI).
(section 16 of 21):
The first codon
from 3013458 to
ought to be
3213379
translated in vivo
as methionine
39, 40
lysine and/or
4.1.1.18
cadaverine
63.40% to
62% to lysine
arginine
or
and/or
emb|Z99104.2|BS
decarboxylase
decarboxylase
4.1.1.19
putrescine
UB0001,
from B. subtilis
(speA)
synthesis
B. subtilis ,
168
(lysine and/or
complete genome
(NP_387908.1)
arginine
(section 1 of 21):
and B. perfrigens
catabolism)
from 1 to 213080
(NP_976355)
41, 42
probable enoyl-CoA
4.2.1.17
leucine
70.30% to
73% to 3-
hydratase (ysiB)
catabolism,
emb|Z75208.1|BS
hydroxybutyryl-
valine/
Z75208,
CoA dehydratase
isoleucine
B. subtilis , genomic
from B. subtilis
catabolism
sequence,
168
89009 bp
(NP_390732.1)
43, 44
similar to
1.1.1.35
isoleucine
71.60% to
76% to 3-
3-hydroxyacyl-CoA
catabolism
emb|Z99120.2|BS
hydroxyacyl-CoA
dehydrogenase
UB0017,
dehydrogenase
B. subtilis ,
from B. subtilis
complete genome
168
(section 17 of 21):
(NP_391163.1)
from 3213330 to
3414388
45, 46
3-methyl-2-
1.2.4.2
leucine
75.70% to
78% to E1
oxobutanoate
catabolism,
emb|X54805.1|BS
subunit of
dehydrogenase/
valine/
ODHA, B. subtilis ,
2-oxoglutarate
2-oxoglutarate
isoleucine
odhA gene for
dehydrogenase
dehydrogenase E1
catabolism
2-oxoglutarate
from B. subtilis
component (sic,
dehydrogenase
(CAB13829.2)
i.e. indicated
more generally
in the sequence
listing)
47, 48
probable acid-CoA
6.2.1.-
propionate
62.20% to
72% to long-
ligase (yhfL)
metabolism
gb|AE017001.1|,
chain fatty acid-
B. cereus ATCC
CoA ligase from
14579, section 4
B. subtilis 168
of 18 of the
(NP_388908.1)
complete genome
49, 50
agmatinase (ywhG)
3.5.1.11
cadaverine
80.9% to
95% to
and/or
B. subtilis , gene
agmatinase
putrescine
BSUB0020
(agmatine
synthesis (lysine
(Genebank,
ureohydrolase)
and/or arginine
complete
from B. subtilis
catabolism)
genome)
168 (P70999)
It is evident that the genes found and the gene products derived therefrom are respectively novel genes and proteins with a clear distance from the prior art disclosed to date.
Example 3
Functional Inactivation of One or More of the Genes Shown in SEQ ID NO. 1, 3, 5, 7, 9, 11, 13, 15, 17, 19, 21, 23, 25, 27, 29, 31, 33, 35, 37, 39, 41, 43, 45, 47 and 49 in B. licheniformis
Principle of the Preparation of a Deletion Vector
Each of these genes can be functionally inactivated for example by means of a so-called deletion vector. This procedure is described per se for example by J. Vehmaanperä et al. (1991) in the publication “Genetic manipulation of Bacillus amyloliquefaciens”; J. Biotechnol ., volume 19, pages 221-240.
A suitable vector for this is pE194 which is characterized in the publication “Replication and incompatibility properties of plasmid pE194 in Bacillus subtilis ” by T. J. Gryczan et al. (1982), J. Bacteriol ., volume 152, pages 722-735. The advantage of this deletion vector is that it possesses a temperature-dependent origin of replication. pE194 is able to replicate in the transformed cell at 33° C., so that initial selection for successful transformation takes place at this temperature. Subsequently, the cells comprising the vector are incubated at 42° C. The deletion vector no longer replicates at this temperature, and a selection pressure is exerted on the integration of the plasmid via a previously selected homologous region into the chromosome. A second homologous recombination via a second homologous region then leads to excision of the vector together with the intact gene copy from the chromosome and thus to deletion of the gene which is located in the chromosome in vivo. Another possibility as second recombination would be the reverse reaction to integration, meaning recombination of the vector out of the chromosome, so that the chromosomal gene would remain intact. The gene deletion must therefore be detected by methods known per se, for instance in a southern blot after restriction of the chromosomal DNA with suitable enzymes or with the aid of the PCR technique on the basis of the size of the amplified region.
It is thus necessary to select two homologous regions of the gene to be deleted, each of which should include at least 70 base pairs in each case, for example the 5′ region and the 3′ region of the selected gene. These are cloned into the vector in such a way that they flank a part coding for an inactive protein, or are in direct succession, omitting the region in between. The deletion vector is obtained thereby.
Deletion of the Genes Considered Here
A deletion vector of the invention is constructed by PCR amplification of the 5′ and 3′ regions of one of these genes of interest in each case. The sequences SEQ ID NO. 1, 3, 5, 7, 9, 11, 13, 15, 17, 19, 21, 23, 25, 27, 29, 31, 33, 35, 37, 39, 41, 43, 45, 47 and 49 indicated in the sequence listing are available for designing suitable primers and originate from B. licheniformis , but ought also to be suitable, because of the homologies to be expected, for other species, especially of the genus Bacillus.
The two amplified regions suitably undergo intermediate cloning in direct succession on a vector useful for these operations, for example on the vector pUC18 which is suitable for cloning steps in E. coli.
The next step is a subcloning into the vector pE194 selected for deletion, and transformation thereof into B. subtilis DB104, for instance by the method of protoplast transformation according to Chang & Cohen (1979; “High Frequency Transformation of Bacillus subtilis Protoplasts by Plasmid DNA”; Molec. Gen. Genet . (1979), volume 168, pages 111-115). All working steps must be carried out at 33° C. in order to ensure replication of the vector.
In a next step, the vector which has undergone intermediate cloning is likewise transformed by the method of protoplast transformation into the desired host strain, in this case B. licheniformis . The transformants obtained in this way and identified as positive by conventional methods (selection via the resistance marker of the plasmid; check by plasmid preparation and PCR for the insert) are subsequently cultured at 42° C. under selection pressure for presence of the plasmid through addition of erythromycin. The deletion vector is unable to replicate at this temperature, and the only cells to survive are those in which the vector is integrated into the chromosome, and this integration most probably takes place in homologous or identical regions. Excision of the deletion vector can then be induced subsequently by culturing at 33° C. without erythromycin selection pressure, the chromosomally encoded gene being completely deleted from the chromosome. The success of the deletion is subsequently checked by southern blotting after restriction of the chromosomal DNA with suitable
Such transformants in which the relevant gene is deleted are normally additionally distinguished by a limitation on the formation of the odorous or poisonous substance resulting from the relevant metabolic pathway. In the cases where the cell has no substitute pathway for synthesizing the relevant compound, the relevant metabolic pathway is completely blocked so that this compound is no longer formed at all, and the strain modified in this way no longer has the relevant odorous component.
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The present invention relates to 25 hitherto undescribed genes of B. licheniformis and gene products derived therefrom and all sufficiently homologous nucleic acids and proteins thereof. They occur in five different metabolic pathways for the formation of odorous substances. The metabolic pathways in question are for the synthesis of: 1) isovalerian acid (as part of the catabolism of leucine), 2) 2-methylbutyric acid and/or isobutyric acid (as part of the catabolism of valine and/or isoleucine), 3) butanol and/or butyric acid (as part of the metabolism of butyric acid), 4) propyl acid (as part of the metabolism of propionate) and/or 5) cadaverine and/or putrescine (as parts of the catabolism of lysine and/or arginine). The identification of these genes allows biotechnological production methods to be developed that are improved to the extent that, to assist these nucleic acids, the formation of the odorous substances synthesized via these metabolic pathways can be reduced by deactivating the corresponding genes in the micro-organism used for the biotechnological production. In addition, these gene products are thus available for preparing reactions or for methods according to their respective biochemical properties.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to the fabrication of an integrated circuit structure in which silicidation is selectively performed within individual integrated circuit structures to reduce current leakage.
[0002] Today, our society is heavily dependent on high-tech electronic devices for everyday activity. Integrated circuits are the components that give life to our electronic devices. Integrated circuits, including memory components and logic components, are found in widespread use throughout the world, in appliances, in televisions and personal computers, and even in automobiles. Additionally, modern manufacturing and production facilities are becoming increasingly dependent on the use of machines controlled by integrated circuits for operational and production efficiencies. Indeed, in many ways, our everyday life could not function as it does without integrated circuits. These integrated circuits are manufactured in huge quantities in our country and abroad. Improved integrated circuit manufacturing processes have led to drastic price reductions and performance enhancements for these devices. Examples of performance enhancements include faster processing speeds and reduced power usage.
[0003] The traditional integrated circuit memory cell fabrication process begins with a wafer of silicon and involves four basic operations: 1) layering, 2) patterning, 3) doping, and 4) heat treatment. Layering is the process of depositing materials which have different conductive characteristics such as insulators or conductors in layers on the silicon wafer until the devices are complete. These layers of material can be deposited in geometric patterns so that materials with different conductive characteristics are stacked on top of each other to create an operational integrated circuit in three dimensions. The patterning process used to fabricate integrated circuits is typically performed using lithography followed by a variety of subtractive (etch) and additive (deposition) processes. Doping can be used to create areas of P type (hole-mobile) silicon or N type (electron-mobile) silicon. Complementary metal-oxide-semiconductors (CMOS) are composed of complementary P type and N type Field Effect Transistors (PFETs and NFETS). Heat treatment can be used to activate dopants and repair damage in wafers (annealing) or to provide electrical connections between metal layers and silicon layers (alloying). These fabrication methods are well known in the art.
[0004] One process regularly used in the fabrication of semiconductor structures is silicidation. Silicidation is a process by which a conductive layer of metal-silicon alloy is formed in an integrated circuit structure. Usually, silicidation occurs by blanketing a layer of metal, most commonly titanium or cobalt, across an entire wafer surface and heat-treating the surface to form a conductive metal-silicon compound wherever silicon is exposed. Metal-silicon alloys such as titanium disilicide (TiSi2) or cobalt disilicide (CoSi2) can be formed at the areas of exposed silicon. Silicidation is desirable in semiconductor structures in many instances because the application of this conductive layer reduces the resistance in silicon active regions, especially in polysilicon lines. This reduction in resistance will reduce the amount of time that it takes for a signal to travel through the chip or the integrated circuit, will reduce the voltage at which a chip can operate, and will improve the chip's performance.
[0005] While silicidation may reduce resistance between elements, allowing the elements to operate more effectively, this same process of silicidation may also exacerbate current leakage. Current leakage increases power usage and reduces battery life. While competitive forces demand the improved performance associated with silicidation, those same competitive forces also demand reductions in power usage of integrated circuits. Reduced power usage leads to highly desirable longer battery life for devices such as portable computers, cellular telephones, and other portable devices.
[0006] Therefore, there exists a need to improve the performance of integrated circuits or chips while at the same time reducing power usage of the circuit.
BRIEF SUMMARY OF THE INVENTION
[0007] In a first aspect, the invention comprises a semiconductor structure comprising an N+ diffusion and a P+ diffusion formed in a semiconductor substrate; a polysilicon line formed on the substrate intersecting the N+ diffusion and the P+ diffusion; wherein the polysilicon line has a P+ region, an N+ region and an N+/P+ junction area therebetween; a silicide strap extending across the N+/P+ junction area of the polysilicon line wherein the suicide strap forms an electrical connection between the P+ region of the polysilicon line and the N+ region of the polysilicon line; and wherein the N+ diffusion or the P+ diffusion are not silicided.
[0008] In a second aspect, the invention comprises a method for forming a semiconductor apparatus comprising the steps of forming an N+ diffusion and a P+ diffusion; forming a polysilicon line, the polysilicon line having a P+ region and an N+ region, the polysilicon line having an N+/P+ junction area wherein said junction area comprises the area where the P+ region of the polysilicon line and the N+region of the polysilicon line abut each other; and, selectively forming a silicide strap extending across the junction area, wherein the silicide strap forms an electrical connection between the P+ region of the polysilicon line and the N+ region of the polysilicon line; and selectively preventing the formation of silicide on the N+ diffusion and the P+ diffusion.
[0009] In the invention, by selectively applying silicide at the N+/P+ junction, a low resistance connection can be made between the N+ and P+ regions of the polysilicon line, which increases the conductivity in this region. By selectively not applying silicide over the NFET and PFET regions, the current leakage that occurs as a result of blanket silicidation is minimized.
[0010] The foregoing and other 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.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] The embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like designations denote like elements, and
[0012] [0012]FIG. 1 is a cross-section through the gate area of a semiconductor transistor illustrating the types of leakage that can occur with silicidation;
[0013] [0013]FIG. 2 is a flow chart illustrating an embodiment of steps in the fabrication of a semiconductor structure of the present invention;
[0014] [0014]FIG. 3 is a cross-sectional view taken at line 50 of FIG. 1, of the region of selective silicidation, illustrating steps in the fabrication of the present invention;
[0015] [0015]FIG. 4 is a cross-sectional view taken at line 50 of FIG. 1, of the region of selective silicidation, illustrating steps in the fabrication of the present invention;
[0016] [0016]FIG. 5 is a cross-sectional view taken at line 50 of FIG. 1, of the region of selective silicidation, illustrating steps in the fabrication of the present invention; and,
[0017] [0017]FIG. 6 is a top view of an SRAM cell illustrating the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Best Mode for Carrying Out the Invention
[0019] This invention provides a device and method to selectively allow silicide to form on parts of an integrated circuit structure and block silicide from forming on other parts of an integrated circuit structure so that the benefits of silicidation, decreased resistance between elements, can be achieved while reducing unwanted byproducts of silicidation including current leakage between elements.
[0020] Semiconductor structures can be treated or doped with chemicals to make N type regions, electron conduction regions, or P type regions, hole conduction regions. The creation of these regions is an essential step in producing the complementary P type and N type field effect transistors (PFETs and NFETs) which are components of Complementary Metal Oxide Semiconductor (CMOS) devices. One such CMOS device is a Static Random Access Memory or SRAM device. While an SRAM cell is the embodiment that will be described here, those of ordinary skill in the art will recognize that the invention may be applied to any semiconductor structure where P type polysilicon abuts N type polysilicon.
[0021] Silicidation is a valuable and helpful process in the fabrication of semiconductor structures.
[0022] Silicidation decreases the resistance of silicon active regions, especially polysilicon lines. This reduction in resistance reduces the amount of time required for a signal to travel through the chip and also reduces the voltage at which a chip can operate. Also, silicidation creates an electrical short between N type and P type regions that would otherwise exhibit diodic behavior. Therefore, silicidation improves the performance of a semiconductor structure or chip.
[0023] Silicidation may also cause current leakage. This current leakage can be a significant portion of the chip standby leakage. Turning now to the figures, FIG. 1 illustrates several types of undesirable current leakage that may occur as a result of silicidation. FIG. 1. is a cross-section across the polysilicon gate 21 of a typical NFET 20 . The NFET 20 of FIG. 1 is shown to illustrate a typical CMOS structure and is not intended to limit the scope of the invention. FIG. 1 illustrates a silicon wafer 26 that has been patterned to define an N+ diffusion, which includes source/drain regions 22 bounded by regions of shallow trench isolation (STI) 25 . The source/drain 22 regions are spanned by a polysilicon gate 21 . The polysilicon gate 21 can be a stacked gate or any other well-known gate architecture. The polysilicon gate 21 may have a layer of gate oxide 64 . Spacers 24 may be present along the sides of the gate 21 . Spacers 24 can be made from a combination of silicon oxide and/or silicon nitride which are both electrical insulators. These spacers 24 can be present to electrically isolate the gate from the source/drain regions.
[0024] In a typical blanket application of silicide, the exposed face of the semiconductor structure is coated with metal such as titanium or cobalt and heat treated so that, in those regions where silicon is exposed, a silicide layer 23 (for example titanium disilicide (TiSi2) or cobalt disilicide (CoSi2)) is formed. In the absence of exposed silicon, no silicide is formed, and unreacted metal can be selectively removed. As illustrated in FIG. 1, silicidation may enhance current leakage in an NFET structure 20 at several locations. While FIG. 1 illustrates several areas which may exhibit current leakage, FIG. 1 is not exhaustive of the types of current leakages which might occur.
[0025] Ideally, no silicide is formed on the surface of the spacers 24 because the spacers 24 are composed of silicon oxide and/or silicon nitride. Therefore, when the silicidation step is performed, no silicide will form because there is no exposed silicon present on the spacers to react with the siliciding metal. However, after the silicidation step, some small amount of residual conducting material may be left on the spacers, resulting in some small amount of leakage between the gate and the source or drain. This “over the spacer leakage” may be a source of current leakage in a typical device.
[0026] Gate-induced Drain Leakage (GIDL) 41 is a parasitic leakage inherent to all CMOS devices and becomes relevant for low leakage devices where GIDL and sub-threshold source to drain current becomes comparable. GIDL 41 is current that flows between the drain and the substrate and is caused by an increase in the electric field under the overlap region due to the proximity of the poly Si gate material.
[0027] In general, silicided N type FETs have higher GIDL values than non-silicided N type FETs. This may be due to several factors. First, during the process of silicidation, silicide may spike deep into the surface of the semiconductor structure. This spiking is referred to as a silicide defect 42 . When silicide defects 42 occur over the source/drain active silicon regions, this suicide defect 42 may result in current leakage into the substrate (wafer) 26 . Second, current leakage may also occur at the edge 43 of the shallow trench isolation (STI) 25 where it meets the silicon wafer 26 . In theory, the surface of the silicon active area or source/drain area 22 and the surface of the adjacent STI 25 is perfectly flat. However, in practice, there may be a depression at this location or the STI 25 may be weak at this abutment. During the process of silicidation, silicide can pool in this depression, or cause “pull-down” as illustrated in FIG. 1. This effect may cause current leakage to the silicon substrate 26 .
[0028] In addition, in theory, a perfectly even and uniform layer of metals can be applied to the surface of a semiconductor device to form a perfect uniform layer of silicide. In practice, it can be very difficult to form a perfectly uniform layer of silicide. Silicide may not form evenly in very small active areas of silicon and/or in small active areas of silicon between polysilicon lines called “canyons.” This poor silicide formation may lead to leakage similar to those described above. In addition, this poor silicide formation may lead to other defects that cause the semiconductor to exhibit poor performance or cause circuits to fail.
[0029] [0029]FIG. 2 is a flow chart illustrating an embodiment of steps in the fabrication of a semiconductor structure which is selectively silicided to allow silicide to form on parts of an integrated circuit structure and block silicide from forming on other parts of an integrated circuit structure of the present invention. In Step 1 , a semiconductor structure of the present invention is fabricated from a prepared silicon wafer 26 . Active regions are defined and trenches are etched in the silicon around the active regions. Isolation material (STI) is deposited into the trenches to isolate active areas. In Step 2 , gates are prepared by depositing gate oxide in the region of the gate and depositing gate polysilicon. Turning now to FIG. 3, a cross-sectional view at line 50 of FIG. 1, of an example of a semiconductor structure which might result from steps 1 and 2 of FIG. 2 is illustrated. FIG. 3 illustrates that this gate polysilicon can be in the form of a long polysilicon line 54 .
[0030] Turning back to FIG. 2, in step 3 , N+ and P+ active areas are implanted to form N+ diffusions (see 66 in FIG. 6) by implanting or doping the exposed silicon in these regions with an N type element such as Arsenic or other suitable element. Similarly, P+ diffusions are formed (see 67 in FIG. 6) by implanting or doping the exposed silicon in these regions with a P type element such as Boron or other suitable element. These N+ diffusions and P+ diffusions, when present in the appropriate architecture on either side of the polysilicon gate, form source/drain regions in NFETs and PFETs. During the implanting step, gate polysilicon, shown in FIG. 3 as long polysilicon lines 54 , are also implanted. This creates a polysilicon line 54 with an N+ region 68 and a P+ region 69 . At a location along the polysilicon line 54 , the N+ region abuts the P+ region to form an N+/P+ junction 70 . Examples of these structures are illustrated in FIGS. 3 - 5 .
[0031] In Step 4 , a blocking layer 80 is selectively applied to the active areas (the regions shown as 82 and 83 in FIG. 6). This blocking layer may be patterned or selectively applied to the active areas by using a mask to limit the application of the blocking layer to the active areas, or by applying a blanket layer of blocking material and selectively removing the blocking material from the application areas. the blocking material may be nitride or other suitable blocking material. An example of this blocking layer 80 is illustrated in FIG. 4.
[0032] In Step 5 , a blocking layer can be applied to selectively expose the N+/P+ junction for silicidation. For example, a layer of blocking material such as nitride can be applied to the entire surface of the semiconductor structure. A layer of photoresist can be applied on top of the nitride hard mask material. The photoresist can be selectively exposed or patterned using a mask. The mask selectively exposes the photoresist to light. Therefore, some areas of photoresist are exposed to light and some areas are in shadow during the light exposure. The exposed photoresist is then developed. Depending on whether a negative or positive tone resist is used, the unexposed or exposed photoresist can then be washed away during rinsing steps. After this patterning step, the semiconductor structure has a layer of nitride or hard mask, covered with a selectively applied layer of photoresist. A “Reactive Ion Etch” (RIE) may be used to etch the areas not protected by photoresist. After the RIE step, the semiconductor structure may have a layer of nitride or hard mask, patterned to expose the polysilicon in the region of the N+/P+ junction. An example of this structure is illustrated in FIG. 4.
[0033] Alternatively, a layer of photoresist can be applied to the surface of the semiconductor structure. A mask can be used to selectively expose photoresist to form a pattern of photoresist on the area of the N+/P+ junction 70 of the polysilicon gate. A layer of nitride or other blocking material can be applied to the semiconductor structure, creating a semiconductor structure with nitride or other blocking material present on top of the active areas, and photoresist present on top of the N+/P+ junction 70 of the polysilicon gate. The photoresist can then be removed using techniques well-known in the industry. As a result of these steps, a layer of blocking material, or hard mask 80 , resides over the active areas of the semiconductor structure and the silicon of the N+/P+ junction region of the polysilicon gate is exposed.
[0034] As will be recognized by those of ordinary skill in the art, many alternative methods can be used to fabricate the structure as shown in FIG. 5. While we have described two such methodologies, these methods are not exhaustive of the methods that can be used to fabricate such a structure.
[0035] In Step 6 , metal such as cobalt or titanium or other suitable metal is applied to the surface of the semiconductor structure and the semiconductor structure is heat-treated to form metal silicide in the area of exposed silicon. In the areas covered with the blocking layer, no silicide is formed. This silicide structure is a silicide strap 75 . An example of this structure is illustrated in FIG. 5.
[0036] In Step 7 , the semiconductor structure is finished. These finishing steps will depend on the requirements of the device and may include applying a blanket dielectric such as nitride, completing devices, creating contacts and metal wiring and other back end of line processing. The nature of the finishing steps is dependent upon the nature of the semiconductor device that is being fabricated.
[0037] FIGS. 3 - 5 are cross-sectional views taken at line 50 of FIG. 1 (see also line 50 of FIG. 6, also indicating the cross-sectional view represented by FIGS. 3 - 5 ), of the region of selective silicidation, the silicide strap, illustrating steps in the fabrication of the present invention. FIG. 3 illustrates the semiconductor structure after the substrate has been prepared, STI 25 has been applied to isolate NFET and PFET active areas, gate oxide 64 has been deposited and polysilicon lines 54 have been deposited. In addition, source/drain regions (not shown in FIGS. 3 - 5 but see 66 and 67 in FIG. 6) and polysilicon lines 54 have been implanted to form P+ diffusions (see 67 in FIG. 6) and N+diffusions (see 66 in FIG. 6). The N+ diffusion is part of at least one NFET (see 66 in FIG. 6) and the P+ diffusion is part of at least one PFET (see 67 in FIG. 6 ). Also shown in FIG. 3 is the N+/P+ junction area 70 .
[0038] As may be recognized by those of ordinary skill in the art, the N+/P+ junction 70 may form a semiconductor diode. However, the application of suicide across this N+/P+ junction 70 creates a low-resistance electrical connection. In an SRAM cell 60 as illustrated in FIG. 6, a low-resistance electrical connection may be more desirable than a diode device.
[0039] Once these steps are complete, (steps 1 - 3 of FIG. 2), selective silicidation may occur. As discussed above, a hard mask 80 may be applied to the top surface of the semiconductor structure, but is blocked from the region of the N+/P+ junction 70 (Steps 4 and 5 of FIG. 2). This step is illustrated in FIG. 4.
[0040] Finally, as illustrated in FIG. 5, cobalt, titanium or other siliciding metal can be applied to the surface of the semiconductor structure and heat treated (Step 6 of FIG. 2). This heat-treatment creates metal-silicide in areas where the silicided metal was applied to exposed silicon. Therefore, a silicide strap 75 is created in the area of the polysilicon line 54 which was not blocked by the blocking layer 80 . In regions protected by the hard mask 80 , or by a layer of nitride, oxide, or other blocking material, no silicidation will take place and residual siliciding metal can be selectively removed.
[0041] [0041]FIG. 6 is a top view of an SRAM cell 60 of the present invention. This SRAM cell 60 is well-known SRAM architecture. While an SRAM cell 60 is illustrated here, those of ordinary skill in the art will recognize that this invention is applicable in any semiconductor structure which utilizes both NFETs and PFETs. The SRAM cell 60 illustrated in FIG. 6 illustrates an embodiment of the silicide strap 75 of the present invention.
[0042] [0042]FIG. 6 illustrates structures that have been created on the silicon substrate to create the SRAM 60 semiconductor structure. Line 50 in FIG. 6 corresponds to line 50 in FIG. 1, and illustrates the cross section illustrated in FIGS. 3 - 5 . A P+ active area 77 and an N+ active area 76 have been defined by isolating active regions using STI processing. The P+ active area 77 includes two PFETs 67 . The N+ active area 76 includes four NFETs 66 . Long polysilicon lines 54 have been deposited to create gate structure for both PFETs 67 and NFETs 66 . Long polysilicon lines 54 have been formed intersecting the P+ active area 77 , forming PFETs 67 , and the N+ active area, forming two of the NFETs 66 . Long polysilicon lines 54 also intersect the P+ diffusions 67 to the N+ diffusions 66 . The N+ active area 76 and the P+ active area 77 are doped. Because this doping step occurs after the polysilicon line 54 has been applied, the polysilicon line 54 is also doped N+ in the N+ area 71 where it overlaps the N+ diffusion 76 and P+ in the P+ area 72 where it overlaps the P+ diffusion 77 . This doping will create an N+/P+ junction 70 , an area of the polysilicon line where the N+ doped region 71 interacts with the P+ doped region 72 , or where the N+ doped region 71 of the polysilicon line abuts the P+ doped region 72 of the polysilicon line.
[0043] Blocking, as discussed in FIGS. 2 - 5 , can be applied as indicated by regions 82 and 83 . As discussed and illustrated in FIGS. 2 and 4, blocking material such as nitride can be applied to block the formation of silicide on these regions. As FIG. 6 illustrates, silicidation can be selectively applied to the region that has not been protected by the application of the blocking agent. Silicide can be selectively applied to the regions outside the blocked regions represented by 82 and 83 . Because only the polysilicon lines 54 are exposed silicon, in the region outside block boxes 82 and 83 (the surrounding regions may be isolation material or STI), only the polysilicon lines 54 that are not in the blocked regions 82 and 83 become silicided upon the application of a siliciding metal and heat treatment. In this manner, the silicide strap 75 is achieved only in the region of the polysilicon lines 54 which is not protected by a blocking agent. The silicide strap 75 is the low resistance connection along the polysilicon line 54 at the N+/P+ junction 70 created by selective silicidation. In addition, because these regions are blocked (see 82 and 83 ), this selective silicidation does not create a layer of silicide across the PFETs 67 and NFETs 66 , which, if present, could lead to the types of current leakage as shown in FIG. 1.
[0044] When a device, such as the SRAM structure of FIG. 6, has been selectively silicided according to an embodiment of the present invention, silicide only resides on a silicide strap 75 which creates a low resistance connection at the N+/P+ junction 70 . This low resistance connection enhances the performance of the semiconductor device. In addition, according to an embodiment of the present invention, silicide does not reside over the active areas 76 and 77 including the source/drain regions of semiconductor devices.
[0045] Because silicide is not present except at the N+/P+ junction 70 , leakages such as those illustrated in FIG. 1 are reduced. Because there is no silicide present on the spacers 24 along the sides of the gate 21 , there is no “over the spacer leakage” between the gate and the source/drain caused by silicide formation (See FIG. 1). Silicide-mediated GIDL will also be absent in devices that are not silicided. Silicide cannot spike over the source/drain region to create current leakage from the source/drain region into the substrate because no suicide is present over the source/drain region. And, no suicide is present at the edge of the STI, so no silicide pooling or suicide “pull-down” can occur, causing current leakage. These and other reductions in current leakage may lead to greater efficiency and less power usage in the semiconductor device. Therefore, selectively silicided semiconductor structures, such as the SRAM cell described in FIG. 6, may use less power than semiconductor structures which do not make use of an embodiment of the present invention.
[0046] While the invention has been particularly shown and described with reference to embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention.
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A selectively silicided semiconductor structure and a method for fabricating same is disclosed herein. The semiconductor structure has suicide present on the polysilicon line between the N+ diffusion or N+ active area and the P+ diffusion or active area at the N+/P+ junction of the polysilicon line, and suicide is not present on the N+ active area and the P+ active area. The presence of this selective silicidation creates a beneficial low-resistance connection between the N+ region of the polysilicon line and the P+ region of the polysilicon line. The absence of silicidation on the N+ and P+ active areas, specifically on the PFET and NFET structures, prevents current leakage associated with the silicidation of devices.
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FIELD OF THE INVENTION
[0001] The invention relates generally to the field of information security and relates specifically to user authentication for retrieving and resetting security credentials.
BACKGROUND OF THE INVENTION
[0002] As computers have become prevalent in schools and the workplace, users are assigned passwords to gain access to an organization's computerized resources. Passwords are required for users to log on to the network, retrieve e-mail, access restricted information and use restricted applications. Rather than requiring users to remember multiple passwords, many organizations use a password manager program that assigns to each user a single password used for accessing all of the organization's computerized resources.
[0003] In order to provide a higher level of security, password manager programs often assign strong passwords. Strong passwords generally comprise at least eight randomly generated characters that include a combination of letters and numbers and sometimes include other special characters. To further enhance security, passwords may change at regular intervals. Because randomly generated strong passwords do not spell out a word, phrase, or date, randomly generated strong passwords are often difficult for users to remember. Frequent password changes increase the difficulty users have remembering passwords. Thus, organizations provide a mechanism for users to retrieve or reset their forgotten passwords. Often, automated mechanisms for retrieving and resetting passwords alleviate the need for live technical support.
[0004] One known automated mechanism for retrieving or resetting forgotten passwords utilizes an interactive World Wide Web interface, a user identification, and a predefined challenge phrase. The user provides a user identification and then responds to a prompt for a predefined challenge phrase. The predefined challenge phrase is an easy to remember phrase previously provided by the user such as the name of a pet, the make of a first car, or the maiden name of the user's mother. After the user responds correctly, the password is sent to the user via e-mail. There are two drawbacks to a system using a predefined challenge phrase. First, the challenge phrase can be known to persons close to the user. Second, receiving an e-mail with the password is impractical if the user cannot access e-mail without the forgotten password. To overcome the problem of not being able to access e-mail to retrieve a password when the user has forgotten the password, live or automated operators are often employed by telephone systems to administer the challenge phrase or other identity authentication and to provide the password.
[0005] Another automated mechanism for retrieving or resetting forgotten passwords via a telephone system uses a second, easy to remember password or Personal Identification Number (“PIN”) to authenticate the user's identity. There are drawbacks to using a PIN because the PIN never expires, the PIN may get copied down, or the PIN may be used in multiple places. As with challenge phrases, these shorter, less secure passwords have a high risk of discovery by others and weaken the higher level of security provided by the strong password.
[0006] One known solution to overcome the limitations encountered when using challenge phrases and secondary passwords for user authentication is voice biometric verification. Voice biometric verification systems use a person's individual speech patterns, called a voice fingerprint, to authenticate identity. Voice biometric verification systems have certain limitations. Bad connections or interference caused by long distance, cellular calls and voice over Internet protocol (“VoIP”) phone systems make voice biometric verification unreliable. Moreover, voice biometric verification may improperly grant access to a caller other than the user, if the caller uses a voice recording of the user. Because of these problems, security experts question the efficacy of voice biometrics over the telephone.
[0007] All security systems seek a balance between a risk of false acceptance and a risk of false rejection. If a security threshold is too stringent, there exists a risk of false rejection which frustrates authorized users who cannot access the secured resources. If the security threshold is too lax, there exists a risk of false acceptance which allows unauthorized users access to secured resources. A need exists for an improved automated method of verifying a user's identity for resetting passwords that does not rely on memorized challenge phrases or biometric voice identification, but which provides unique identity authentication questions that are easy for an authorized user to answer, and difficult for an unauthorized user to answer.
SUMMARY OF THE INVENTION
[0008] An “identity authentication program” (IAP), meets the needs identified above by creating a custom set of authentication questions in response to a user request to have a user password reset. The IAP accesses a record located in a data source containing information related to the user's recent computer activity and generates an authentication question and a corresponding answer based on the record. In order to reset a user password, the user must correctly answer a designated number of questions from the custom set of authentication questions.
[0009] In a preferred embodiment, the IAP bases authentication questions on recent e-mail messages sent by the user. The IAP opens at least one recent e-mail message sent by the user and identifies a set of non-trivial key words in the email message. The IAP provides the user with the recipient's name and the subject line, and prompts the user to enter key words. The user must respond with a certain number of the identified set of non-trivial key words within a predefined number of attempts. For example, the user must identify three of five keywords within five attempts.
BRIEF DESCRIPTION OF DRAWINGS
[0010] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be understood best by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
[0011] FIG. 1 is an exemplary computer network;
[0012] FIG. 2 describes programs and files in a memory on a computer;
[0013] FIG. 3 is a flowchart of a setup component;
[0014] FIG. 4 is a flowchart of a user interface component; and
[0015] FIG. 5 is a flowchart of a data gathering component.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] The principles of the present invention are applicable to a variety of computer hardware and software configurations. The term “computer hardware” or “hardware,” as used herein, refers to any machine or apparatus that is capable of accepting, performing logic operations on, storing, or displaying data, and includes without limitation processors and memory; the term “computer software,” or “software,” refers to any set of instructions operable to cause computer hardware to perform an operation. A “computer,” as that term is used herein, includes without limitation any useful combination of hardware and software, and a “computer program” or “program” includes without limitation any software operable to cause computer hardware to accept, perform logic operations on, store, or display data. A computer program may, and often is, comprised of a plurality of smaller programming units, including without limitation subroutines, modules, functions, methods, and procedures. Thus, the functions of the present invention may be distributed among a plurality of computers and computer programs. The invention is described best, though, as a single computer program that configures and enables one or more general-purpose computers to implement the novel aspects of the invention. For illustrative purposes, the inventive computer program will be referred to as the “identity authentication program” (“IAP”).
[0017] Additionally, the IAP is described below with reference to an exemplary network of hardware devices, as depicted in FIG. 1 . A “network” comprises any number of hardware devices coupled to and in communication with each other through a communications medium, such as the Internet. A “communications medium” includes without limitation any physical, optical, electromagnetic, or other medium through which hardware or software can transmit data. For descriptive purposes, exemplary network 100 has only a limited number of nodes, including telephone 105 , computerized telephone switch 110 , workstation computer 115 , server computer 120 , and persistent storage 125 . Network connection 130 comprises all hardware, software, and communications media necessary to enable communication between network nodes 105 - 125 . Unless otherwise indicated in context below, all network nodes use publicly available protocols or messaging services to communicate with each other through network connection 130 . In a preferred embodiment, computerized telephone switch 110 is adapted to use voice recognition software and speech synthesis software for implementing the user interface component of the IAP.
[0018] IAP 200 typically is stored in a memory, represented schematically as memory 220 in FIG. 2 . The term “memory,” as used herein, includes without limitation any volatile or persistent medium, such as an electrical circuit, magnetic disk, or optical disk, in which a computer can store data or software for any duration. A single memory may encompass and be distributed across a plurality of media. Further IAP 200 may reside in more than one memory distributed across different computers, servers, logical partitions, or other hardware devices, such as a computerized telephone switch. The elements depicted in memory 220 may be located in or distributed across separate memories in any combination, and IAP 200 may be adapted to identify, locate and access any of the elements and coordinate actions, if any, by the distributed elements. Thus, FIG. 2 is included merely as a descriptive expedient and does not necessarily reflect any particular physical embodiment of memory 220 . As depicted in FIG. 2 , though, memory 220 may include additional data and programs. Of particular import to IAP 200 , memory 220 may include password manager 230 , configuration file 250 , data source A 260 , data source B 262 , data source C 264 , and query file 270 with which IAP 200 interacts. IAP 200 has three components: configuration component 300 , user interface component 400 and data gathering component 500 .
[0019] Password manager 230 exists in the art and manages the single user identification and password for an organization's computerized resources. IAP 200 can be adapted to integrate with or interact with password manager 230 . Configuration component 300 allows a system administrator to define settings related to IAP 200 and saves the settings to configuration file 250 . Specifically, the system administrator uses configuration component 300 to select a data source from which IAP 200 generates authentication questions. User interface component 400 prompts a user for a user identification, asks the user an authentication question, and verifies the user's answers before providing the user with a new password. Data gathering component 500 generates questions and answers used by user interface component 400 based on information in a data source, such as data source A 260 . Data source A 260 , data source B 262 , and data source C 264 contain records related to recent user computer activities. For example data source A 260 may be a user's e-mail repository in persistent storage 125 , data source B 262 may be a network event log located on server computer 120 , and data source C 264 may be a local event log saved on workstation computer 115 . The questions and answers created by data gathering component 500 are saved to query file 270 .
[0020] Referring to FIG. 3 , configuration component 300 starts when initiated by a system administrator ( 310 ). Configuration component 300 prompts the system administrator for changes to the setup of IAP 200 using voice prompts or visual cues such as radio buttons or drop down menus ( 312 ). If the system administrator wants to change the source of recent computerized activities on which to base authentication questions ( 314 ), the system administrator selects a data source, such as data source A 260 ( 316 ) and configuration component 300 saves the changes to configuration file 250 ( 318 ). Each data source is a collection of records related to a user's recent computerized activities. In this example data source A 260 is a user's e-mail repository in persistent storage 125 , data source B 262 is a network event log located on server computer 120 , and data source C 264 is a local event log saved on workstation computer 115 . Network event logs may contain records of statistics related to how many times the user logged on or logged off to the network, or accessed certain files on the network. Local event logs may contain records of statistics related to how many times the user restarted the computer, experienced a computer crash, removed a CD or DVD, connected a PDA or MP3 player to the computer, or connected the computer to a wireless network within a fixed period of time. Similarly, a data source may relate to recent chat or IM sessions, recently accessed web sites, or other computer applications accessed by the user. If the system administrator wants to change the authentication questions related to records in a data source, such as data source A 260 ( 320 ), the system administrator selects a set of authentication questions ( 322 ) and configuration component 300 saves the changes to configuration file 250 ( 324 ). The system administrator can select from several questions for different embodiments the data source, such as data source A 260 . For example, if data source A 260 , an e-mail repository, is selected, the records are e-mails. The prompt may provide the recipient, the date, and the time of an e-mail message, and the authentication question may request non-trivial key words included in the e-mail message. Other authentication questions may request information about other details in the e-mail message such as names of blind-copied recipients or if the message has any attachments or replies. If the system administrator wants to change the number of authentication questions, the number of allowed attempts, or the number of correct answers required ( 326 ), the system administrator sets the number of authentication questions, allowed attempts and correct answers ( 328 ) and configuration component 300 saves the changes to configuration file 250 ( 330 ).
[0021] Referring to FIG. 4 , user interface component 400 starts when accessed by a user seeking to retrieve or reset a password ( 410 ). User interface component 400 accesses configuration file 250 ( 412 ), prompts the user for a user identification, and reads the supplied user identification ( 414 ). User interface component 400 invokes data gathering component 500 ( 416 ) and provides the user identification. User identification component 400 waits for data gathering component 500 to generate query file 270 ( 418 ). User interface component 400 prompts the user with an authentication question from query file 270 ( 420 ) and determines if the response is correct by comparing the user's response to the answer in query file 270 ( 422 ). If the user's response is incorrect at step 422 , user interface component 400 determines if more attempts to answer the authentication question are available based on the requirements of configuration file 250 ( 424 ). If more attempts are available at step 424 , user interface goes back to step 420 and prompts the user by repeating the same authentication question. If more attempts are not available at step 424 , user interface gives an “authentication failed” response ( 426 ) and stops ( 436 ). If the user's response is correct at step 422 , user interface component 400 determines if more authentication questions need to be asked based on the requirements of configuration file 250 ( 428 ). If more authentication questions need to be asked at step 428 , user interface component 400 goes back to step 420 and prompts the user with a different authentication question. If more authentication questions need not be asked at step 428 , user interface component 400 requests a new password from password manager 230 ( 430 ). Password manager 230 resets the user's password, or provides the user's existing password, depending on how password manager 230 is configured. User interface component 400 receives the new password from password manager 230 ( 432 ), provides the new password to the user ( 434 ) and stops ( 436 ).
[0022] Referring to FIG. 5 , data gathering component 500 starts when initiated by user interface component 400 ( 510 ). Data gathering component 500 accesses setup file 250 ( 512 ) and opens the data source designated by configuration file 250 , such as data source A 260 ( 514 ). Data gathering component 500 identifies the last record associated with the user identification received from user interface component 400 in data source A 260 ( 516 ). Data gathering component 500 verifies that the record is a valid record and is capable of being used as a source of information for authentication questions as specified in setup file 250 ( 518 ). In this example, data source A 260 is an email repository, and the last record is the last e-mail sent. The e-mail message must have sufficient non-trivial content to be a valid record for generating an authentication question. For data source B 262 containing a network usage log and for data source C 264 containing a local usage log, the last record should have statistics of recent activities from the current day to be a valid record. If data gathering component 500 determines that the last record is not a valid record at step 518 , data gathering component 500 goes back to step 516 and selects the next record. If data gathering component 500 determines that the last record is a valid record at step 518 , data gathering component 500 generates authentication questions and answers based on the record and the requirements of configuration file 250 ( 520 ). Data gathering component determines if another record is required by configuration file 250 ( 522 ). If data gathering component 500 determines another record is required at step 522 , data gathering component 500 goes back to step 516 and selects the next record. If data gathering component 500 determines no other records are needed at step 518 , data gathering component 500 saves the authentication questions and answers to query file 270 ( 524 ) and stops ( 526 ).
[0023] A preferred form of the invention has been shown in the drawings and described above, but variations in the preferred form will be apparent to those skilled in the art. In particular, IAP 200 can be implemented on a graphical user interface, on a World Wide Web based application using text rather than voice telephony. In an alternate embodiment, IAP 200 bases authentication questions on other details about recent e-mail messages besides keywords, such as the name of a blind-copied recipient, or whether the message received a response, whether the message was filed or whether the message was deleted. The IAP 200 may also use authentication questions asking how many times the user performed other computerized tasks within a fixed period of time. Other embodiments of IAP 200 may use wireless communication devices such as cellular phones and PDAs that combine voice, text and graphical interfaces. The preceding description is for illustration purposes only, and the invention should not be construed as limited to the specific form shown and described. The scope of the invention should be limited only by the language of the following claims.
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The “identity authentication program” (IAP) creates a custom set of authentication questions in response to a user request to have a user password reset. The IAP accesses a record located in a data source containing information related to the user's recent computer activity and generates an authentication question and a corresponding answer based on the record. In order to reset a user password, the user must correctly answer a designated number of questions from the custom set of authentication questions. In a preferred embodiment, the IAP bases authentication questions on recent e-mail messages sent by the user. Because the questions are generated at the time of the user's request, the answers are unique and can not be memorized. Because the questions are based on recent activities of the user, the questions are hard to guess by an unauthorized person.
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[0001] This application claims priority to, and incorporates herein by reference in its entirety, the following pending U.S. patent applications:
[0002] Ser. No. 60/449,415 (Attorney Docket No. 1030-006), titled “Netting-Reinforced Turf Systems and Methods”, filed 24 Feb. 2003;
[0003] Ser. No. 10/208,631 (Attorney Docket No. 1030-005), titled “Device, System, and Method for Controlling Erosion”, filed 29 Jul. 2002; and
[0004] Ser. No. 60/392,430 (Attorney Docket No. 1030-004), titled “Agricultural Device”, filed 28 Jun. 2002.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Certain of the wide variety of potential embodiments will be more readily understood through the following detailed description, with reference to the accompanying drawings, in which:
[0006] FIG. 1 is a block diagram of an exemplary embodiment of a system 1000 ;
[0007] FIG. 2 is a flowchart of an exemplary embodiment of a method 2000 ;
[0008] FIG. 3 is a perspective view of an exemplary embodiment of a netting-backed vegetated mat system 3000 ;
[0009] FIG. 4 is a flowchart of an exemplary embodiment of a method 4000 ;
[0010] FIG. 5 is a flowchart of an exemplary embodiment of a method 5000 ;
[0011] FIG. 6 is a perspective view of an exemplary embodiment of a cropping system 6000 ;
[0012] FIG. 7 is a perspective view of an exemplary embodiment of a system 7000 ; and
[0013] FIG. 8 is a top view of an exemplary embodiment of a retention pond system 8000 .
DETAILED DESCRIPTION
[0014] Certain exemplary embodiments generally relate to devices, systems, and methods, at least some of which can be useful for controlling erosion, retaining sediment, preventing siltation, treating runoff, removing pollutants, remediating environmental damage, protecting plants, bordering play areas, absorbing spills, establishing vegetation, protecting ecosystems, and/or restoring waterways and/or other riparian areas.
[0015] Certain exemplary embodiments provide netting and/or mesh-based containment systems, methods, and/or devices. Although the following description is frequently directed to filled mesh tubes, it will also be apparent that this description can generally and/or frequently apply to one or more “sheets” of compost-filled or unfilled mesh netting, and/or one or more sections of netting-backed vegetated mat. Moreover, netting-backed vegetated mat can be combined with filled mesh tubes to create one or more exemplary embodiments.
[0016] As used herein, the term “tube” means an elongate member having a longitudinal axis and defining a longitudinal cross-section resembling any closed shape such as, for example, a circle, a non-circle such as an oval (which generally can include a shape that is substantially in the form of an obround, ellipse, limaron, cardioid, cartesian oval, and/or Cassini oval, etc), and/or a polygon such as a triangle, rectangle, square, hexagon, the shape of the letter “D”, the shape of the letter “P”, etc. Thus, a right circular cylinder is one form of a tube, an elliptic cylinder is another form of a tube having an elliptical longitudinal cross-section, and a generalized cylinder is yet another form of a tube. A tube can be formed of a mesh material, and can be filled with a filler material.
[0017] Certain exemplary embodiments include a system that can include mesh tubes and/or enclosures that are filled with any of a variety of materials, including compost, composted products, mulch, sawdust, soil, gravel, and/or various other organic and/or inorganic substances. Such filled tubes can be filled on-site, which can reduce the transportation cost of the systems. Moreover, such filled tubes can be relatively heavy, thereby resisting and/or avoiding floating away in heavy rain.
[0018] Certain embodiments of such filled tubes can be used in a variety of ways such as on an erosion-prone slope, across a small drainage ditch, or surrounding a drain. The tubes can be held in place by their own weight and/or by stakes, which can be driven through the tubes and into the ground. In certain embodiments, attached to the tubes can be additional anchoring mesh, through which anchors can be driven to secure the tubes to the ground.
[0019] Certain exemplary embodiments include a method for filling and placing the filled tubes on-site. The tubes can be filled using a pneumatic blower truck, an auger, and/or by hand.
[0000] System 1000
[0020] FIG. 1 is a block diagram of an exemplary embodiment of a system 1000 . System 1000 can include a filling 1010 , which can be contained in a storage enclosure 1020 and delivered via a delivery mechanism 1030 to a mesh tube 1040 (or a mesh netting).
[0021] Filling 1010 can comprise any of a number of materials, including compost, composted organic materials, organic feedstocks, composted products, mulch, wood shavings, lime, clay, pea gravel, gravel, sand, soil, wood chips, bark, pine bark, peat, soil blends, straw, hay, leaves, sawdust, paper mill residuals, wood wastes, wood pellets, hemp, bamboo, biosolids, coconut fibers, coir, wheat straw, rice straw, rice hulls, corn husks, corn, grain, corn stalks, oat straw, soybean hulls, palm wastes, palm leaves, agricultural waste products, manure, wool, hair, sugar cane bagasse, seed hulls, jute, flax, hulls, organic waste, cat litter, activated charcoal, diatomaceous earth, chitin, ground glass, alum, aluminum oxide, alum sludge, iron oxide, iron ore, iron ore waste, ironite, iron sulfate, pumice, perlite, rock fragments, mineral fragments, ion exchange substances, resin, and/or beads, zeolites, plant seeds, plugs, sprigs, spores, mycorrizhae, humic acid, and/or biological stimulants, microorganisms, microflora, rhizo spheres, myco spheres, and/or ecosystems, etc. Filling 1010 can comprise a base material selected from the preceding list, and one or more additives, selected from the preceding list. Any such additive can be added to and/or blended with the base material prior to, during, and/or after filling of the tube, and/or can be added to the tube prior to and/or during the filling of the tube with the base material.
[0022] Filling 1010 can comprise a substrate, such as compost, mulch, gravel, bark, fibers, etc., which has been inoculated with a fungus or other microorganism, and/or upon which a fungus and/or other microorganism has been grown. Filling 1010 can comprise a material having a predetermined absorption and/or adsorption capability.
[0023] Certain embodiments of filling 1010 , such as compost, can provide treatment of runoff water by physically straining and/or entrapping the runoff, biologically treating, binding, remediating, and/or degrading unwanted, harmful, and/or polluting substances; and/or chemically binding and/or degrading certain pollutants. Such runoff, substances, and/or pollutants can include metals (e.g., cadmium, chromium, cobalt, copper, lead, mercury, and/or nickel,), metalloids, (e.g., arsenic, antimony, and/or silicon, etc.), nonmetals (e.g., sulfur, phosphorus, and/or selenium, etc.), hydrocarbons and/or organic chemicals (such as 2,4,6-trinitrotoluene), nutrients (e.g., fertilizer, nitrates, phosphates, sewage, and/or animal waste, etc.), and/or pathogens (e.g., e. coli, staphylococcus, rotovirus, and/or other bacteria, protozoa, parasites, viruses, and/or prions, etc.), etc.
[0024] Certain embodiments of filling 1010 , such as compost, can be weed seed-free, disease-free, and/or insect-free, and can be derived from a well-decomposed source of organic matter. Certain embodiments of such compost can be free of refuse, contaminants, and/or other materials toxic and/or deleterious to plant growth. In certain embodiments, the compost can have a pH that measures anywhere between approximately 5.0 and approximately 8.0, including all values therebetween, and including all sub-ranges therebetween, such as for example, approximately 5.4 to approximately 7.6, etc. Certain embodiments of such compost can be produced according to an aerobic composting process meeting 40 CFR 503 (or equivalent) regulations. Certain embodiments of such compost can have a moisture content of less than 60%.
[0025] In certain embodiments, such as perhaps those involving water filtration, the particle size of the compost can conform to the following: 99% passing a 1 inch sieve, 90% passing a 0.75. inch sieve, a minimum of 70% greater than a 0.375 inch sieve, and/or less than 2% exceeding 3 inches in length. The mean, median, minimum, and/or maximum size of the compost can be varied according to the application. For example, if increased filtering is desired, or if no sediment is trapped upstream of the tube, the size of the compost can be decreased, or better ground contact can be attempted. Conversely, if too much water is retained in, for example, an erosion-prevention application, the size of the compost can be increased.
[0026] In certain embodiments, such as those use for creating a plant growing environment, the minimum particle size can be eliminated, thereby effectively ensuring that some fines will remain that can help vegetation become established.
[0027] Certain embodiments of compost can be comprised of approximately 100 percent compost, i.e., pure compost. Certain embodiments of compost, such as those used for sediment control, can contain less than a predetermined dry weight of inert, foreign, and/or man-made materials, that amount selected from a range of about 0.1% to about 20%, including every value therebetween, such as for example about 0.25, 0.5, 0.749, 1.001, 1.5, 2, 4.936, 7.5, 9.9999, 15, etc. percent, and including every sub-range therebetween, such as for example about 0.6 to about 10 percent, etc. Certain embodiments of compost can have predetermined materials added thereto, such as any of those filling materials and/or plant materials listed herein.
[0028] For example, certain embodiments of filling 1010 can include, support, and/or encompass one or more microorganisms, microflora, rhizospheres, mycospheres, and/or ecosystems that can biologically and/or chemically break-down, decompose, degrade, bind, and/or filter unwanted pollutants in the water that flows therethrough.
[0029] Certain embodiments of filling 1010 can include entities such as colonies, colony forming units, spores, seeds, bulbs, plugs, sprouts, sprigs, and/or seedlings of microorganisms, bacteria, fungi, and/or plants. As these entities become established, these entities can provide numerous beneficial functions.
[0030] For example, certain living entities can assist with remediating the environmental impact of the expected effluent. For example, plants commonly called cattails, reeds, rushes and/or skunk cabbage can be useful for treating certain types of sewage. Thus, for example, a potential wetland area downstream of a septic field could be surrounded and/or filled with a filled tubes seeded with an appropriate variety of plant.
[0031] As another example, certain plants, such as mustard, can be useful for absorbing particular heavy metals. As yet another example, the root systems of plants growing from a filled tube can serve to anchor the filled tube into the adjacent soil. This anchoring can serve to prevent run-off from moving or washing away the filled tube.
[0032] As a further example, certain embodiments of the filled mesh tube can eventually provide plants that can improve the aesthetic image of the filled tube. Thus, rather than permanently presenting a black, brown, or gray-colored compost-filled tube, a sprouted filled tube can present, for example, blooming flowers, groundcovers, vines, shrubs, grasses (such as turn seed, annual rye, crown vetch, birds foot trefoil, and/or fescues), and/or aquatic plants, etc.
[0033] As another example, via a technique called mycoremediation, certain fungi and/or fungal components, such as macrofungi (including mushrooms commonly referred to as shiitakes, portabellas, criminis, oysters, whites, and/or morels), white-rot fungi (such as P. chrysosporium ), brown-rot fungi, mycelium, mycelial hyphae, and/or conidia, can be useful for decomposing and/or breaking down pollutants and/or contaminants, including petroleum, fertilizers, pesticides, explosives, and/or a wide assortment of agricultural, medical, and/or industrial wastes. Certain of such fungi and/or fungal components are available from Fungi Perfecti of Olympia, Wash.
[0034] In certain embodiments, a microbial community encompassed within the filling of the mesh tube can participate with the fungi and/or fungal components to break down certain contaminants to carbon dioxide and water. Certain wood-degrading fungi can be effective in breaking down aromatic pollutants and/or chlorinated compounds. They also can be natural predators and competitors of microorganisms such as bacteria, nematodes, and/or rotifers. Certain strains of fungi have been developed that can detect, attack, destroy, and/or inhibit the growth of particular bacterial contaminants, such as Escherichia coli ( E. coli ).
[0035] Certain embodiments of the filling can include one or more fertilizers, flocculants, polymers, chemical binders, and/or water absorbers, etc., any of which can be selected to address a particular need and/or problem, such as to fertilize the growth of a predetermined plant species and/or to bind a predetermined chemical. For example, the filling can include a predetermined quantity of iron ore powder, which can be used to bind phosphorus.
[0036] Storage enclosure 1020 can at least partially surround filling 1010 , and can be a vessel, tank, hopper, truck, and/or pile, etc. Delivery mechanism 1030 can be a hose, tube, pipe, duct, and/or chute, and can include a mechanical and/or pneumatic component, such as an auger, vibrator, and/or fan, etc. for biasing filling 1010 toward and/or into mesh tube 1040 (or over an approximately flat mesh netting, not shown). Delivery mechanism 1030 can provide, meter, blend, and/or mix two or more components of filling 1010 prior to and/or during the filling of mesh tube 1040 .
[0037] Moreover, delivery mechanism 1030 can be replaced with a manual approach, whereby a human places filling 1010 into mesh tube 1040 (and/or a mesh netting, not shown). Delivery mechanism 1030 can include a nozzle, reducer, and/or hose adapter that allows a standard hose (such as a hose having an approximately 4 or 5 inch diameter) to fill a larger and/or smaller diameter mesh tube.
[0038] Mesh tube 1040 (and/or a mesh netting, not shown) can be fabricated from a flexible netting material, which can be woven, sewn, knitted, welded, molded, and/or extruded, etc. One source of netting material is Tipper Tie-net of West Chicago, Ill.
[0039] The netting material can be biodegradable, such as cotton, a natural fiber, UV-sensitive plastic, and/or biodegradable polymer, potentially formed from a plastic and/or starch, and in certain embodiments, can biodegrade at a predetermined rate of biodegradation. For example, the netting material can be selected to biodegrade within about 1 month to about 3 years, including every value there between, such as about 3, 4.69, 6.014, 9, 11.98, 15, 16.4, 18, 23.998, 30.1, and/or 35, etc. months, and including every sub-range there between, such as from about 6.1 to about 12.2 months, etc.
[0040] Alternatively, all and/or any portion of the netting material can resist biodegradation. The netting material can be fabricated from, plastic, UV-inhibited plastic, polyester, polypropylene, multi-filament polypropylene, polyethylene, LDPE, HDPE, rayon, and/or nylon. Thus, when a tube is installed, the netting material can have a non-degradable portion that can be oriented downwards, so that the reinforcement provided by the netting remains, and a degradable portion that can be oriented upwards.
[0041] The netting material can be of any diameter and/or thickness, ranging from approximately 0.5 mils to approximately 30 mils, including all values therebetween, including approximately 0.5, 0.75, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 15, 18, 20, 22, 25, 28, and/or 30 mils, and including all sub-ranges therebetween, such as for example, from approximately 1.1 mils to approximately 26.36 mils, etc. The netting material can be in any available mesh size (mesh opening), from a mesh as small as that of women's pantyhose, and including a nominal mesh opening of approximately: 0.001, 0.005, 0.010, 0.025, 0.050,0.0625, 0.125, 0.25, 0.375, 0.5, 0.625, 0.75, 0.875, 1.0, 1.125, 1.25, 1.375, and/or 1.5, etc. inches, including all values therebetween, and including all sub-ranges therebetween, such as for example, from approximately 0.0173 inches to approximately 0.7 inches, etc. The netting material can have any mesh opening pattern, including diamond, hexagonal, oval, round, and/or square, etc. Mesh tube 1040 (and/or “sheets” of mesh netting, not shown) can be fabricated in standard lengths, such as any of approximately 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 50, 75, 100, 125, 150, 200, 250, 300, 400, and/or 500, 1000, 5000 etc. foot lengths, including all values therebetween, and including all sub-ranges therebetween, such as for example, from approximately 17.85 feet to approximately 292 feet, etc. Any number of mesh tubes 1040 can be coupled together in a process called ‘sleeving’, to form a continuous mesh tube (and/or mesh netting sheet, not shown) of any size, including lengths of as long as 1000, 2000, 3000, 4000, 5000, 7500, and/or 10,000, etc. or more feet, including all values therebetween, and including all sub-ranges therebetween, such as for example, from approximately 1243 feet to approximately 14,452 feet, etc. Thus, certain lengths of filled mesh tubes can be intended to be portable, and other lengths of filled mesh tubes can be intended to be immobile.
[0042] Mesh tube 1040 (and/or one or more “sheets” of mesh netting, not shown) can be filled (and/or covered) completely or incompletely. When filled completely, a longitudinal cross-section of mesh tube 1040 can be generally curvilinear in shape, such as a circle or a non-circle, such as an oval (which generally can include a shape that is substantially in the form of an obround, ellipse, limaçon, cardioid, cartesian oval, and/or Cassini oval, etc.). Moreover, the cross-section can have a simple, closed, non-circular, curvilinear and/or partially curvilinear shape. For example, the cross section can be shaped substantially like the letter D, rotated such that the flat portion is parallel with and/or adjacent a surface supporting mesh tube 1040 . As another example, the cross section can be generally shaped as a polygon, such as a triangle, rectangle, square, hexagon, etc., rotated such that a flat side is parallel with and/or adjacent a surface supporting mesh tube 1040 . As still another example, the cross-section can have any substantially closed shape, provided that mesh tube 1040 presents at least one substantially flat side that can be positioned substantially parallel and/or adjacent a surface supporting mesh tube 1040 . Placing a flat side downward and/or against a supporting surface can help maintain a position of mesh tube 1040 , thereby potentially preventing rolling, sliding, and/or other dislocation.
[0043] Mesh tube 1040 can have a major cross-sectional width (i.e., major diameter and/or other largest cross-sectional dimension) ranging from approximately 3 inches to approximately 30 inches, including approximately 3, 4, 5, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, and/or 30, etc. inches, and including all sub-ranges therebetween, such as for example, approximately 4.17 inches to approximately 17.9 inches, etc. Thus, the ratio of the length of mesh tube 1040 to its major width can be approximately 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 75, 100, 150, 200, 300, 400, and/or 500, etc. or larger, and including all sub-ranges therebetween, such as for example, from approximately 21 to approximately 183, etc.
[0044] Mesh tube 1040 can have opposing longitudinal ends, the end nearest the delivery device called the proximal end 1042 and the end furthest the delivery device called the distal end 1044 . Distal end 1044 can be closed and/or sealed prior to the delivery of filling 1010 into mesh tube 1040 . After delivery of filling 1010 into mesh tube 1040 , proximal end 1042 can be closed and/or sealed. The method of closing and/or sealing either of ends 1042 , 1044 can include knitting, sewing, folding, welding, stapling, clipping, clamping, tying, knotting, and/or fastening, etc.
[0045] Similarly, sheets of mesh netting can be closed, sealed, and/or attached via knitting, sewing, folding, welding, stapling, clipping, clamping, tying, knotting, and/or fastening, etc.
[0046] Attached to mesh tube 1040 (and/or one or more “sheets” of mesh netting, not shown) can be an anchoring device 1046 , such as a flap fabricated from mesh netting, such as that used to fabricate mesh tube 1040 . Such a flap can range in dimensions with the size of the tube and/or the expected forces that might bear upon the tube. For example, an 8-inch diameter tube might have two 4-inch wide flaps that are made from the same mesh material as the tube, and that extend along the entire length of the tube. Stakes 1048 can be driven through each of these flaps and into the underlying substrate. This can secure both sides of the tube, and can create additional stability for the tube.
[0047] Alternatively, anchoring device 1046 can be fabricated from any fabric. In another alternative embodiment, anchoring device 1046 can comprise a string, rope, cable tie, sod stakes, re-bar, wood stakes, and/or wire, etc. attached to mesh tube 1040 (and/or one or more “sheets” of mesh netting, not shown).
[0048] Alternatively, anchoring device 1046 can comprise an unfilled end of mesh tube 1040 , which can be secured via stakes 1048 to, for example an underlying and/or adjacent support surface (e.g., soil, ground, sand, pavement, etc.).
[0049] Mesh tube 1040 , one or more “sheets” of filled or unfilled mesh netting (not shown), and/or one or more sections of harvested netting-backed vegetated mat (not shown) can be attached to a geo-surface, such as the ground, soil, sand, silt, sod, earth, dirt, clay, mud, peat, gravel, rock, asphalt, concrete, pavement, a streambed, a stream bank, a waterway bank, a pond bank, a ditch, a ditch bank, and/or a slope, etc. The means for attaching mesh tube 1040 can include an attachment device 1048 that protrudes through mesh tube 1040 and/or anchoring device 1046 . As an example, an attachment device 1048 , such as a metal or wooden stake, could be hammered through a mesh-anchoring device 1046 , such as a mesh flap, and into a ditch bed to secure a mesh tube or vegetated mat across the flow path of a ditch to form a “ditch check”. Such a ditch check can slow water flow, encourage the deposition of silt and/or sediment, and/or potentially encourage the growth of plants whose root systems can further discourage run-off and/or erosion.
[0050] In certain embodiments, a plurality of filled mesh tubes 1040 can be installed adjacent each other and parallel an expected flow of water in a channel or potential channel, such as a stream bed, gully, swale, ditch, and/or trench, etc. Such tubes can form and/or line a floor and/or side walls of the channel, thereby resisting erosion of the channel.
[0051] In certain embodiments, an installed filled mesh tube and/or one or more sections of harvested netting-backed vegetated mat (not shown) can at least partially impede the flow of water into a storm water basin inlet, thereby potentially preventing clogging of the piping that drains the basin and/or filtering the water that enters the basin.
[0052] In certain embodiments, multiple mesh tubes 1040 can be stacked, for example following the contour of a steep slope, thereby forming a wall that can function to retain soil and reduce surface erosion. In certain embodiments, mesh tubes located higher up the wall can be of smaller cross-sectional width than those lower in the wall. Uphill from the tubes can be placed and/or backfilled, in some cases pneumatically, a geo-surface material and/or media, such as soil, mesh netting-back turf, sod, earth, dirt, clay, mud, peat, gravel, rock, and/or a filling material, as described earlier. Such a geo-surface material can be used to restore an eroded zone, such as when a stream bank has eroded beneath existing trees, exposing the trees and making them vulnerable to toppling. By installing multiple mesh tubes as a form of retaining wall, and back-filling with suitable material for supporting the tree and/or sustaining the tree's previously-exposed roots, the stream bank can be restored and the tree can potentially be saved.
[0000] Method 2000
[0053] Certain exemplary embodiments can employ a method 2000 for forming a storm water control system, erosion control system, sediment control system, silt reduction system, soil retention system, water protection system, water filtration system, pollution remediation system, plant protection system, plant initiation system, and/or erosion remediation system.
[0054] Method 2000 can include numerous activities, of which no particular activity or particular sequence of activities is necessarily required. For example, at activity 2010 , a distal end of a mesh tube can be closed and/or sealed, such as by typing a knot in the tube. At activity 2020 , a delivery mechanism, such as a blower hose or an auger outlet, can be inserted into an open proximate end of the mesh tube. Alternatively, mesh tube can be filled from an outlet of a chipper, shredder, chopper, and/or straw blower. Alternatively, a mesh tube having open ends can be slid over a blower hose, a proximate end of the tube potentially slid over a hose attachment, and a distal end of the tube closed and/or sealed prior to filling.
[0055] At activity 2030 , a filling can be discharged from the delivery mechanism into the mesh tube. The filling can be supplied to the delivery mechanism by, for example, a blower truck that contains a supply of the filling and is coupled pneumatically to the blower hose. Such blower trucks can include a pneumatic blower mounted on a portable truck that can be capable of reaching remote areas. A typical blower truck can blow filler down a hose of up to 700 feet in length or more, and can be obtained from Express Blower Inc. (Cincinnati, Ohio), Finn (Cincinnati, Ohio), and/or Peterson Pacific (Eugene, Oreg.). A typical blower truck can fill 8 or 12″ diameter mesh tubes at a rate of from about 600 to about 1000 feet or more per hour, including all values and all subranges therebetween. The blower truck can be calibrated for proper airflow to filler ratio, thereby preventing the mesh tube from being under or over filled. Water can be added to the filler to reduce dust. During filling, the length of the mesh tube can “shrink” by up to 20 percent, due to an increase in the width of the mesh tube.
[0056] In certain embodiments, the blower hose can be terminated by a cone or funnel-like attachment (such as a “diffuser” that slows the velocity of the filling) comprising a first proximate end having a longitudinal cross-sectional width that allows the terminal end of the hose to fit around and/or within the attachment. The hose attachment can comprise a second distal end having a longitudinal cross-sectional width that can approximately match the pre-filled nominal width and/or the desired cross-sectional shape, as described herein (e.g., circular, non-circular, curvilinear, partially curvilinear, polygonal, having at least one flat side, etc.), of the unfilled and/or filled mesh tube. The proximate end of the hose attachment can be a permanent attachment or a temporary attachment that is hooked, tied, screwed, taped, and/or otherwise attached to the blower hose.
[0057] The unfilled mesh tube can be slid over the attachment and hose, with only a distal end of the tube extending beyond the attachment. The distal end of the unfilled mesh tube can be tied, stapled, sealed, and/or otherwise closed. As filler begins to enter the distal end of the mesh tube, additional lengths of unfilled mesh tube can be fed slowly off the end of the hose and the attachment, keeping the filling portion of the mesh tube taught, and allowing the mesh tube to “walk” itself off of the hose. Alternatively, the hose can “back out” of the mesh tube. In certain embodiments, when properly filled, the mesh tubes can be rather full, creating a tightly stretched, fully expanded material that is difficult to pinch. When the proximal end of the mesh tube is reached, blowing can be stopped and approximately 8 inches, or an appropriate length, of unfilled mesh tube can be left for tying off.
[0058] In certain embodiments, the blower hose can be terminated by an attachment that applies a shape to the mesh tube and/or filling. For example, the attachment can have a cross-sectional shape in the form of a circle, non-circle, oval, a polygon (e.g., a triangle, square, etc.), etc. Thus, the cross-sectional shape of the filled mesh tube can take on, resemble, and/or be substantially influenced by the cross-sectional shape of the attachment, which might resemble the letter “D”, rotated such that the flat side is facing downward. The use of such an attachment can help maximize contact between the mesh tube and the supporting surface (e.g., ground).
[0059] As another example, a hopper can drop the filling into an auger that conveys the filling into the mesh tube. Activity 2030 can occur anywhere. That is, the mesh tube can be filled off-site (“ex-situ”) and/or on-site (“in situ”), which can include at the ultimate desired location for the filled tube.
[0060] At activity 2040 , the delivery mechanism can be withdrawn from the mesh tube when the mesh tube has been filled to the desired level. At activity 2050 , the proximate end of the mesh tube can be closed and/or sealed. Alternatively, the filled tube can be attached to a second tube in a process called sleeving, in which one tube overlaps the other by anywhere from about 1 to about 4 feet, thereby effectively extending the length of the first tube. If needed, the two tubes can be attached together using, for example, twist ties, zip ties, stakes or the like. Then the filling process can continue. Additional tubes can be further attached to form a continuous tube of any desired length.
[0061] In certain embodiments, a small amount of filler material can be applied adjacent, outside of, and/or upstream from the filled tube, to potentially resist water from flowing under and/or undercutting the filled tube. In certain embodiments, the filled tube can be stepped on or otherwise compressed to achieve better ground contact.
[0000] Cropping Applications
[0062] Certain exemplary embodiments provide tubular mesh netting materials containing growing media useful for crop production.
[0063] Certain exemplary embodiments provide a cropping system that utilizes specialized sock filling equipment to fill mesh tubes as well as certain techniques for row spacing, fertilizing, irrigation, planting of plugs, weed control, seeding rates, etc.
[0064] An embodiment of such a cropping system can use a mesh tube that can be filled with one or more chosen growing media, including composted products. The mesh or netting material can be filled with an auger, pneumatically, and/or with other devices to create a growing “roll”, which can by installed to simulate a raised bed garden. In this manner, certain embodiments of the cropping system can allow elevation of roots and can be combined with drip irrigation and/or fertigation (i.e., fertilization via irrigation) techniques.
[0065] FIG. 6 is a perspective view of an exemplary embodiment of a cropping system 6000 . Among its many potential components, system 6000 can comprise a first mesh tube 6100 that is coupled, attached, or placed adjacent to a second mesh tube 6200 . A cross-sectional shape 6300 of at least first mesh tube 6100 can be at least partially curvilinear and non-circular, and can have a substantially flat side or bottom 6400 , which can be supported by the ground or any other support 6500 , such as pavement, concrete, sand, mulch, a table, patio, landscape timbers, a deck, and/or turf, etc.
[0066] At least first mesh tube 6100 can contain a filling 6600 and can contain an irrigation hose (a.k.a., tube, line, pipe, etc.) 6700 that can deliver water nutrients, fertilizer, pest treatments, etc., via continuous, intermittent, and/or drip irrigation to plants 6800 growing from and/or adjacent the mesh tube. Irrigation hose 6700 can be positioned anywhere within and/or adjacent tube 6100 , including at approximately the center, top, and/or another predetermined location, including along an external surface of the mesh tube. Moreover, any outlets of hose 6700 can be oriented in any predetermined and/or random direction.
[0067] A landscaping material 6900 , such as mulch, wood chips, and/or straw, etc., that serves, for example, a walkway, playground, landscaping bed, etc. can be applied against an outside surface of at least first mesh tube 6100 , which can serve to physically constrain, border, and/or resist the dispersal of landscaping material 6900 . Because mesh tube 6100 can be filled with a relatively soft filler, the likelihood of human injury from contact with mesh tube 6100 is relatively low. Thus, mesh tube 6100 can provide a relatively soft, non-injuring border for such areas as playgrounds.
[0068] In certain embodiments, at least first mesh tube 6100 can serve as a portable planter. To irrigation hose 6700 can be connected a garden hose for watering of the portable planter, which can be useful for patio gardening of plants such as tomatoes, peppers, beans, flowers, herbs, and/or other plants.
[0069] In certain embodiments, at least first mesh tube 6100 can be installed adjacent to, and/or supported by, a landscape architectural element, such as for example, an: archway, arbor, pergola, rafter, purlin, column, balustrade, trellis, post, pedestal, statute, ornament, planter, and/or roof, etc. Thus, such a landscape architectural element can serve as support 6500 .
[0070] Using certain embodiments of mesh tubes and/or the cropping systems can allow a crop farmer to continue cultivation of the soil between the rows of mesh tubes with mechanical devices for weed control and/or to plant these areas in turf that can be mowed and/or maintained. This system can allow crop farmers to grow within an all-organic system, which can raise a market value of crops produced.
[0071] Using certain embodiments of mesh tubes and/or the cropping systems can be installed substantially below grade, at grade, and/or above grade. For example, a nursery and/or crop farmer might install an irrigated filled mesh tube containing plants above grade. When it is time to harvest and/or transfer a portion of the plants in the tube, a shovel, spade, or other tool could be used to cut through the mesh tube's netting and irrigation hose on either side of the desired plant(s), thereby separating the desired plant(s) from the remaining row of plants.
[0072] Certain embodiments of the mesh tubes can be biodegradable and can alleviate problems of clean-up When rows or field are replanted with other crops. The degradation of certain embodiments of mesh tubes can be customized to varying times, depending on the cropping system used. For instance, a mesh tube can be manufactured to last a full year in the field or it can degrade in six months or less. Whatever the time frame, materials can be manufactured to meet the degradation time frame.
[0073] Certain embodiments of the cropping system can employ specialized equipment, which can fill the mesh tubes, and/or a roller that can flatten the socks and/or compress them into an elongated shape having, for example, a non-circular, oval, rectangular, triangular, and/or closed polygonal cross-section. Certain of these forms, such as the obround, elliptical, rectangular, triangular, etc., and other forms having a flat-, pseudo-flat-, or flattenable-bottomed cross-section, can provide a firm seed bed for seeds or plugs to be inserted into the mesh tube via either a direct seeder which penetrates the mesh netting with a punch or an awl-like device which can create a planting hole for pre-started plugs. Other options can include the insertion of bare root plants and/or live cuttings, which can root into the media contained within the mesh tube. Still other options can include using a process called “live staking”, which can involve inserting a freshly cut twig or branch through the netting soon after cutting. Such cuttings can have the ability to grow without requiring rooting times. Exemplary plants include willows, dogwoods, etc.
[0074] Certain plant diseases can be controlled using an integrated pest management approach with certain embodiments of the cropping system. Since soil-borne diseases can be caused by wet conditions and/or poorly drained soils, the ability of certain embodiments of the system to dissipate water can reduce the prevalence of such diseases. Additionally, certain embodiments of the cropping system can provide disease control via its composted materials.
[0075] Moreover, certain embodiments of the mesh tubes can include traditional, “natural”, and/or organic chemicals, such as herbicides, pesticides, and/or fertilizers, etc., and even bacteria, fungi, and/or insects, etc., combined with the compost. Other physical items can be added to assist in insect control, including, but not limited to, diatomaceous earth, chitin, ground glass, and/or other rock or mineral fragments.
[0076] Thus, certain embodiments of mesh tubes and/or the cropping system can provide any one or more of the following:
Mesh netting that can be filled (in any manner) with compost, blended soils, soils, and/or other growing medias for the production of crop agriculture; Netting materials that can be biodegradable, tubular in design, and/or used for agricultural production in row crops; Cotton mesh material that can be biodegradable, for containment of a growing media in relation to crop agriculture; A combined system of a mesh tubes containing growing media inoculated with specialized disease resisting agents; A mechanism to provide other innoculants and/or soil additives for a cropping system which may or may not be involved in crop agriculture; A method for portably providing mesh tubes to remote locations; A method for filling mesh tubes at remote locations; A method for using mesh tubes as containment systems for growing plugs, plants, and/or seeds in an agricultural setting; A method for using mesh tubes as containment systems for growing plugs, plants, and/or seeds in a garden setting; A method for using mesh tubes to contain a growing medium for plugs, plants, and/or seeds; A method for using mesh tubes as a wholesale plant distribution mechanism; A method for using mesh tubes as a retail plant distribution mechanism; A method for using mesh tubes as a retail/wholesale distribution mechanism for sales of small growing systems capable of being shipped and/or marketed; A method for using mesh tubes as containment systems for wetland plants; and/or A method for using mesh tubes as a treatment mechanism for agricultural runoff.
[0092] Certain embodiments of mesh tubes and/or the cropping system can allow portability that is unavailable in many other products. Future evolutions and product introductions may include patio planters, edging, wetland plantings, and other choices that may be pre-seeded and sold at various discount garden centers or mass merchandisers.
[0093] Finally, since the compost and/or the components which can make-up biodegradable netting (e.g., netting formed from cotton, and/or corn, etc.) are annually renewable, the bio-based appeal for mesh tubes and the system can yield favorable attention from the USDA and other audiences currently placing emphasis on bio-based or sustainable programs.
[0000] Vegetated Mat Applications
[0094] Exemplary embodiments can provide methods for growing vegetated mats via rolling out plastic sheeting over a growing platform, rolling out a mesh netting material over certain portions of the plastic sheeting, and applying compost and seed and/or other plant material over the netting. After approximately 4 to 6 weeks of irrigation in appropriate growing conditions, the resulting rollable netting-backed and/or netting-reinforced vegetated mat can be harvested. The vegetated mat is not necessarily grown on and/or in traditional soil (i.e., the top layer of the earth's surface, typically comprising a miscellaneous mix of rock, mineral particles, and organic matter). That is, in certain embodiments, the mat can be grown on a “non-soil” growing platform and/or can be grown “soil-lessly” with and/or in a non-soil growing medium, such as compost. Thus, below-grade cutting is not necessarily required for harvesting the growing vegetation. Instead, the vegetated mat can be simply rolled up off of the plastic sheeting, placed on a pallet, and shipped to an installation site.
[0095] Exemplary embodiments can provide a non-soil platform grown, rollable, netting-backed and/or netting-reinforced, vegetated mat that is lightweight, soil-less, and/or relatively disease resistant. In certain embodiments, the vegetated mat can be staked into place like traditional sod, but because the vegetated mat can be a one hundred foot or longer strip, the chances of it moving can be slim. In certain embodiments, the vegetated mat system can immediately resist erosion while the vegetated mat system roots in.
[0096] Via certain exemplary embodiments of a system and/or method, several crops of vegetated mat can be harvested per year on a given growing area. Crops can be based on annually renewable, recycled, organic, bio-based, locally made, organic and natural products (compost), which means costs for shipping to market can be reduced because a number of locally available vegetated mat technicians can be trained to make the netting-back and/or netting-reinforced vegetated mat locally to reduce shipping of the vegetated mat over long distances. Typical crops can require about 6 weeks or less from planting to harvest. This means a given platform area can turn from about 1 to about 10 (including all values and sub-ranges therebetween) or more crops annually, even in a temperate climate range.
[0097] FIG. 3 is a perspective view of an exemplary embodiment of a netting-backed vegetated mat system 3000 . Among other things, system 3000 can comprise a non-soil vegetated mat growing platform 3100 , sheeting material 3200 , netting 3300 , compost 3400 , seed 3500 , seedlings 3600 , and transplantable vegetated mat 3700 .
[0000] Vegetated Mat Growing Platform 3100
[0098] It should be noted that soil is not required to either grow and/or to support exemplary embodiments of the vegetated mat. In fact, parking lots, asphalt, pavement, concrete, gravel, dry streambeds, hard-packed clay, sand areas, beaches, mulched surfaces, brownfields, greenhouse tables, or even an existing vegetated mat can be used as a growing platform on which to place the plastic sheeting upon which to grow vegetated mats. In extreme climates where heat is an issue, care can be taken in the timing of the seeding to make sure that the tender seedlings, sprouts, etc. of the vegetated mat do not overheat in the sun. This can be a particular concern on blacktop. When white plastic sheeting is used, however, cooler vegetated mat platform temperatures can be created. Moreover, exemplary embodiments of the vegetated mat system do not necessarily require or cause any significant removal of soil during harvesting, thereby avoiding removal of valuable minerals and/or organic matter from the underlying platform. Exemplary embodiments of the vegetated mat system can weigh about ½ the weight of traditional sod.
[0000] Sheeting 3200
[0099] Any standard (e.g., generic) nursery grade plastic sheeting can be used, in any color, including white, gray, black, etc. The thickness of the sheeting can be from approximately 0.05 mils to approximately 20 mils, including all values therebetween, such as approximately 1.02, 2.33, 3, 4, 5, 6.17, 7.44, 8, 9, 10, 12.1, 15, 17.2, etc. mils, and including all sub-ranges therebetween, such as for example, approximately 0.11 mils to approximately 16 mils, etc. In certain embodiments, small drain holes can be provided in the sheeting, and/or can be created in the sheeting such as via rolling a spike roller across the sheet. The drain holes can be from approximately 0.1 millimeters to approximately 2 millimeters, including all values therebetween, such as approximately 0.101, 0.251, 0.3, 0.4, 0.5, 0.602, 0.749, 0.8, 0.9, 1.0, 1.19, 1.5, 1.75, etc. millimeters, and including all sub-ranges therebetween, such as for example, approximately 0.2 millimeters to approximately 1.73 millimeters, etc. In certain embodiments, even smaller drain holes can be provided. In certain embodiments, the drain holes can be sized to be smaller in width than roots of the seedlings.
[0000] Netting 3300
[0100] Exemplary embodiments of the vegetated mat system can use a netting having a number of openings and/or sizes. An average, median, and/or mode for the mesh opening size can be selected from approximately ⅛ inch to approximately 3 inches, and all values therebetween, including for example approximately 0.15, 0.24, 0.5, 0.76, 1.01, 1.5, 2.26, etc., and including all sub-ranges therebetween, such as for example, approximately 0.2 inches to approximately 0.73 inches, etc. These openings can be of any shape, including diamond, square, round, octagon, hexagonal, triangular, or any other shape, including irregular shapes. For vegetated mats expected to be harvested earlier in the growing cycle, a generally smaller mesh size could be used than for those expected to be harvested later. The netting can be made in any length, any width, and any thickness. The netting can be biodegradable and/or non-biodegradable, as described herein. One source of netting material is Tipper Tie-net of West Chicago, Ill., which can provide a netting having strings made of HDPP tape, which are 5 mil before machine orientation, and which have a tensile strength of 2000+ grams.
[0000] Compost 3400
[0101] Exemplary embodiments of the vegetated mat system can utilize a filling such as compost or other growing media capable of supporting plant life, as described herein. In certain embodiments, the compost can be approximately 100% compost. In certain embodiments, the compost can include and/or be present with predetermined additives, such as those described herein, including one or more fertilizers, pre-emergents, herbicides, insecticides, pesticides, admixtures, aggregates, flocculants, polymers, chemical binders, and/or water absorbers, etc., chosen to enhance the vegetated mat system and/or its performance in a predetermined environment.
[0000] Seed 3500
[0102] Exemplary embodiments of the vegetated mat system comprise a plant material, such as seeds, seedlings, bulbs, plugs, sprouts, sprigs, cuttings, spores, colonies, etc., and/or other forms of propagated plant material. The plant material can be mixed with the compost prior to installation of the compost. For example, seed can be mixed with the compost and the mixture blown onto the netting material. The plant material can be installed simultaneously with the compost and/or after the compost. Further, the plant material can be inoculated with fungi, bacteria, and/or other microorganisms.
[0103] Exemplary embodiments of the vegetated mat system are not necessarily limited to any particular type, genus, and/or species of plant material. For example, vegetables, fungi, berries, flowers, crops, nursery stock, annuals, perennials, wildflowers, turf grasses, native grasses, beach plants, aquatic plants, desert plants, woodland plants, and/or marsh plants, etc., and a host of other plants and/or combinations of plants can possibly be grown in a vegetated mat system. Further, an entire rhizosphere and/or ecosystem can be established in a vegetated mat system. Moreover, any plant that is hard to establish in a mat or vegetated mat environment might benefit from this system because of the benefits of compost and netting Exemplary embodiments of the vegetated mat system can provide a quickly transplantable vegetated mat when the window of good growing conditions does not allow native seeding procedures to allow for successful establishment.
[0000] Method 4000 —Planting
[0104] FIG. 4 is a flowchart of an exemplary embodiment of a vegetated mat planting method 4000 , which can include any number of activities, of which no particular activity or particular sequence of activities is necessarily required.
[0105] For example, at activity 4100 , an area can be selected to serve as a platform for growing the vegetated mat (e.g., one square acre). The platform can be a parking lot, pavement, greenhouse table, sand area, or even existing turf. At activity 4200 , the platform can be leveled and covered in plastic sheeting. Normal nursery grade sheeting, such as white Visqueen can be used. At activity 4300 , the sheeting can be staked and/or weighted dawn, if desired.
[0106] At activity 4400 , strips of plastic mesh netting can be rolled out parallel to each other, with about a 1 inch spacing between strips. The netting can be any width from approximately 0.5 feet to approximately 20 feet, including all values therebetween, such as for example approximately 0.75, 1.02, 1.97, 2.49, 3.001, 4, 5.1, 6, 7.98, 10.21, 12.03, 16, or 19.97, etc. feet, and including all sub-ranges therebetween, such as for example, approximately 2 feet to approximately 6 feet, etc. One or more layers of netting can be applied to a given area. In certain embodiments, a bottom layer is provided over the plastic sheeting, then the compost is applied. In certain embodiments, the bottom layer is applied and then a top layer is applied over the compost mixture, thereby forming a “compost sandwich”. In yet another exemplary embodiment, multiple layers of netting are rolled out over each a common area, and compost is installed between the netting layers. The netting can be staked, if desired.
[0107] At activity 4500 , compost and seed can be approximately evenly applied by any of a variety of methods, including manually, mechanically (with a spreader), and/or pneumatically, etc. The seen can be pre-mixed with the compost, delivered with a seed injection system via a blower truck, and/or applied after the compost. The layer of compost can be approximately 0.125 inches to approximately 2 inches thick, including all values therebetween, such as for example 0.2, 0.333, 0.51, 0.748, 1, 1.497, etc. inches, and including all sub-ranges therebetween, such as for example from about 0.25 to about 0.49 inches, etc.
[0108] At activity 4600 , the mat can be irrigated as needed, such as two to four times daily during warm days, by any irrigation means, including manually, via sprinklers, and/or from overhead irrigation or equivalent.
[0000] Method 5000 —Harvesting and Installation
[0109] Because exemplary embodiments of the vegetated mat system can be laid down in convenient pre-cut strips of netting, all that is needed when harvest begins is a rolling device that pulls up the vegetated mat from the plastic. Thus, conventional harvesting equipment currently available for the traditional lawn turf market can be used to roll up the vegetation strips.
[0110] The vegetated mats can be provided in convenient shipping sizes, such as in strips of from approximately 1 foot to approximately 10 foot in width, including all values therebetween, such as 2.02, 3.9, 6, etc. feet, and all sub-ranges therebetween. Rolls of the strips in the wider range can be provided if appropriate pallets are provided to assure adequate support. Otherwise, standard 48 inch pallets can be used.
[0111] Because traditional soil is not required as a growing platform and/or growing medium, exemplary embodiments of the vegetated mat system can eliminate the traditional below-grade “sod cutting” component of harvesting.
[0112] Once the vegetated mat begins growing on the plastic, reasonable care can be taken to harvest the mat and get the mat to market quickly. However, unsprouted vegetated mats and/or vegetated mats that have not fully rooted can also be a marketable commodity. Once the existing vegetated mat is removed, another crop may be planted immediately, reducing the need for working fields, etc. In this manner, harvested vegetated mats can be harvested, rolled, and/or placed upon pallets for delivery. With certain fast growing varieties of plants, germination can be present when the mat reaches the marketplace and the mat can be rolled into place as a partially or pre-germinated vegetated mat that can resist erosion.
[0113] FIG. 5 is a flowchart of an exemplary embodiment of a vegetated mat transplantation method 5000 , which can comprise a number of activities, of which no particular activity or particular sequence of activities is necessarily required.
[0114] At activity 5100 , about four to six weeks after planting, the vegetated mat can be simply rolled up either by hand and/or mechanically prior to being shipped. Certain embodiments can utilize mechanized sod rollers, such a Skid-Steer or Bobcat mounted sod harvester and/or roller.
[0115] At activity 5200 , in certain situations, prior to placing the vegetated mat at the installation site, a relatively thin layer of compost can be applied to the soil receiving the vegetated mat. At activity 5300 , the vegetated mat can be installed in areas that have adequate irrigation or during times of adequate rainfall to make sure the vegetated mat ‘knits’ into the underlying compost and/or existing soils. At activity 5400 , during installation, the vegetated mat can be cut manually and/or mechanically to fit the areas required. At activity 5500 , the vegetated mat can be watered. Watering can be frequent at first, tapering off over about 2 weeks to less frequent, more thorough intervals.
[0000] Environmental Impact
[0116] Certain exemplary embodiments of the vegetated mat system can use little or no chemicals to produce because compost generally does not need fertilizers and is generally naturally disease resistant to many soil-born diseases. For certain sites, compost used in the creation of exemplary embodiments of the vegetated mat system can benefit poor local soils. Also, the compost and/or vegetated mat can act as a long term soil conditioner, filter, and/or binder of contaminants that migrate onto, into, and/or through the vegetated mat. In specialized areas where cleanup is required, specially designed versions of the vegetated mat system can be employed, these systems created according to prescriptions derived from agronomic formulations for using compost, compost admixtures, and/or plant materials. Such systems can provide for a reduction of leaching; binding, absorbing, and/or adsorbing of nutrients, metals, potentially toxic compounds or chemicals; and/or resisting runoff of nutrients, sediment, and/or other environmental contaminants.
[0117] FIG. 7 is a perspective view of an exemplary embodiment of a system 7000 that can be particularly useful for controlling water flow on a sloped surface. According to system 7000 , any number of mesh tubes 7200 , 7300 , 7400 can be installed on a sloped surface 7100 . A mesh tube, such as 7200 , can be installed parallel to a local slope of the surface. That is, mesh tube 7200 can be installed parallel to an expected flow of run-off water on an adjacent portion of sloped surface 7100 , which can prevent water from accumulating, standing, forming puddles, etc. Avoiding the accumulation of unwanted rain or other water can help decrease the likelihood of disease spread among a crop growing on the surface. Additional mesh tubes, such as 7300 can be installed parallel to water flow in a different portion of the surface having a different local slope. Any number of mesh tubes can be installed end-to-end.
[0118] In certain embodiments, a plurality of mesh tubes 7350 can be installed in a meandering, zig-zag, and/or herringbone pattern to maximize the mesh tube surface area encountered by water that flows by mesh tubes 7350 , thereby potentially maximizing the filtering effect of mesh tubes 7350 . Such an embodiment can be particularly useful when industrial, storm, and/or sewer waters must be treated prior to release. Moreover, the ground and/or soil bordered by such mesh tubes can also be lined with compost or other media capable of providing filtration.
[0119] In certain embodiments, a plurality of filled mesh tubes 7400 can be installed substantially adjacent each other and/or substantially parallel an expected flow of water in a channel or potential channel, such as a stream bed, gully, swale, ditch, and/or trench, etc. Such tubes can form and/or line a floor and/or side walls of the channel, thereby resisting erosion of the channel and/or replacing rip rap (large rocks) or check dams.
[0120] In certain embodiments, a mesh tube 7450 can be installed perpendicular and/or non-parallel to a local slope of the surface and/or an expected flow of water, to serve to baffle, divert, and/or slow run-off water flow and/or erosion in certain predetermined areas.
[0121] In certain embodiments, any mesh tube, such as mesh tubes 7350 , 7400 , 7450 can be used to divert flows of water that might otherwise cause flooding. For example, the mesh tube can be filled with a dense material, such as clay, that would allow a wall to be built capable of withstanding and/or diverting substantial flooding. Such embodiments can be a possible replacement for sand bags, which are commonly used for flood prevention and dike building, but can suffer from having multiple joints where water can penetrate.
[0122] In certain embodiments, a mesh tube 7500 can be installed such that a first end is adjacent and/or connected to an second end of mesh tube 7500 , thereby forming a substantially closed shape, such as a circle, oval, polygon, etc. Mesh tube 7500 can serve to -prevent water, sediment, contaminants, fertilizer, etc. from accessing a tree or other plant(s) surrounded by mesh tube 7500 . Mesh tube 7500 can also filter any water that does pass through mesh tube 7500 . Moreover, mesh tube 7500 can restrain water, sediment, contaminants, fertilizer, mulch, etc. within the substantially closed shape formed by mesh tube 7500 , and/or filter water than passes through mesh tube 7500 to escape from within that shape. Thus, tube 7500 can be used to de-water manure, biosolids, factory sludges, papermill residuals, and/or other slurries or slurry-like materials.,
[0123] In certain embodiments, one or more mesh rube, arranged in any configuration, can be installed and back-filled with a growing medium to elevate a growing zone contained therein. Within the fully and/or partially enclosed growing zone can be plants, such as for example, vegetables, berries, fruits, herbs, grains, crops, etc. Alternatively, the plants can grow from the top of the mesh tubes. In either case, growing the plants above-grade can potentially prevent the leaves, flowers, and/or fruit of the plants, or even the entire plants, from being exposed to soil, standing water, puddles, floods, splashes, etc., and thereby help prevent the establishment, growth, and/or spreading of soil-borne and/or water-borne pathogens, such as grey mold, botrytis, leaf spot, leaf blight, red stele, anthracnose, powdery mildew, leather rot, leak, verticillium, black root rot, leaflet rot, bud rot, yellow crinkle, hard rot, leaf blotch, fusarium, rhizoctonia, pythium, crown rot, etc. Moreover, if the plants are surrounded by such growing media as compost, the growing media can create a microclimate that can be slightly warmer than the soil at grade, thereby potentially preventing frost and/or snow damage to the plants and possibly decreasing time to market before fruiting/harvest begins.
[0124] Using mesh tubes to elevate plants can also raise the plants to a more workable elevation for gardeners, farmers, pickers, and/or others who tend to and/or harvest the plants. In unelevated zones between mesh tubes, vegetated mat and/or other groundcovers can be grown to enhance the drainage, human support attributes, and/or aesthetic performance of the unelevated zones.
[0125] Any of mesh tubes 7100 - 7500 can be color-coded to provide easy visual identification of a property of the tube, such as its nominal diameter or width, length, mesh size, material of construction, filling, product code, SKU, manufacturer, and/or distributor, etc. The tube can be primarily a single color, with a second, third, fourth, etc. color potentially used as a banding, stripe, spot, and/or in any other pattern to provide additional information. Such tubes can have stenciled names, numbers, logos, etc. imprinted thereon during the manufacturing process or afterward for product identification, marketing, etc. In certain embodiments, filled mesh tubes can be arranged such that they present a visible pattern, such as words, symbols, etc. when viewed from above, such as from an bridge, hilltop, and/or airplane.
[0126] FIG. 8 is a top view of an exemplary embodiment of a retention system 8000 . System 8000 can comprise an influent, such as a liquid and/or slurry, flowing via pipe and/or inlet 8100 into a retention zone 8200 , such as an enclosure, pond, marsh, etc. A wall 8300 defining retention zone 8200 can be formed of a mesh enclosure, such as a filled mesh tube, substantially as described herein. In certain exemplary embodiments, wall 8300 can be backed by an impermeable membrane and/or liner.
[0127] The influent can be storm water, spring water, stream water, outfall water from sewer treatment or drinking water plants, factory or farm discharges, contained contamination pumping discharges, run-off, and/or effluent, etc. The influent can follow a serpentine flow path 8400 through retention zone 8200 , potentially encountering one or more overflow inlet weirs 8500 that can be substantially perpendicular to flow path 8400 .
[0128] The serpentine flow path 8400 can flow across a floor 8600 of retention zone 8200 , which can be formed of a plurality of filled mesh tubes, substantially as described herein, and/or one or more netting-backed and/or netting-reinforced vegetation mats, substantially as described herein. Floor 8600 can be sloped from an entrance to retention zone 8200 toward an exit of retention zone 8200 to facilitate flow. A slope of floor 8600 can be from about 0.25 percent to about 10 percent, including every value therebetween, such as about 0.999, 1.5, 2.1, 2.5, 3.0001, 5, 7.48, etc. percent, and every sub-range therebetween, such as from about 0.8 percent to about 1.25 percent, etc.
[0129] Serpentine flow path 8400 can be at least partially defined by one or more baffles 8700 . The serpentine flow path 8400 also can be at least partially defined by, and/or influenced by, one or more flow diverters and/or erosion buffers 8800 . Effluent can exit retention zone 8200 at outlet 8900 , potentially after flowing over an outlet weir 8500 .
[0130] Baffles 8700 , buffers 8800 , outlet 8900 , and/or weir 8500 can be formed of one or more filled mesh tubes, substantially as described herein, and/or one or more netting-backed and/or netting-reinforced vegetation mats, substantially as described herein. Any component of system 8000 , including inlet 8100 , retention zone 8200 , wall 8300 , flow path 8400 , weir 8500 , floor 8600 , baffle 8700 , buffer 8800 , and/or outlet 8900 can be designed, selected, constructed, arranged, dimensioned, sized, and/or installed in a predetermined manner to accommodate expected (design) and/or actual site conditions, hydraulic load, volume, flow rate, flow frequency, flow consistency, residence time, contaminant load, sediment load, filtering needs, decontamination needs, etc. For example, components of retention system 8000 can be designed to accommodate a maximum flowrate of from about 0.25 feet per second (fps) to about 15 fps or greater, including every value therebetween, such as about 0.3333, 0.5, 0.75, 0.9123, 1.023, 1.5, 2, 6.7, 9.9, 12.8, etc. fps, and every sub-range therebetween, such as from about 0.8 fps to about 1 fps, from about 1.02 fps to about 9 fps, etc.
[0131] Any of wall 8300 , weir 8500 , floor 8600 , baffle 8700 , buffer 8800 , and/or outlet 8900 can be seeded and/or comprise plant material which can be chosen and/or planted in a predetermined manner to accommodate actual and/or expected site conditions. For example, a mesh tube and/or vegetation mat of retention system 8000 can be seeded with local native species, such as high marsh and/or low marsh vegetation, per Metropolitan Washington Council of Governments (MWCG) guidelines.
[0132] It should be understood that the preceding is merely a detailed description of one or more exemplary embodiments and that numerous changes to the disclosed embodiments can be made in accordance with the disclosure herein without departing from the spirit or scope of the invention. The preceding description, therefore, is not meant to limit the scope of the invention. Rather, the scope of the invention is to be determined only by the appended claims, every element of which can be replaced by any one of numerous equivalent alternatives without departing from the spirit or scope of the invention, only some of which equivalent alternatives are disclosed in the specification.
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At least one exemplary system comprises a tubular mesh enclosure formed from a mesh material having a nominal opening size of less than 0.5 inches, said tubular mesh enclosure having an opposing pair of ends, at least one of said opposing pair of ends sealed; and a filling surrounded by said tubular mesh enclosure; said system defining a length and a generally non-circular longitudinal cross-section defining a major width, a ratio of said length to said major width greater than approximately 40. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. This abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b).
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FIELD OF THE INVENTION
This invention relates to an improved process for the spinning production of filaments. More particularly, this invention relates to such an improved process wherein filaments of aromatic polyamide can be spun at a substantially increased rate while maintaining a high tenacity.
BACKGROUND AND PRIOR ART
Blades, U.S. Pat. No. 3,767,756, describes so-called air-gap spinning of anisotropic acid solutions of aromatic polyamides through a noncoagulating fluid, for example, air, and then into a coagulating liquid, for example, water. The spinnerets disclosed in Blades have a radial configuration of apertures and the filaments are coagulated in relatively still coagulating baths.
Yang, U.S. Pat. No. 4,340,559, describes a process improved over that disclosed in Blades. In Yang, the anisotropic spinning solution is passed through a layer of noncoagulating fluid, into a shallow, flowing, bath of coagulating liquid, and out of the bath through an exit orifice at the bottom of the bath, along with overflow coagulating liquid. The flow of coagulating liquid in the bath is nonturbulent but becomes turbulent at the site of localized jets arranged symmetrically about the exit tube and below but closely adjacent to the exit orifice. Moreover, flow of the coagulating liquid is increased by the force of the jets. Jets mentioned in Yang are radial or circular and are used to direct coagulating liquid in addition to the coagulating liquid which is caused to cascade, by free-fall, down the sides of the spin tube of small, circular, cross-section.
In the Yang apparatus, individual filaments are dragged over a solid lip or edge at the orifice from the bath.
European Patent Application 85/305646, published Feb. 19, 1986 as EP 172,001, discloses a process for spinning high-strength, high-modulus aromatic polyamide filaments using a free-falling coagulating bath. The filaments are produced by air-gap spinning an anisotropic solution of the polyamide in sulfuric acid, forming a single vertical warp of filaments, and conducting the filaments vertically downward into a gravity-accelerated and free-falling coagulating liquid. The coagulating liquid may be caused to be free-falling by passing the liquid over the edge of a continuously supplied reservoir so that the liquid forms a waterfall. After the filaments have been formed by contact with the coagulating liquid, they may be contacted with additional coagulating liquid such as by a side stream of liquid fed into the gravity-accelerated and free-falling coagulating liquid. Such a side stream may be fed into the existing stream in a nonturbulent manner and at about the speed of the filaments.
A "warp" is defined herein as an array of filaments aligned side-by-side and essentially parallel.
SUMMARY OF THE INVENTION
The present invention provides a process and an apparatus for preparing filaments from a solution of polymer by extruding the solution through linearly arranged apertures in a spinneret; that is, through apertures arranged in rows and staggered to provide a vertical warp of uniformly spaced filaments which travel downward through an air gap, and are coagulated and forwarded to a collecting means. Jets are located on each side of the warp adjacent the spinneret for jetting opposed sheets of liquid from each side of the warp at an angle with the warp to meet at a common line across the width of the warp below the face of the spinneret to coagulate the filaments. Each of the sheets of liquid is wider than the warp at the common line and each has a vertically downward component of velocity less than the downward velocity of the filaments.
This invention is particularly directed toward preparing para-aromatic polyamide filaments from an optically anisotropic acid solution of the para-aromatic polyamide by extruding an acid solution of the aromatic polyamide through linearly arranged apertures and coagulating the warp, thus formed, by jetted sheets of coagulating liquid.
The sheets, after meeting, join and envelop the filaments;--moving at a velocity from about 20 to about 99% of the velocity of the filaments. At higher than about 99%, process problems develop which disrupt the continuity of operation; and, at lower than about 20%, the benefits of the invention are not realized over the processes of the prior art.
Operation of the invention must be controlled to avoid backsplash of the jetted sheets. When sheet velocity is too high, or the included angle between the sheets is too great, or the thickness of the jetted sheet is too large, the impingement of the sheets will cause the coagulating liquid to be splashed back on, as yet, uncoagulated filaments;--thus causing uneven fiber product qualities.
Backsplash may occur at sheet velocities of less that 99% of the velocity of the filaments if other conditions of the process are altered in such a way to generate such backsplash. Backsplash should be avoided in the practice of the present process.
The apparatus can include at least one guide for changing direction of the filaments below the location where the jetted sheets of liquid meet.
It has been recognized that increased spinning speeds cause a variation in fiber quality when radial spinnerets are used because the filaments, as they are drawn into the coagulating liquid, draw the coagulating liquid along and cause a depression in the surface of the coagulating liquid. That depression in the coagulating liquid creates a longer air gap for filaments near the center of the radial spinneret arrangement than the air gap for filaments at the edge of the arrangement. The variation in air gap yields a significant variation in fiber quality. U.S. Pat. No. 4,702,876 recognized the problem and attempted a solution by reducing the amount of coagulating liquid drawn away with the filaments.
It has, also, been recognized that high spinning speeds create a significant drag on the filaments due to the large difference in velocity between the filaments and the coagulating liquid and the resultant drag on the filaments.
The present invention provides fiber quality improvement and increased spinning speeds by mitigating both of the above-mentioned conditions. The use of a linear spinneret and a linear coagulating liquid delivery means eliminates the variation in path lengths through the air gap experienced with radial spinneret devices; and the use of high speed, laminar, jets of coagulating liquid--with no associated low speed or quiescent components--reduces the relative filament-to-coagulating liquid speeds and substantially eliminates coagulating liquid drag on the filaments. Filaments made by the present invention are not forced together and do not come into contact with any solid or mechanical surfaces until after being coagulated.
Spinning speeds for practice of this invention can range from less than 100 or 200 meters per minute to 1000 or 2000 meters per minute or, perhaps, higher.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of apparatus suitable to carry out the process of the invention.
FIG. 2 is a cross-sectional elevation view of FIG. 1 taken on lines 2--2 of FIG. 1.
FIG. 3 is a partial cross-sectional elevation view of another apparatus suitable to carry out the process of the invention.
FIG. 4 is a simplified schematic diagram of the coagulating liquid flow control system.
FIGS. 5 and 6 are simplified representations of acceptable patterns of apertures for use in the spinneret for practicing this invention.
FIG. 7 is a graphical representation of the tenacity of fibers for different spinning speeds comparing fibers of the prior art with fibers made by the present invention.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT
Referring now to the drawings in which like or corresponding parts are designated by like reference characters throughout the several views, the apparatus chosen for purposes of illustration is shown in FIG. 1 and generally includes a spinning solution manifold 10 with its spinning solution supply pipe 12 connected thereto and a spinneret body 14 attached to the manifold. Spinneret apertures 16 are linearly arranged in accordance with FIGS. 5 and 6 wherein apertures 16 are arranged in rows across face 15 of spinneret body 14 and the positions of the apertures in each row are staggered so as to provide a warp 20 of uniformly spaced filaments 22 when coagulated and condensed below the spinneret.
Two linear jet bodies 30, 32 are located on opposite sides of the spinneret body and are supplied with coagulating liquid by means of supply pipe 34. A filament warp direction-changing guide 38 is located above liquid-collecting tank 39. A means for forwarding the warp of filaments, such as by a rotating spool, is designated by the element 40.
Referring to FIG. 2 it can be seen that jet bodies 30 and 32 are opposed to each other, are mounted at opposite sides of spinneret body 14 and parallel with the array of apertures 16, and can be insulated from the spinneret body by insulation panels 27 and 29. The jet bodies are capable of delivering sheets of coagulating liquid 31 and 33 from jet slots 35 and 37 to impinge at common line 21 across the warp 20 of filaments. The jet bodies 30 and 32 are directed such that extensions of the slots 35 and 37 meet at common line 21 vertically beneath the face 15 of the spinneret. The jet bodies 30 and 32 supply linear, substantially laminar flow, sheets of liquid 31 and 33. By "substantially laminar flow" is meant that the sheets of liquid are transparent to the eye. The sheets of coagulating liquid are wider than warp 20 at line 21.
From FIG. 3, it can be seen that the jet bodies 30 and 32 need not be mounted in direct juxtaposition with the spinneret body 14; but can be affixed to the apparatus separate from the spinneret body. When such an arrangement as in this FIG. 3 is used, the angle formed between the jetted sheet of liquid 31 or 33 and the warp 20 is often larger than the angle formed in the arrangement of FIG. 2.
Referring to FIG. 4, the coagulating liquid is supplied to a jet body 30 from a source 50 by means of pump 52 through control valve 54 and flow meter 56, all connected serially to pipe 34 supplying the jet body. The velocity of the jetted sheets can be varied by altering the operation of pump 52, by changing the setting of control valve 54, and by varying the thickness of jet slots 35 and 37.
In operation, an acid solution of para-aromatic polyamide is extruded through apertures 16 in spinneret 14 as filaments to form a vertical warp 20. The warp 20 is passed through an air gap 13 and is then coagulated by jetting two opposed transparent sheets of liquid 31, 33 toward the warp to meet at common line 21 across the warp. The liquid flows downwardly with the filaments and is separated from the filaments and caught in container 39 as the filaments change direction around guide 38. The filaments are then forwarded by means of element 40.
Although the length of the air gap is not necessarily critical to operation of this invention, the preferred air gap is 1 to 3 cm and can range from 0.5 to 7 or, perhaps, slightly more at the highest spinning speeds.
Although not critical or important to practice of this invention, the preferred coagulating liquids are aqueous, either water alone or water containing minor amounts of sulfuric acid. The coagulating liquid is usually at an initial temperature of less than 25° C., often less than 10° C., and preferably no higher than 5°.
The spinning solution is often at a temperature above 20° C. and usually is about 80° C. A preferred spinning solution is one that contains poly(p-phenylene terephthalamide). Other examples of appropriate aromatic polyamides or copolyamides are described in U.S. Pat. No. 3,767,756.
The array of apertures in the spinneret plate is preferably in a single row or a few rows, and are preferably less than six rows and not more than ten.
In spinneret plates with large numbers of apertures, the warp is usually divided into at least two sections with jetted sheets of coagulating liquid impinging each section. When very long linear spinnerets are used, there is a considerable distance required to gather the filaments of a wide warp down into a yarn. By dividing a wide warp into sections, the filaments can be more effectively gathered into yarn. Each section of a warp can be impinged by an individual pair of jetted sheets or all of the sections in a warp can be coagulated by a single pair of jetted sheets which sheets can, generally, be separated with a portion following each section.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the conduct of the following examples, there were used different spinnerets and different coagulating jets. Those spinnerets and those coagulating jets will be described in some detail but it should be understood that a variety of spinnerets and coagulating jets can be used to practice this invention.
Spinneret "A", as shown in FIG. 5, had capillaries of 0.064 mm diameter and less than 0.2 mm length. There were 134 apertures in four rows and the apertures were in hexagonal closepacked arrangements. Yarn made using Spinneret A was 200 denier.
Spinneret "B", as shown in FIG. 6, had apertures similar to those in Spinneret A. There were 134 apertures in four offset rows. Yarn made using Spinneret B was 200 denier.
In practice of this invention, spinnerets, generally, have capillaries of 0.05 to 0.075 mm in diameter and the rows of capillaries are, generally, spaced apart 0.5 to 1.5 mm.
The different spinnerets were used with different coagulating jet configurations to demonstrate several embodiments of the invention. In one such configuration, designated to be Design 1 for purposes of this description, a pair of coagulating jet bodies were mounted adjacent to and somewhat beneath the face of the spinneret. That configuration is shown in Fig. 3. Due to the bulk of the coagulating jet bodies, the included angle for the line of impingement was 45° and the air gap was about 3.8 to 4.4 cm. The included angle is that angle made by the jetted sheets 31 and 33 (or the extension of slots 35 and 37) at common line 21 and the air gap is the distance from the face of spinneret 14 to the common line of impingement 21.
In another configuration, designated to be Design 2 for purposes of this description, a pair of coagulating jet bodies were mounted adjacent to and directly juxtaposed with the spinneret body somewhat above the spinneret face. That configuration is shown in FIG. 2. The included angle for the line of impingement was 30° and the air gap was about 1.3 cm.
It is believed that the magnitude of the included angle is important to practice of this invention only insofar as it is necessary to select an included angle which will not result in backsplash. Included angles of about 20 to 60 could be used.
Information relating to the manufacture of jet bodies which will yield substantially laminar flow (will yield jetted sheets which are transparent) can be found in Rev. Sci. Instrum., Vol. 53, No. 12, pp. 1855-1858, 1982, Harri et al. and Applied Physics, Vol. 3, pp. 387-391, 1974, Wellegehausen et al.
Tenacity was the yarn property which was used as a measurement of fiber quality for demonstration of the present invention. It would be expected that fibers of high tenacity would exhibit correspondingly high qualities in other areas.
Tenacity was determined on yarn which had been washed, neutralized, dried, and wound up. Yarn to be tested was conditioned for at least 16 hours at 24° C. and 55% relative humidity. Yarn samples were given a twist sufficient to yield a twist multiplier of 1.1; and were broken with a gage length of 25.4 cm. Twist multiplier is defined as equal to the quantity [(twists/inch)(denier of yarn) 1/2 /73].
The results of tests on five yarns were averaged. The rate of elongation was 10 percent per minute and load-elongation curves were plotted from a tensile testing machine. Denier of the yarn was determined by weighing a known length. Tenacity was obtained from the load-elongation curve and the calculated denier.
EXAMPLE 1
Poly(p-phenylene terephthalamide) was dissolved in 100.1% sulfuric acid to yield a 19.4%, by weight, spinning solution. The solution was spun at about 80° C. through Spinneret A with the coagulating jets of Design 1. After an air gap of about 3.8 cm, the spun filaments met with the opposed jets of coagulating liquid at the line of impingement and, immersed in the jetted coagulating liquid, were conducted past a change of direction pin and to a forwarding roll. The jetted coagulating liquid was, also, 3% sulfuric acid and was maintained at a temperature of about 3° C.
The width of the jets was about 7.6 cm and, for this example, the thickness of the jet slots was set at about 0.076 mm. Spinning was conducted at three speeds using three different speeds for the jetted sheets. Results are shown in Table I.
EXAMPLE 2
In this example, all parameters of the spinning and jet coagulating configuration were maintained the same as in Example 1 except that the thickness of the jet slots was increased to about 0.101 mm. Spinning was conducted at four speeds using four different speeds for the jetted sheets. Results are shown in Table I.
EXAMPLE 3
In this example, the spinning solution of Example 1 was spun at about 80° to 85° C. through Spinneret B with the coagulating jet bodies of Design 2. After an air gap of about 1.27 cm, the spun filaments met with the opposed jets of coagulating liquid at the line of impingement and, immersed in the jetted coagulating liquid, were conducted past a change of direction pin and to a take-up spool. The jetted coagulating liquid was 3% sulfuric acid and was maintained at a temperature of about 3° C.
The width of the jets was about 5.1 cm and, for this example, the thickness of the jet slots was set at about 0.127 mm. Spinning was conducted at two speeds using two different speeds for the jetted sheets. Results are shown in Table I.
TABLE I______________________________________ Spinning Speed Jet Speed Yarn TenacityEXAMPLE (m/m) (m/m) (gpd)______________________________________1 594 548 26.2 686 634 25.9 777 676 25.72 503 460 25.4 594 543 25.8 686 627 26.1 777 710 25.1*3 594 574 27.2 686 663 27.2 594 574 27.3**______________________________________ *Backsplash reduced quality of fibers. **Run at 85° C. spinning solution temp. The others run at 80° C.
EXAMPLE 4
In this example, the spinning solution of Example 1 was spun at about 85° C. through Spinneret B with coagulating jet bodies of Design 2 as in Example 3.
The thickness of the jetted sheets was varied in three runs wherein the spinning speed was maintained constant at 594 meters per minute (m/m). The jet velocity was set at 578 m/m; but was reduced to 486 m/m for the thickest jet sheet to avoid backsplash. The results are shown in Table II. Note that the reduced jet speed resulted in slightly reduced tenacity.
TABLE II______________________________________Jet Slot Thickness Yarn Tenacity(mm) (gpd)______________________________________5 27.26 27.77.5 26.4______________________________________
EXAMPLE 5
In this example, the spinning solution of Example 1 was spun at about 80° C. through Spinneret B with coagulating jet bodies of Design 1 and the length of the air gap was varied in three different runs. The spinning speed was set at 594 m/m, the jet velocity was set at 548 m/m, and the jet slot thickness was set at 0.076 mm. Results are shown in Table III.
TABLE III______________________________________Air gap Yarn Tenacity(cm) (gpd)______________________________________1.9 27.03.2 26.34.4 25.6______________________________________
EXAMPLE 6
In this example, the spinning solution of Example 1 was spun at about 85° C. through Spinneret B with coagulating jet bodies of Design 2 and the spinning speed, the jet velocity, and the jet slot thickness were varied in three runs. The air gap was maintained at about 1.3 cm. The results are shown in Table IV.
TABLE IV______________________________________Spinning Speed Jet Speed Jet Slot Thickness Yarn Tenacity(m/m) (m/m) (mm) (gpd)______________________________________594 574 0.076 26.0732 707 0.076 25.8594 574 0.101 26.3______________________________________
EXAMPLE 7
In this example, the spinning solution of Example 1 was spun at about 70° to 80° C. through a spinneret similar to Spinneret B and modified slightly such that there were a total of three separate segments of four rows of 63 apertures all in a linear configuration. There were a total of 252 apertures for each segment and the segments were separated by a distance of about 2.5 cm.
There were three pairs of coagulating jet bodies of Design 2 mounted such that each spinneret segment was centered between a pair of jet bodies. Fibers were spun, as in the previous examples, at several different spinning speeds utilizing the highest jet speed which could be used without causing backsplash or a problem with separation of the filaments from the coagulating liquid at the change of direction guides. The thickness of the jet slots was set at 0.101 mm and the air gap was about 1.9 cm. Filaments spun from all three of the spinneret segments were run to separate change of direction guides and were, then, consolidated into a single yarn of about 1134 denier. Results are shown in Table V and a graphic representation of the yarn tenacity as a function of the spinning speed is provided in FIG. 7.
As a comparative example, the same spinning solution, at the same spinning conditions, was spun through a radial spinneret having 767 apertures arranged in concentric circles within an outer circle of about 3.8 cm and of a diameter to yield a yarn of 1150 denier. The solution was spun from the circular array of apertures into a coagulating tray/jet apparatus corresponding to Tray G shown in FIG. 1 of U.S. Pat. No. 4,340,559. The spin tube had a diameter of about 7.6 mm. The solution was spun through an air gap of about 0.65 cm at four different spinning speeds with the jets of that apparatus increasing correspondingly. Results are shown in Table V and a graphic representation of the yarn tenacity as a function of the spinning speed is provided in FIG. 7.
FIG. 7 clearly shows that the tenacity of fibers made by the present invention is substantially unchanged by increase in the spinning speed while the tenacity of fibers made by the indicated prior art process and apparatus is markedly reduced with increase in spinning speed.
TABLE V______________________________________Spinneret Spinning Speed Jet Speed Yarn TenacityType (m/m) (m/m) (gpd)______________________________________Linear 320 309 25.4Linear 457 441 25.8Linear 594 574 25.8Linear 732 707 25.7Radial 320 491 25.5Radial 457 670 24.0Radial 594 851 23.2Radial 732 1026 22.6______________________________________
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Coagulating a warp of filaments from a linear spinneret by delivering a transparent, jetted sheet of coagulating liquid equally and uniformly along each side of the warp.
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FIELD OF THE INVENTION
The invention relates to ion-sensitive compounds. More particularly, the invention relates to ion-sensitive compounds comprising a receptor designed to bind anionic species by the formation of a receptor-substrate complex.
BACKGROUND OF THE INVENTION
Anion receptors comprising a plurality of quaternary amine groups are known. Examples of such compounds may be seen in P.G. Potvin and J-M Lehn, Prog. Macrocyclic Chem., 1987, 3, 214.
L .A. Summers, "The Bipyridinium Herbicides", Academic Press, New York, 1980, describes the use of certain compounds comprising diquaternary 2,2'-bipyridinium moieties in herbicidal applications.
Metal ion centres have also been utilised in systems for the recognition of anions as described in D.N. Reinhoudt, J. Am. Chem. Soc. 1992, 114, 9671-9673.
PROBLEM TO BE SOLVED BY THE INVENTION
There is a continuing need to provide new receptor compounds for a variety of applications. For example, there is a need for compounds which can be incorporated in electrochemical or optical sensors for anion determination. There is also a need for compounds which can be used in removal devices where levels of a given anion need to be kept low.
It is also desirable to provide receptor compounds which can be readily synthesised.
SUMMARY OF THE INVENTION
The ion-sensitive compounds of the invention have the formula A 2+ B 2- wherein A represents a cation capable of forming a receptor-substrate complex with an anion, and B represents one or more counter anions, characterised in that the cation is an anion receptor represented by the formula I ##STR2## or by the formula II ##STR3## wherein
R 1 and R 2 are each independently a substituted or unsubstituted alkyl group, a substituted or unsubstituted aryl group or R 1 and R 2 taken together with the atoms separating them represent the atoms necessary to complete a (2)-cryptand; and,
R 3 and R 4 are each independently H or a lower alkyl group having from 1 to 4 carbon atoms, or R 3 and R 4 taken together represent an ethylene bridging group.
The invention also provides a method of sensing an anion in solution by contacting the anion with a compound comprising a cation which is a receptor for the anion to form a receptor-substrate complex and sensing a detectable change which results from the formation of the complex characterised in that the compound is a compound of the invention.
ADVANTAGEOUS EFFECT OF THE INVENTION
The compounds of the invention show selectivity to anions and are useful for the electrochemical and/or optical detection of anions, especially halides and particularly chlorides.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cyclic voltammogram of a compound of the invention.
FIG. 2 is a graph showing the fluorescence of a compound of the invention.
FIG. 3 is a 1 H NMR titration curve of a compound of the invention and Cl - in CD 3 CN solution.
DETAILED DESCRIPTION OF THE INVENTION
Preferably, R 1 and R 2 are each independently a substituted or unsubstituted alkyl group having from 1 to 20 carbon atoms e.g. methyl, ethyl, propyl, butyl, pentyl, hexyl, eicosyl. Suitable substituents include alkyloxy, aryloxy, alkylamido, arylamido, atkylsulfonamido, arylsulfonamido, dialkylamino, cyano and nitro. Specific examples of such R 1 and R 2 groups include butyl and methoxyethyl.
Preferably, R 1 and R 2 are each independently a substituted or unsubstituted phenyl group. Suitable substituents include alkyloxy, aryloxy, alkylamido, arylamido, alkylsulfonamido, arylsulfonamido, dialkylamino, cyano and nitro. A specific example of such a group is 3,4-dimethoxyphenyl.
R 1 and R 2 taken together with the atoms separating them may represent the atoms necessary to complete a (2)-cryptand. Preferably, the (2)-cryptand comprises two ionisable hydroxy groups. The two ionisable hydroxy groups together with the two amide protons shown in formula I and II are preferably arranged tetrahedrally with respect to each other within the cavity defined by the (2)-cryptand. Preferably, the (2)-cryptand comprises a bridged, conformationally locked ring system. In a particularly preferred embodiment, the (2)-cryptand comprises a bridged calix(4)arene. Attachment of the calix(4)arene to the two amide groups shown. in formula I and II may be through the 1 and 3 positions of the calix(4)arene, respectively, whereby the 2- and 4-hydroxy groups in the calix(4)arene ring represent two ionisable hydroxy groups.
Preferably, R 1 and R 2 taken together have the following structure ##STR4## wherein R 7 , R 8 , R 9 and R 10 are each independently hydrogen, a substituted or unsubstituted alkyl group, a substituted or unsubstituted aryl group, an alkylamido group, an arylamido group, an alkylsulfonamido group, an arylsulfonamido group or a nitro group; and,
R 5 and R 6 are each independently a substituted or unsubstituted alkylene group e.g. --(CH 2 ) 2 --.
Preferably, R 7 , R 8 , R 9 and R 10 are each independently H, a substituted or unsubstituted alkyl group having from 1 to 20 carbon atoms e.g. methyl, ethyl, propyl, butyl, pentyl, hexyl and eicosyl. Tertiary alkyl groups are particularly preferred e.g. t-butyl. Suitable substituents include alkylamido, arylamido, alkoxycarbonyl, aryloxycarbonyl, alkylsulfonamido, arylsulfonamido, alkylcarbonyl, alkoxy, cyano and nitro.
Preferably, R 7 , R 8 , R 9 and R 10 are each independently a substituted or unsubstituted phenyl group. Suitable substituents include alkyloxy, aryloxy, alkylamido, arylamido, alkylsulfonamido, arylsulfonamido, alkyloxycarbonyl, aryloxycarbonyl and nitro.
Preferably, R 3 and R 4 are each methyl groups.
B 2- represents any suitable anions which together with A 2+ are capable of forming a stable compound. Examples of such anions include sulphate, nitrate, phosphate, borate and halide e.g. iodide. Preferably, B 2- represents weakly coordinating anions such as hexafluorophosphate and tetrafluoroborate.
The 4,4'- and 5,5'-amide disubstituted bipyridine compounds of the invention can be synthesised via condensation reactions of respective 4,4'- and 5,5'-bischlorocarbonyl-2,2,'-bipyridines with appropriate primary amines e.g. an arylamine, an alkylamine or a bisaminecalix(4)arene. The resulting bisamide can then be quaternised to give compounds of structure I e.g. by sequential treatment with dialkyl sulphate and ammonium hexafluorophosphate. Alternatively, the resulting bisamide can be converted into a compound of structure II by reaction with [RuCl 2 (bipy) 2 ].2H 2 O e.g. by refluxing with [RuCl 2 (bipy) 2 ].2H 2 O in a suitable solvent such as ethylene glycol. The resulting complex can be precipitated on addition of a suitable salt such as ammonium hexafluorophosphate.
The compounds of the invention can be used in a method of sensing anions. as indicated above. The detectable change resulting from formation of the complex can be measured by any suitable means such as NMR measurement, electrochemical measurement e.g. cyclic voltammetry, or optical measurement e.g. fluorescence spectroscopy.
Specific examples of the preparation of compounds of the invention are given as follows.
EXAMPLE 1
N,N'Dibutyl-6,6'-binicotinamide
5,5'dicarboxy-2,2'bipyridine (0.24 g, 0.98 mmol) was refluxed in 25 ml of thionyl chloride freshly distilled from triphenylphosphite .for 40 hours under nitrogen. The solid eventually disappeared to produce a yellow solution, after which the excess thionyl chloride was distilled off. and the yellow solid was dried for several hours in vacuo. The 2,2'-bipyridyl-5,5'-dicarboxylic acid chloride was dissolved in dry THF (20 ml) to which was then added dropwise butylamine (10 ml, 101 mmol) dropwise at room temperature under nitrogen and washed in 10 ml THF. A white precipitate formed almost immediately. The reaction was then stirred for 24 hours after which the solid was removed by filtration and washed with THF 3×20 ml and water 2×10 ml. The solid was then heated in 50 ml deionised water at 90° C. for 30 minutes after which it was filtered and dried in the oven (0.20 g, 57%).
Elemental analysis calculated for C 20 H 26 N 4 O 2 ;C, 67.8%, H, 7.4%, N, 15.8%. Found C, 66.6%, H, 7.7%, 15.6%.
5,5'-Di(butylaminooxo)-1,1'-dimethyl-2,2'-bipyridinium dihexafluorophosphate
5,5'-Di(butylaminooxo)-2.2'-bipyridine (0.11 g, 0.31 mmol) was heated at 80° C. in dimethylsulphate (10 ml, 106 mmol) for 24 hours to produce a red solution. The dimethylsulphate was distilled off under reduced pressure. The solid was dissolved in 100 ml deionised water to which was added ammonium hexafluorophosphate (2.00 g, 12 mmol) in 5 ml water which gave a brown precipitate, which was collected by vacuum filtration. The brown precipitate was purified by column chromatography on silica with acetonitrile as the elutant giving a brown solid after removal of the solvent (0.12 g, 57%).
The compound has the structure of Formula I wherein R 1 and R 2 are each butyl and R 3 and R 4 are each methyl.
EXAMPLE 2
2,2'-Bipyridyl-5,5'-dicarboxylic acid
5,5'Dimethyl-2,2'-bipyridine (4.53 g, 24.6 mmol) was dissolved in concentrated sulphuric acid (50 ml). After cooling to 0° C. chromium (VI) oxide (14.88 g, 148.8 mmol) was ground and added in small proportions over a 2 hour period. The red mixture was heated to 65° C. for 17 hours while stirring giving a green solid which was washed into 350 ml ice/water with concentrated sulphuric acid (50 ml) to give a fine green suspension. The green solid was isolated over several days via vacuum filtration. The solid was dissolved up in 4M sodium hydroxide (500 ml) which was then acidified with 1M hydrochloric acid to pH8 whereupon chromium (III) hydroxide precipitated. The dark green precipitate was filtered off under gravity to give a pale yellow filtrate which upon further acidification with 1M hydrochloric acid to pill precipitated the product which was collected by vacuum filtration and dried in vacuo (yield 4.89 g, 81%).
N,N'-Bi(3,4-dimethoxyphenyl)-6.6'-binicotinamide
5,5'-dicarboxy-2,2'-bipyridine (0.50 g, 2.05 mmol) was refluxed in 25 ml of thionyl chloride freshly distilled from triphenylphosphite for 22 hours under nitrogen. The solid eventually disappeared to produce a yellow solution, after which the excess thionyl chloride was distilled off and the yellow solid was dried for several hours in vacuo. The 2,2'-bipyridyl-5,5'-dicarboxylic acid chloride .was then used in situ without further isolation. The yellow solid was partly dissolved up in dry THF (10 ml) to which was then added dropwise 4-aminoveratrole (6.31 g, 41.1 mmol) dropwise in dry THF (30 ml) at room temperature under nitrogen and washed in with a further 10 ml THF. A buff precipitate formed almost immediately. The reaction was then stirred for 15 hours after which the solid was removed by filtration and washed with THF 3×20 ml and water 2×10 ml. The solid was then heated in 50 ml deionised water at 90° C. for 30 minutes after which it was filtered and dried in the oven (0.42 g, 47%) .
The compound has the structure of Formula II wherein R 1 and R 2 are each 3,4-dimethoxyphenyl.
Elemental analysis calculated for C 28 H 26 N 4 O 6 ;C, 65.4%, H, 5.1%, N, 10.9%. Found C, 64.1%, H, 5.1%, 10.4%.
Ru.sup.(II) (bipyridyl) 2 Complex Salt
5,5'-Bis(3,4-dimethoxyphenylaminooxo )-2,2'-bipyridine (0.10 g, 0.195 mmol) was dissolved in DMF (40 ml) with [Ru.sup.(II) (bipy) 2 Cl 2 ].2H 2 O(0.103 g, 0.195 mmol) and heated at 80° C. for 17 hours. The solution went from purple to dark brown, the solution was filtered, and washed with 10 ml water. The volume was reduced, and ammonium hexafluorophosphate (2.5 g, 15 mmol) in 5 ml of water was added. A brown precipitate was obtained, which was purified on Sephadex LH20 in acetonitrile methanol 50:50.
Elemental analysis calculated for C 48 H 42 N 8 O 6 RuP 2 F 12 .H 2 O;C, 46.7%;H, 3.6%;N, 9.1%. Found C, 46.2%; H, 3.5%; N, 9.1%.
EXAMPLE 3
1,3 Biscyanocalix(4)arene
A slurry of paratertiarybutylcalix(4)arene (3.0 g, 4.05 mmol) and anhydrous potassium carbonate (1.12 g, 8.1 mmol) was stirred in predried acetone (100 ml) at room temperature for 10 minutes. Bromoacetonitrile (0.77 ml, 8.1 mmol)was added and the reactants stirred for 48 hours at room temperature. The salt precipitated was removed by filtration and the acetone removed under reduced pressure to leave the crude product. This was taken up in dichloromethane and washed with 1×100 ml hydrochloric acid, the solvent again removed under reduced pressureto leave the product as a white crystalline solid. Yield 95%.
1,3 Bisaminecalix[4]arene
A slurry of the 1,3 biscyanocalix[4]arene (1.5 g, 2.2 mmol) and lithium aluminjure hydride (0.66 g, 17.6 mmol) was refluxed in dry diethylether (75 ml) for 4 hours under a nitrogen atmosphere. The reaction flask was then placed into an ice bath and the excess lithium aluminium hydride destroyed using water (dropwise, vigorous stirring). The alumina precipitated was filtered and washed with chloroform and the solvents removed under reduced pressure to leave the product as a white crystalline solid. Yield 75%.
Bipyridylcalix[4]arene
The 1,3 bisaminecalix[4]arene (1.00 g, 1.36 mmol), triethylamine (0.38 ml, 2.72 mmol) and dimethylaminopyridine (microspatulae) were dissolved in dichloromethane (250 ml) and stirred at room temperature under a nitrogen atmosphere. To this mixture 4,4'-bischlorocarbonyl-2,2'-bipyridine (0.34 g, 1.36 mmol) in dichloromethane (100 ml) was added dropwise. White fumes. of triethylamine hydrochloride were observed on the addition and the reactants were stirred for a further 16 hours at room temperature. The reaction mixture was washed with 3×100 ml water, dried over magnesium sulphate and the solvent removed under reduced pressure to leave the crude pink product. This was purified using column chromatography. Silica (mesh 230-400); eluent methanol:ethylacetate:dichloromethane (2:2:1), (Rf 0.80). Yield 35%.
On scaled-up reactions the amine and acid chloride were added simultaneously to a stirring solution of triethylamine and dimethylaminopyridine in dry dichloromethane. The crude product was first purified on a silica column using an eluent of chloroform:acetone:methanol.(6:2:1), (Rf 0.35) followed by a second column as stated above.
Bipyridyl Ruthenium Complex PF 6 -Salt
A slurry of the bipyridylcalix[4]arene (0.10 g, 0.106 mmol) and ruthenium dipyridyl (0.055 g, 0.106 mmol) in ethanol (4 ml), water (4 ml) and acetic acid (0.5 ml) was refluxed for 4-6 hours. The reaction was followed using silica thin layer chromatography plates with an eluent the same as the reaction solvent. The product formation is monitored using long wavelength ultra violet light and appears at Rf 0.38. On completion of the reaction the solvents were removed under reduced pressure followed by further drying under high vacuum at 50° C. The crude reaction mixture was purified on a Sephadex™ column (LH20-100) eluent neat acetonitrile. The column was eluted very slowly and the orange product collected after approximately 5 hours. Fractions were monitored by thin layer chromatography as described above. The solvent was removed from the product under reduced pressure to leave the chloride salt of the complex. The chloride salt was taken up in water and deposited as the hexafluorophosphate salt by addition of ammonium hexafluorophosphate to the solution. Yield 65%.
The compound has the structure of Formula II wherein R 1 and R 2 taken together have the calix(4)arene structure described above in which R 7 , R 8 , R 9 and R 10 are each tert-butyl and R 5 and R 6 are each --(CH 2 ) 2 --.
The chemical structures of the compounds prepared in Examples 1 to 3 were confirmed by NMR and mass spectroscopy measurements.
EXAMPLE 4
On addition of tetrabutyl ammonium chloride (TBAC) to a solution of the compound of Example 2 in deuteriochloroform a shift was observed in the 1 H NMR signals due to protons adjacent to the chloride binding site. These results are shown below. ##STR5## wherein bipy represents bipyridyl.
______________________________________ Δδ/ppm Δδ/ppmProton 1 × Cl.sup.-- 2 × Cl.sup.--______________________________________a.sup. 0.10 --b.sup. 0.21 0.32c.sub.1 0.07 0.11c.sub.2 0.05 0.07______________________________________
The cyclic voltammogram of the compound was recorded as shown in FIG. 1. This was very similar to that of known ruthenium (II) tris-bipyridyl complexes whose electrochemical response has been well documented.
The cathodic shifts observed on addition of chloride anion to the compound of Example 2 (peak A) are shown as follows:
______________________________________Equivalents of C1 1.0 2.0 5.0Oxidation Shift (V) 0.01 0.02 0.03Reduction Shift (V) 0.01 0.02 0.04______________________________________
The effect of the addition of chloride ions on the fluorescence of the compound of Example 2 is shown in FIG. 2. Increasing chloride concentration causes a decrease in fluorescence.
EXAMPLE 5
On addition of tetrabutyl ammonium chloride to the compound of Example 1 a downfield shift was observed in the 1 H NMR signals due to protons adjacent to the chloride binding site. These results are shown below: ##STR6## wherein the proton atoms of the methyl groups are the "e" protons.
______________________________________ Δδ/ppm Δδ/ppmProton +1 equivalent of Cl.sup.-- +2 equivalent of Cl.sup.--______________________________________a 0.29 0.54b 0.19 0.27c 0.12 0.17d 0.05 0.07e 0.02 0.02______________________________________
EXAMPLE 6
Anion recognition by the compound of Example 3 has been demonstrated by 1 H NMR and cyclic voltammetry. Addition of tetrabutyl ammonium halides, hydrogen sulphate and dihydrogen phosphate to solutions of the compound in CD 3 CN resulted in perturbations of the receptor's, protons. With chloride, the amide proton of the compound is shifted downfield by Δδ1.5ppm; the 3,3'-bipyridyl proton of the receptor was also perturbed. These effects are summarised in the resulting titration curve shown in FIG. 3.
Comparison of the results of cyclic voltammetry for the compound of the invention shown in Table 1 below with the known electrochemical properties of [(bipy) 3 Ru](PF 6 ) 2 provides further evidence for anion recognition.
______________________________________Redox couple +3/+2.sup.d +2/+1.sup.e +1/0.sup.e 0/-1.sup.e______________________________________E.sub.1/2 (free, V).sup.a 1.12 -1.39 -1.79 -2.02ΔE(H.sub.2 PO.sub.4.sup.--,mV).sup.b,c -- 175 <5 <5ΔE(HSO.sub.4.sup.--,mV).sup.b -- 15 <5 <5ΔE(Cl.sup.--,mV).sup.b -- 70 <5 <5ΔE(Br.sup.--,mV).sup.b -- 60 <5 <5ΔE(I.sup.--,mV).sup.b -- 40 <5 <5______________________________________ .sup.a Obtained in acetonitrile solution containing 0.1M [Bu.sup.n.sub.4 N]PF.sub.6 as supporting electrolyte. Solutions were about 5 × 10.sup.-4 M in compound and potentials were determined with reference to Ag.sup.+ /Ag electrode (330 ± 5 mV vs. SCE) at 21 ± 1° C. at 50 mVs.sup.-1 scan rate. .sup.b Cathodic shifts of reduction potential produced by presence of anions (up to 10 equivalents) added as their tetrabutyl ammonium salts. .sup.c DMSO was added (up to 50% v/v) before the addition of H.sub.2 PO.sub.4.sup.-- to prevent precipitation of complex. .sup.d Metal centred oxidation. .sup.e Ligand centred reduction.
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Ion-sensitive compounds have the formula A 2+ B 2- wherein A represents a cation capable of forming a receptor-substrate complex with an anion, and B represents one or more counter anions, the cation being an anion receptor of the formula ##STR1## wherein R 1 and R 2 are each independently a substituted or unsubstituted alkyl group, a substituted or unsubstituted aryl group or R 1 and R 2 taken together with the atoms separating them represent the atoms necessary to complete a (2)-cryptand; and,
R 3 and R 4 are each independently H or a lower alkyl group having from 1 to 4 carbon atoms, or R 3 and R 4 taken together represent an ethylene bridging group.
The compounds may be used for sensing anions.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] In some embodiments this invention relates to implantable medical devices, their manufacture, and methods of use. More particularly some embodiments of this invention relate to delivery systems for intravascular stents, such as catheter systems of all types, which are utilized in the delivery of such devices.
[0005] 2. Description of the Related Art
[0006] A stent is a medical device introduced to a body lumen and is well known in the art. Typically, a stent is implanted in a blood vessel at the site of a stenosis or aneurysm endoluminally, i.e. by so-called “minimally invasive techniques” in which the stent in a radially reduced configuration is delivered by a stent delivery system or “SDS” to the site where it is required.
[0007] In some circumstances however, a stent or other medical device which is tracked through body vessels ultimately is not implanted and needs to be removed. Non-implantation may result from a number of causes including but not limited to lack of success in reaching the intended target lesion. When the stent will not be implanted its removal becomes necessary. Stent removal can involve both pulling the stent back in the opposite direction of its insertion as well as possibly pushing the stent further into a body vessel. The already tracked device at this point however could have experienced flexing which can cause flaring at one or more ends of the stent. This can result in the flared end(s) of the stent catching on portions of the body vessel upon further movement in either direction and thus cause embolization or vessel damage.
[0008] The art referred to and/or described above is not intended to constitute an admission that any patent, publication or other information referred to herein is “prior art” with respect to this invention. In addition, this section should not be construed to mean that a search has been made or that no other pertinent information as defined in 37 C.F.R. §1.56(a) exists.
[0009] All US patents and applications and all other published documents mentioned anywhere in this application are incorporated herein by reference in their entirety.
[0010] Without limiting the scope of the invention a brief summary of some of the claimed embodiments of the invention is set forth below. Additional details of the summarized embodiments of the invention and/or additional embodiments of the invention may be found in the Detailed Description of the Invention below.
[0011] A brief abstract of the technical disclosure in the specification is provided as well only for the purposes of complying with 37 C.F.R. 1.72. The abstract is not intended to be used for interpreting the scope of the claims.
BRIEF SUMMARY OF THE INVENTION
[0012] Some embodiments of the invention are directed to features that can be incorporated into catheters in general, and particularly stent delivery systems (SDS) to facilitate proximal and distal (if desired) edge protection to the stent in the event of aborting stent delivery and/or deployment. This invention contemplates a number of embodiments where any one, any combination of some, or all of the embodiments can be incorporated into a stent delivery system and/or a method of use.
[0013] At least one of the embodiments of the inventive concept is directed to an SDS having an outer neck which extends distally into the balloon cone or distally into the balloon working region. The inventive concept also contemplates at least one embodiment directed to an SDS having a tapered outer neck. At least one embodiment encompassed by the inventive concept is directed to an SDS having one or more aperture extending through the side walls of the outer neck. In at least one embodiment these apertures facilitate the inflation or deflation of a balloon.
[0014] One or more embodiments of the inventive concept are directed to a second reinforcing member located at the distal end of the SDS which protrudes into the distal cone of the balloon, protrudes into the distal side of the working region of the balloon, has one or more inflating or deflating apertures, has a tapered shape, or any combination thereof.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0015] The invention is best understood from the following detailed description when read in connection with accompanying drawings, in which:
[0016] FIG. 1 is an image of a Stent Delivery System (SDS) in which the region immediately proximal to the crimped stent has been edge protected to facilitate easy removal from a body vessel.
[0017] FIG. 2 is an image of an SDS in which the region immediately proximal to the crimped stent has been edge protected and has longitudinal slots.
[0018] FIG. 3 is an image of an SDS in which the region immediately proximal to the crimped stent has been edge protected and the outer lumen has circumferential slots.
[0019] FIG. 4 is an image of an SDS in which both the region immediately proximal to the crimped stent and the region immediately distal to the crimped stent have been edge protected.
[0020] FIG. 5 is an image of an SDS in which the region immediately proximal to the crimped stent has been edge protected and the outer lumen has a plurality of apertures.
[0021] FIG. 6 is an image of an SDS in which the region immediately proximal to the crimped stent has been edge protected and the outer lumen has a plurality of longitudinally displaced slots.
[0022] FIG. 7 is an image of an SDS in which the region immediately proximal to the crimped stent has been edge protected, the outer lumen has a plurality of apertures, and the outer lumen has a distally widened conical shape.
[0023] FIG. 8 is an image of an SDS in which the region immediately proximal to the crimped stent has been edge protected, the outer lumen has a plurality of apertures, and the outer lumen has a proximally widened conical shape.
[0024] FIG. 9 is an image of an SDS after the balloon has been inflated in which both the region immediately proximal to the crimped stent and the region immediately distal to the crimped stent have been edge protected.
[0025] FIG. 10 is an image of an SDS with a common circumferential surface.
[0026] FIG. 11 is an image of an SDS with an outwardly protruding balloon.
[0027] FIG. 12 is an image of an SDS with an outwardly folded balloon.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The invention will next be illustrated with reference to the figures wherein the same numbers indicate similar elements in all figures. Such figures are intended to be illustrative rather than limiting and are included herewith to facilitate the explanation of the apparatus of the present invention. For the purposes of this disclosure, like reference numerals in the figures shall refer to like features unless otherwise indicated. Depicted in the figures are various aspects of the invention. Elements depicted in one figure may be combined with, or substituted for, elements depicted in another figure as desired.
[0029] Referring now to FIG. 1 there is shown a stent delivery system (SDS) ( 1 ) in an unexpanded configuration. The SDS ( 1 ) comprises an unexpanded stent ( 4 ) crimped about a catheter or shaft ( 3 ). The stent ( 4 ) has a proximal edge ( 5 ) and a distal edge ( 11 ) and is constructed to have a tubular structure with a diameter ( 20 ). The diameter ( 20 ) has a first magnitude which permits intraluminal delivery of the tubular structure into the body vessel passageway, and a second expanded and/or deformed magnitude (as shown in FIG. 9 ) which is achieved upon the application of a radially, outwardly expanding force.
[0030] The SDS ( 1 ) also comprises an outer tube or shaft ( 34 ) which defines an outer lumen. Within the outer tube ( 34 ) is a portion of an inner tube ( 14 ). The inner tube ( 14 ) defines an inner lumen. A portion of the inner tube ( 14 ) extends beyond the outer tube ( 34 ) and the crimped stent ( 4 ) is disposed about at least a portion of the inner tube ( 14 ). Sandwiched between the stent ( 4 ) and the portion of the inner tube ( 14 ) extending out of the outer tube ( 34 ) is a portion of an expansion balloon ( 6 ). The expansion balloon ( 6 ) extends longitudinally beyond both edges ( 5 , 11 ) of the stent ( 4 ) and is functionally engaged to both the outer tube ( 34 ) and the inner tube ( 14 ) forming a substantially fluid tight seal between the outer and inner lumens. The portion of the balloon ( 6 ) engaged to the outer tube ( 34 ) is the waist ( 7 ) of the balloon. At times, positioned at or near the longitudinal position on the SDS ( 1 ) adjacent to the proximal end of either the balloon ( 6 ) or the stent ( 4 ) are one or more marker bands ( 9 ). The marker band ( 9 ) can contain a radiopaque material used for following the progress of the SDS ( 1 ) through the body vessel and/or can be used to block off unwanted longitudinal movement of the stent ( 4 ) along the catheter ( 3 ). Although FIGS. 1-12 illustrate the marker bands ( 9 ) as cylindrically trapezoidal, it is contemplated by the inventive concept that they be rectangular or in any other shape.
[0031] The SDS ( 1 ) of FIG. 1 is shown in its expanded state in FIG. 9 . During a stent implantation, the SDS ( 1 ) is positioned adjacent to an implantation site of a body vessel and fluid is injected through the outer lumen ( 34 ) into the balloon ( 6 ). The injected fluid causes the balloon ( 6 ) to radially expand. A balloon ( 6 ) will typically have a proximal end region ( 15 ), a distal end region ( 17 ) and a working region ( 19 ) extending between the proximal end ( 15 ) and distal end ( 17 ) regions. As the balloon ( 6 ) expands, the working region ( 19 ) in turn expands the stent ( 4 ) which when fully expanded to the second magnitude diameter ( 20 ), is then implanted at the implantation site.
[0032] In at least one embodiment, the proximal and distal end regions ( 15 , 17 ) are respectively proximal and distal cones ( 15 , 17 ). The proximal and distal cones ( 15 , 17 ) comprise those portions of the balloon ( 6 ) which longitudinally spans from the waist ( 7 ) to a portion of the working region ( 19 ) which is both closest to the waist ( 7 ) and most distant from the inner lumen ( 14 ) when in the second expanded state. The cones ( 15 , 17 ) are so named because when expanded, those portions of the balloon ( 6 ) progressively expand away from the catheter ( 3 ) in a tapered or conical manner.
[0033] On some occasions however, the stent implantation will be aborted and the stent ( 4 ) must be removed from either the implantation site or from whichever body vessel the SDS ( 1 ) has tracked the stent ( 4 ) within. FIG. 1 illustrates at least one embodiment of the present invention where the end ( 5 ) of the stent ( 4 ) is reinforced by the extension of the outer neck ( 35 ) to a position considerably within the proximal balloon cone ( 15 ). The outer neck ( 35 ) comprises a portion of the outer tube ( 34 ) immediately proximal to the crimped stent ( 4 ). The outer neck ( 35 ) has two regions, a second region ( 22 ) and a third region ( 23 ) which is distal to the second region ( 22 ). The outer neck ( 35 ) is engaged to the balloon waist ( 7 ) at the second region ( 22 ). Both regions of the outer neck ( 35 ) are narrower than the main portion or first region ( 21 ) of the outer tube ( 34 ).
[0034] As illustrated in FIG. 1 , the protrusion of the outer neck ( 35 ) into the balloon cone ( 15 ) provides reinforcement to the SDS ( 1 ) by limiting the flexibility of the unexpanded balloon ( 6 ). This decrease in balloon ( 6 ) flexibility reduces the amount the stent ( 4 ) can be bent when being tracked in any direction through body vessels while disposed about the balloon ( 6 ). By reducing the amount that the stent ( 4 ) can bend, it becomes less likely that the ends ( 5 , 11 ) of the stent ( 4 ) will flex and flare outwards and snag or catch onto a wall of a body vessel and potentially cause damage or embolization. The reinforcement also makes it less likely that compressive forces encountered while tracking the SDS ( 1 ) through body vessels would deform the balloon and prevent proper inflation
[0035] The protrusion of the outer neck ( 35 ) into the cone ( 15 ) has other benefits as well. The reinforcement provided by the protrusion, helps the SDS ( 1 ) resist bending in response to torque from levering forces applied along the length of the SDS ( 1 ) by movements of the mass at the end of the guide tip ( 29 ). By reducing bending of the SDS ( 1 ), misaligning of the balloon ( 6 ) and increased the flaring of the stent ( 4 ) is avoided. In addition, the protrusion of the outer neck ( 35 ) into the cone ( 15 ) also facilitates balloon ( 6 ) inflation. This is because the inflating fluid fed into the balloon ( 6 ) exits the third region ( 23 ) much closer to the working region ( 19 ) of the balloon preventing excessive accumulation of fluid in the cone ( 15 ) and providing more inflating pressure against the working region ( 19 ). The protrusion also protects the balloon material while it is folded onto the SDS ( 1 ) and while the stent ( 4 ) is crimped to the SDS ( 1 ). Lastly, the reinforcement makes the balloon ( 6 ) better able to avoid deformation in response to interacting with the force of the impact between the expanding stent ( 4 ) and the walls of the body vessel at the site of the stenosis.
[0036] There are a number of embodiments according to which the outer neck ( 35 ) can protrude into the cones ( 15 ). In at least one embodiment as shown in FIG. 4 , the outer neck ( 35 ) extends radially past the marker band ( 9 ). In at least one embodiment, the outer neck ( 35 ) extends longitudinally past the marker band ( 9 ) to a position longitudinally closer to the stent ( 94 ). Alternatively the marker band ( 9 ) can be closer to the stent than the outer neck ( 35 ). In at least one embodiment as shown in FIGS. 4 and 9 a second reinforcing member ( 40 ) analogous to the protruding outer neck ( 35 ) can also be positioned adjacent to the distal end of the stent ( 11 ) and protrude into the distal cone ( 17 ) providing similar reinforcing properties at the distal end of the SDS ( 1 ).
[0037] In at least one embodiment as illustrated in FIG. 12 , the outer neck ( 35 ) can longitudinally protrude so far into (or past) the cone ( 15 ) that it longitudinally extends to a position substantially flush with the edge of the stent ( 4 ). In at least one embodiment, the flush positioning causes a balloon bulge ( 24 ) to abut the stent end ( 5 ) which extends further radially than the stent end ( 5 ). This more radial extension causes the bulge ( 24 ) to block any radially vectored impacts or interactions between the stent edge ( 5 ) and body vessels. In addition, positioning the outer neck ( 35 ) almost flush against the stent end ( 5 ) can wedge the stent ( 4 ) into place and pinion the stent to resist any outward flaring caused by torque being applied to the stent ( 4 ).
[0038] Referring now to FIG. 10 there is shown at least one embodiment of the inventive concept directed to an SDS ( 1 ) which can remove a non-implanted stent ( 4 ). In this SDS ( 1 ), the main portion ( 21 ) of the outer tube ( 34 ), the balloon waist ( 7 ) about the second region ( 22 ), and the crimped stent ( 4 ) are all sized such that their outer surfaces share a substantially similar circumference ( 12 ) relative to an axis ( 16 ) extending longitudinally through the center of the SDS ( 1 ). This common circumference ( 12 ) provides the SDS ( 1 ) a generally uniform surface facing the body vessel the SDS is tracked through. This uniform surface limits the likelihood of a portion of the SDS ( 1 ) becoming snagged against a portion of the body vessel whether the SDS is being moved in a proximal or distal direction.
[0039] As shown in FIG. 1 , the inventive concept also contemplates at least one embodiment in which a gap ( 8 ) between the proximal edge ( 5 ) of the stent ( 4 ) and the distal end of the third region ( 23 ) of the outer neck ( 35 ) helps protects against harmful contact between the SDS ( 1 ) and a body vessel it is being tracked through. Within this gap ( 8 ), the material of the balloon ( 6 ) flows radially and longitudinally outward from beneath the stent ( 4 ) to a position outside of the outer neck ( 35 ). The folded balloon material within the gap will have a diameter smaller than that of the stent ( 4 ). This outward flowing balloon material wraps a portion of the balloon ( 6 ) around the proximal edge ( 5 ) of the stent ( 4 ) reducing the exposure of any irregular surface of the stent edge ( 5 ) to the body vessel the SDS ( 1 ) is being tracked through.
[0040] The gap ( 8 ) is properly spaced to accommodate balloon materials of a specific thickness such that the outer surface of the balloon ( 6 ) curves or arcs along an optimal path. In at least one embodiment illustrated in FIG. 1 , the balloon material curves out from beneath the stent ( 4 ) to a position which is substantially flush and smooth with the common circumferential perimeter ( 12 ) without any bulging of either the stent ( 4 ) or the balloon ( 6 ).
[0041] In at least one embodiment illustrated in FIG. 11 , the gap ( 8 ) is spaced such that it causes the outer surface of the balloon ( 6 ) to have an outward bulge ( 24 ) which protrudes beyond the circumferential perimeter ( 12 ) of the stent ( 4 ). Because the outward bulge ( 24 ) protrudes further in a radial direction than the stent end ( 5 ), the bulge ( 24 ) prevents the stent end ( 5 ) from coming into contact with any of the body vessels when the SDS ( 1 ) impacts against body vessels it is being tracked through. As illustrated in FIG. 4 , at least one embodiment of the inventive concept is directed to a distal gap ( 8 ) between the distal end of the stent ( 11 ) and the proximal side of a second reinforcing member ( 40 ). The inventive concept contemplates a distal gaps as that of FIG. 4 in which there is no bulge protruding further in a radial direction than the stent end ( 5 ) as well as a spaced distal gap ( 8 ) allowing for an arced bulge similar to that of FIG. 11 at the distal side of the stent ( 4 ).
[0042] Referring now to FIGS. 7 and 8 there is shown an SDS ( 1 ) with a tapered outer neck ( 35 ). As FIG. 7 shows, at least a portion of the outer neck is tapered or conically shaped with a wider proximal area. In the alternative as shown in FIG. 8 , at least a portion of the outer neck ( 35 ) is tapered with a wider distal area. The inventive concept also contemplates non-linear outer necks ( 35 ) including but not limited to outer necks ( 35 ) which are arced, slanted, waved, irregularly shaped, or which have one or more angled portions between distal and proximal ends with substantially similar or the same circumferences, and any combination thereof. In at least one embodiment, the angling of the tapering in the outer neck ( 35 ) reinforces the stent edge(s) by being directed opposite to the flare causing flexing that the stent ( 1 ) encounters. In at least one embodiment, a second reinforcing member at the distal side of the SDS ( 1 ) is similarly tapered.
[0043] FIGS. 2 , 3 , 5 , 6 , 7 , and 8 illustrate SDSs ( 1 ) in which there are one or more cavities or apertures ( 18 ) extending through the wall of the outer necks ( 35 ). Because these illustrations disclose details of at least the outer surface of the outer neck ( 35 ), they do not explicitly show the inner tube ( 14 ) or guide wire ( 33 ) passing through the outer neck ( 35 ). It would be clear however, to practitioners of ordinary skill in the art however that these illustrations disclose embodiments in which one, both, or none, of the guide wire ( 33 ) and the inner lumen ( 14 ) pass through the outer neck ( 35 ) of the outer tube ( 34 ). Similarly, the inventive concept contemplates embodiments in which the various apertures ( 18 ) of FIGS. 2 , 3 , 5 , 6 , 7 , and 8 are also present on the distal side of the SDS ( 1 ) positioned on a second reinforcing member (such as ( 40 ) in FIG. 4 ) analogous to the outer neck ( 35 ).
[0044] Sometimes an SDS ( 1 ) having an already inflated or partially inflated balloon ( 8 ) needs to be removed. FIG. 2 illustrates at least one embodiment in which an SDS ( 1 ) has at least one aperture ( 18 ) through which the fluid which previously inflated the balloon ( 6 ) can be drained or suctioned through. These apertures ( 18 ) can be one or more rectangular slots (as shown in FIG. 2 ) as well as circles, ellipse, squares, or any other known shape in the art. Similarly the apertures can have their opening extend in a longitudinal manner (as in FIG. 2 ), in a circumferential manner (as in FIG. 3 ), diagonally, or in any possible combination of longitudinal, diagonal, or circumferential extension.
[0045] The number of the apertures ( 18 ), their size, and their distribution across the outer neck ( 35 ) can vary depending on the desired rate of fluid flow. In at least one embodiment, at least one aperture ( 18 ) extends longitudinally across a majority of the length of the outer neck ( 35 ). Similarly, in at least one embodiment, at least one aperture ( 18 ) extends circumferentially across a majority of the circumference of the outer neck ( 35 ). Also, in at least one embodiment one or more of the apertures ( 18 ) have one way openings or valves which reduce or prevent fluid flow while the balloon ( 6 ) is either being inflated or deflated, but allows fluid flow when the balloon ( 6 ) is being respectively deflated or inflated. Embodiments in which the end of the aperture ( 18 ) facing the outer lumen may have a different width or circumference than the end of the aperture ( 18 ) on the outer surface of the outer neck ( 35 ) and/or of any point along the length of the aperture ( 18 ) between these two ends are contemplated by this inventive concept. In addition, embodiments in which the apertures ( 18 ) facilitate a balloon ( 18 ) to be inflated more rapidly or easily than to be deflated or vice versa are contemplated by this inventive concept.
[0046] The apertures ( 18 ) can be of particular utility during the deflation of a balloon ( 6 ). During deflation, because the apertures ( 18 ) are positioned within the cones ( 15 , 17 ) they can directly drain or suction fluid from the cones ( 15 , 17 ). This helps to remove fluid that otherwise does not drain well from the narrow confines of the proximal and distal tips of the cones ( 15 , 17 ). The drainage or suction provided by the apertures combined with the drainage or suction that the distal end of the third region ( 23 ) applies to the working region ( 19 ) assures that fluid is effectively drained from all portions of the balloon ( 6 ).
[0047] In at least one embodiment, as illustrated in FIG. 3 , at least one aperture ( 18 ) is positioned on the outer neck ( 35 ) longitudinally adjacent to the tip of the proximal cone ( 15 ) which is located at the waist-cone transition point ( 39 ). Because the tip of the cone ( 15 ) is so narrow it is a harder location to apply a suction force to and it retains fluid with a greater surface tension. The positioning of at least one aperture ( 18 ) at the waist-cone transition point ( 39 ) allows for targeted drainage from the tip of the cone. In at least one embodiment, there are at least two apertures located on opposite sides of the outer neck ( 35 ).
[0048] In some embodiments the stent, the SDS, or other portion of an assembly may include one or more areas, bands, coatings, members, etc. that is (are) detectable by imaging modalities such as X-Ray, MRI, ultrasound, etc. In some embodiments at least a portion of the coating of the stent and/or adjacent assembly is at least partially radiopaque.
[0049] In addition, any coating can also comprise a therapeutic agent, a drug, or other pharmaceutical product such as non-genetic agents, genetic agents, cellular material, etc. Some examples of suitable non-genetic therapeutic agents include but are not limited to: anti-thrombogenic agents such as heparin, heparin derivatives, vascular cell growth promoters, growth factor inhibitors, Paclitaxel, etc. Where an agent includes a genetic therapeutic agent, such a genetic agent may include but is not limited to: DNA, RNA and their respective derivatives and/or components; hedgehog proteins, etc. Where a therapeutic agent includes cellular material, the cellular material may include but is not limited to: cells of human origin and/or non-human origin as well as their respective components and/or derivatives thereof. Where the therapeutic agent includes a polymer agent, the polymer agent may be a polystyrene-polyisobutylene-polystyrene triblock copolymer (SIBS), polyethylene oxide, silicone rubber and/or any other suitable substrate. It will be appreciated that other types of coating substances, well known to those skilled in the art, can be applied to the stent as well.
[0050] In some embodiments at least a portion of the stent is configured to include one or more mechanisms for the delivery of a therapeutic agent. Often the agent will be in the form of a coating or another layer (or layers) of material placed on a surface region of the stent, which is adapted to be released at the site of the stent's implantation or areas adjacent thereto.
[0051] This completes the description of the preferred and alternate embodiments of the invention. The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. The various elements shown in the individual figures and described above may be combined, substituted, or modified for combination as desired. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”.
[0052] Further, the particular features presented in the dependent claims can be combined with each other in other manners within the scope of the invention such that the invention should be recognized as also specifically directed to other embodiments having any other possible combination of the features of the dependent claims. For instance, for purposes of claim publication, any dependent claim which follows should be taken as alternatively written in a multiple dependent form from all prior claims which possess all antecedents referenced in such dependent claim if such multiple dependent format is an accepted format within the jurisdiction (e.g. each claim depending directly from claim 1 should be alternatively taken as depending from all previous claims). In jurisdictions where multiple dependent claim formats are restricted, the following dependent claims should each be also taken as alternatively written in each singly dependent claim format which creates a dependency from a prior antecedent-possessing claim other than the specific claim listed in such dependent claims below.
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A system to deliver or remove an inflation expandable stent in a body vessel. The system avoids causing damage or embolisms to a body vessel it is traversing by restraining the edges of the stent from scraping against the walls of the body vessel. The edges are restrained by balloon folds, compressive wedging, and angled reflective resistance. In addition the device can also inflate or deflate the balloon more efficiently.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a compact food package and more particularly to a compact food package having a retortable, food-containing pouch and a container for the pouch.
2. Description of the Prior Art
The prior art is well aware of sealed packages adapted for storing perishable food for an indeterminate duration. According to well-established practice, appropriately sterilized, perishable food is often stored for a long duration in pouches, bags or like enclosures which are hermetically sealed so as to prevent the entry of micro-organisms into the package. Such pouches, bags or like enclosures typically comprise suitable plastic sheet material. An airtight seal is readily provided by heat sealing adjoining edges of the plastic material.
In many packaging applications, it is not necessary or desired to preserve food without refrigeration for a long duration. Therefore, the packaging container is designed to provide only limited protection from exposure to the environment of the food items contained in the package.
In both types of packaging applications mentioned above, however, it is often necessary to provide structural strength to the food package in addition to any structural strength provided by the sealable plastic enclosure. Therefore, it has become widespread practice to utilize a semi-rigid plastic, cardboard or like shell for at least partially containing the food. The plastic or cardboard shell is then closed by a stretchable, thin plastic or like sheet. U.S. Pat. Nos. 3,695,900; 3,916,030; 3,619,215; 3,922,362; 2,776,215; 2,776,216 and 2,261,129 disclose such food packages having a relatively stiff base and a preferably transparent, thin plastic sheet enclosing the base and the food items contained therein.
Additional disclosures relevant to food packaging in general can be found in U.S. Pat. Nos. 3,865,302; 4,055,672 and 2,135,479.
A significant disadvantage of the food packages provided by the prior art is that the sealed bag or pouch which contains the food, is relatively readily punctured or otherwise damaged during transportation or storage. Accidental damage to the bag or pouch becomes especially undesirable when the package is intended for preserving the food without refrigeration for an indeterminate duration. It is readily understood that in such a case, accidental damage to the bag or pouch may result in total destruction of the food item contained therein.
Accordingly, the prior art does not provide a compact, lightweight food package having the features of the herein-disclosed package which provides improved protection for food of all kinds, including soft or liquid food items, such as preserves or jellies.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an inexpensive, lightweight compound package for food products.
It is another object of the present invention to provide a lightweight protective shell for a food containing pouch which occupies a minimum amount of space and is therefore particularly suited for use by hikers, outdoorsmen and the like.
It is still another object of the present invention to provide an inexpensive and lightweight shell for a food containing pouch which provides maximum protection against accidental damage to the pouch during shipping or shelf display.
These and other objects and advantages are attained by a compound package having a hermetically sealed pouch and a container for the pouch. The pouch, which contains food preserved for a long duration, has a substantially flat circumferential seam. The container has two members which define a cavity to accommodate the pouch. The pouch substantially completely fills the cavity whereby structural support is lent by the pouch to the container. A circumferential rim is provided on each member of the container which in the assembled package engages the seam of the pouch and effectively positions and holds the pouch between the members from its seams.
The objects and features of the present invention are set forth with particularly in the appended claims. The present invention may be best understood by reference to the following description, taken in connection with the accompanying drawings in which like numerals indicate like parts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of the present invention;
FIG. 2 is a perspective view of the preferred embodiment of the present invention with a container for the pouch being disposed in an open position;
FIG. 3 is a perspective, partially exploded view of the preferred embodiment of the present invention with the container for the pouch being disposed in an open position;
FIG. 4 is a cross-sectional view of the preferred embodiment of the present invention, the cross-sections being taken at lines 4--4 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The following specification taken in conjunction with the drawings sets forth the preferred embodiment of the present invention in such a manner that any person skilled in the food-packaging and plastic manufacturing arts can use the invention. The embodiment of the invention disclosed herein is the best mode contemplated by the inventor for carrying out his invention in a commercial environment, although it should be understood that various modifications can be accomplished within the parameters of the present invention.
Referring now to FIGS. 1 through 4, a preferred embodiment of a food-containing pouch 10 and a protective container 12 thereof are disclosed. The food-containing pouch 10, best shown individually in FIG. 3, and in the cross-sectional view of FIG. 4, comprises two relatively thin substantially rectangular sheets 14. The sheets 14 may be composed of suitable, heat-sealable, transparent plastic material. Such materials are used widely in the food packaging arts. In the preferred embodiment, however, the sheets 14 comprise a layer (not shown) of aluminum foil which on the inside surface thereof is coated with the suitable plastic material.
In the process of packaging of a food item 16, such as a fruit preserve, jelly or the like, the appropriately sterilized food item 16 is placed between the sheets 14. The sheets 16 are then sealed along their entire circumferential edge 18 by a suitable method such as heat sealing of the plastic laminate which comprises the inside layer of the sheets 18. The sealing process is conducted in such a manner that food is excluded from the sealed portions.
It is to be noted that materials and methods of enclosing food in heat-sealed plastic plackages or pouches are well known in the prior art. Therefore, details of manufacturing the sealed pouch 10 used in the present invention need not be disclosed here. It is sufficient to disclose in detail only those features of the pouch 10 which render it uniquely adapted for use in the present invention.
By appropriately selecting a suitable material for the pouch 10, the pouch may be significantly heat resistant. As a result, it is possible to package food items in the pouch 10 which require cooking or heating prior to consumption. Thus, by providing a heatable or retortable pouch in which the food can be stored as well as heated, a user is saved the convenience of having the open the pouch and transfer its contents into other cooking vessels.
As it is shown in FIGS. 3, 4 and 5, the sealing process results in a substantially flat seam 20. The pouch 10 itself, when filled with the food item 16, is substantially flat, with a food containing portion 22 having a significantly wider cross-section (best shown in FIG. 4), then the seam portion 20.
Referring now particularly to the exploded view of FIG. 3, the container 12 for the pouch 10 is disclosed. The container 12 comprises two panel members 24 and 26, which in the preferred embodiment have many similar features. The panel members 24 and 26 are substantially rectangular in shape and have a substantially flat rim or edge portion 28. As this will be explained below in more detail, the rim or edge portions 28 serve the purpose of engaging the seam 20 of the pouch 10.
A protruding portion 30 is disposed immediately adjacent to the rim portion 28 in one of the panel members 26. In the other panel member 24, an indentation or offset portion 32 is present to accommodate the protruding portion 30 when the two panel members 24 and 26 occupy a closed, substantially parallel, aligned position, shown in FIG. 1.
In both panel members 24 and 26, an inwardly sloping intermediate portion 34 is contiguous respectively to the protruding portion 30 or indentation 32. A substantially flat, rectangular portion 36 abuts the intermediate portion 34 in both panel members 24 and 26.
The two panel members 24 and 26 are pivotally joined to one another on a longer side 38 of each panel member by a thin, relatively flexible portion 40. Such a flexible plastic portion is commonly referred to as a living hinge in the plastic manufacturing arts. Briefly, a living hinge is a thin section of plastic which due to its particular mode of manufacture has a minimal amount of "plastic memory" or "set" relative to its designated direction or rotation or flexing. Therefore, the living hinge is capable of undergoing a relatively large number of bending or flexing motions without any attendant structural damage.
As it is apparent from the above description the entire container 12 including the living hinge 40 is advantageously of a unitary construction. The container 12 is readily manufactured from styroform or similar plastic foam material. The process of manufacturing articles of various shapes and sizes from styrofoam or like material, including the manufacture of the living hinge, is well established in the prior art and therefore, need not be disclosed here in detail.
The entire container 12 is dimensioned and configured to accommodate the pouch 10. Thus, the container 12 in a closed position, wherein the panel members 24 and 26 are disposed substantially parallel relative to one another, incorporates a cavity. The pouch 10 is placed within the cavity wherein it substantially fills the void. The panel members 24 and 26 engage with their respective inner surfaces 42 and 44 substantially the whole outer surface of the food containing portion 30 of the pouch 10. As a result, the pouch 10 with its food contents 16 significantly contributes to the structural strength of the entire package. The pouch 10 contributes to the container's 12 ability to withstand an impact without splitting, breaking or suffering like damage. On the other hand, the container 12 protects the pouch 10 from being punctured or ruptured by a sharp object. It is readily apparent that the container 10 renders the handling, transportation and storage of the pouch 10 significantly easier and safer.
Referring now again to FIGS. 2, 3 and 4, the seam 20 of the pouch engaging the rim or edge portions 28 of the panel members 24 and 26, is shown. As the seam 20 is engaged on both of its sides by the rim 28 of one of the panel members, the pouch 10 is securely held in place in position between the panel members 24 and 26. Additionally, any well known closure means such as a rubberband or a string (not shown) may be utilized to prevent the container 12 from opening.
The novel, compound food package of the present invention is ideally suited for storing any type of food solid in semi-solid or liquid food items such as preserves, jellies, purees or the like. The scope of the present invention is intended to cover such applications. It should also be understood that although the hereinbefore disclosed configuration for the container and the pouch 10 is preferred, the present invention may be practiced by modifying the same within the generic principles taught here. For example, the pouch 10 and the container 12 may have other than a rectangular shape, and the two panel members 24 and 26 may be joined by means other than a living hinge. Accordingly, such apparent modifications are within the scope of the present invention.
The light weight, overall flat shape and its ability to serve as a storage as well as a cooking container renders the compound food package of the present invention particularly suitable for use by hikers, backpackers, outdoorsmen and the like. It will be readily apparent to those skilled in the art that various modifications of the present invention are possible within the generic principles disclosed herein. Accordingly, the scope of the present invention should be interpreted solely from the following claims.
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A compound food package having a sealed, heat resistant pouch and a container therefor, is disclosed. The pouch, which contains uniformly distributed food items, has a substantially flat circumferential seam. The container is composed of semi-rigid plastic material. It contains a cavity into which the pouch is placed. The container has substantially flat rim portions. The rim portions engage the seam of the pouch and position and hold the pouch by its seam. The pouch is in intimate contact with the inner surfaces of the container, thereby counteracting inwardly directed forces and significantly contributing to the overall strength of the package.
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BACKGROUND OF THE INVENTION
Columns are well known devices designed to strip desired volatile components from a mixture of liquids often containing solids. Such columns require intimate and continuous contact of vapors moving upwards with liquid moving counter-currently downwards. Different designs for columns have been proposed, including columns packed with Raschig rings, saddles, etc., bubble-cap columns, and other variations designed to cause a continuous mixing and interfacing of downwardly flowing liquid with upwardly flowing vapors so as to cause the maximum amount of volatile components to vaporize in concentrated form from the liquid fed to the column. Such columns are frequently tall (10-15 ft.), and if joined to other equipment (such as a rectifying column), may be part of a single column of 25-35 ft. tall. Because they are so tall and of lightweight construction, these columns are not easy to clean. Boiling-out with caustic solution or strong acid solution together with injection of steam is not feasible because the head pressure of such a tall column of liquid is much too great to be contained by the ordinary column construction. Cleaning, therefore, must frequently be accomplished by dismantling the column and scraping the dismantled internal components to remove the formed encrustations. The cleaning procedures are especially important considerations when the liquid being treated in the column forms a heavy encrustation such as a fermented mash, because the scale which forms readily attaches itself to the surfaces in the column and clogs up the passageways. Need for cleaning is necessarily frequent with such feed stock and down-time may become a significant factor of cost when recovering alcohol from fermented mash.
It is an object of this invention to provide a novel and simple distillation column section which can be readily cleaned. Another object is to provide a distillation column section which is particularly useful in handling a liquid containing scale-forming components. Another object is to provide a novel parallelogram design of four distillation column sections. Still other objects will be apparent from the more detail description which follows.
BRIEF DESCRIPTION OF THE INVENTION
This invention relates to a distillation column section comprised of one or more enclosed ribbon channel having an access passageway at each end thereof and having a zigzag pattern, two spaced zigzag walls forming the top and bottom of the channel and two side walls defining the lateral width of each channel; the channel being a plurality of similar zigzag portions joined to each other to form a series of consecutive zigzag portions, each having a substantially vertical surface joined at an angular junction to a substantially horizontal surface; the column being oriented such that as the liquid flows through the channel from one passageway to the other by gravity it partially fills sections of the channel to form a series of adjoining consecutive vapor spaces which are separated from each other by angular junctions submerged at spaced intervals in the liquid.
This invention also relates to a distillation column for the separation of a vapor from a mixture of liquid and vapor comprising four substantially identical column sections arranged in the shape of a parallelogram symmetrical about a central vertical plane, each column section forming one side of the parallelogram with the two columns on each side of the central plane forming two parallel flow halves of the column, each section having a thin elongated ribbon channel for vapor-liquid flow formed by spaced angularly corrugated top and bottom walls oriented with one end of the channel at an elevation higher than the other end such that the channel will form a series of consecutive pools of liquid flowing downward by gravity, each pool separated from the next adjacent pool by a vapor space through which vapor flows upward, means for introducing a mixture of liquid and vapor at the top of the halves, means for introducing heated vapor at the bottom of the halves, means for removing vapor at the top of the halves, and means for removing liquid at the bottom of the halves.
This invention also relates to a distillation process for separating volatile components from a mixture of liquids, in which the improvement comprises passing a liquid mixture of components downward through a vapor-liquid contact zone and passing vapor upwards through that contact zone in counter-current flow with the liquid mixture cascading in a stair step fashion over a series of falls into a series of pools, consecutively, from one pool to the next lower pool, and vapor passing upward consecutively through a series of vapor spaces above said pools and falls, each vapor space being separated from the adjacent vapor space by a portion of the downward flowing liquid mixture.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed to be characteristic of this invention are set forth with specific emphasis in the appended claims. The invention itself, however, both as to its organization and method of operation, together with further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings in which:
FIG. 1 is a front elevation view of the equipment and the connecting pipe lines used in a distillation procedure to strip alcohol from a feed of fermented mash, in accordance with this invention.
FIG. 2 is a top plan view of a single-tier distillation column section of this invention.
FIG. 3 is a side elevation view of the single-tier column section of FIG. 2.
FIG. 4 is a cross-section taken at 4--4 of FIG. 2.
FIG. 5 is an enlarged view of a portion of the cross-section of FIG. 4 showing how the liquid and vapor is mixed in the process with a single-tier column section of this invention.
FIG. 6 is a schematic view in perspective of a distillation column of eight column sections arranged in two parallelogram formations.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 there is shown a processing method using a single-tiered stripping column for treating an aqueous fermented mash to recover alcohol. A typical feedstock is a slurry (mash) of about 20% solids and 80% liquid resulting from the fermentation of corn, rye, barley, or other materials containing simple sugars into alcohol. The liquid component of this mash is a mixture of water and alcohol along with various dissolved, non-fermented sugars and nonsugars. This feedstock is fed into preheater 28 via line 27. Steam is introduced into the heating coil of preheater 28 through line 29 and leaves as condensate through lines 30. The temperature of the mash is raised to about 212 degrees F. in preheater 28 and then fed through line 32 into the top 43 of stripping column 33. The liquid mash flows by gravity downwards through thin ribbon channel 10 to the bottom 42. At the same time steam is fed through line 34 into the bottom 42 of column section 33 and is passed upwardly through channel 10. The steam in channel 10 passes upwardly in intimate contact with the liquid mash flowing counter-currently downwardly, and in so doing, causes the alcohol to vaporize and join the upward flow vapor. The combined water and alcohol vapors exit from column 33 into line 36 leading to condenser 37 where the vapors are condensed to a liquid which is withdrawn through line 41 as the desired product. Condenser 37 is cooled by cold water entering via line 39 and leaving as warm water via line 40. Preheater 28 is connected to line 36 at 38 through line 31 to equilibrate pressure in the preheater 28 and the column section 33. Spent cooling water in line 40, distilled mash in line 35 and condensate from 30 are rejected for further treatment and/or disposal as waste.
The details of column section 33 may be seen in FIGS. 2-4. Column 33 is comprised of a zigzag ribbon channel 10 which is totally enclosed except for entrances and exits at the top 43 and at the bottom 42. At the top 43 there is an exit 18 for vapors leaving channel 10 and an entrance 19 for mash to be fed into channel 10. At bottom 42 there is an entrance 17 for steam to be fed into channel 10 and an exit 20 for mash to leave channel 10. As shown in FIGS. 3 and 4, the top manifold 14 is a passageway to accommodate lines 18 and 19 and connect them to channel 10. Similarly, bottom manifold 15 is a passageway to connect channel 10 to lines 17 and 20. Channel 10 between manifolds 14 and 15 is formed by joining a plurality of angle beams having an L-shape and joined to each other along their two edges to form an angular corrugation similar to stair steps. Two identical such structures are formed and nested together with a thin space between the two plates to serve as channel 10. Two flat, planar side walls 13 are joined to the spaced corrugations to close channel 10 at each side of the corrugations. The result therefore is a thin ribbon which zigzags in a staircase fashion from top end 43 to bottom end 42.
In FIG. 5 there is an illustration of an enlarged portion of channel 10 as seen in FIGS. 3 and 4 showing how mash and vapor are interfaced throughout the channel. Channel 10 is formed by upper wall 11, lower wall 12 and two sidewalls 13. The column section 33 is oriented so as to be placed at approximately 30 degrees from the horizontal as shown at 21. Liquid mash flows down column section 33 through channel 10 in the direction of arrow 44. Steam and alcohol vapors flow up column section 33 in channel 10 in the direction of arrow 45. Liquid mash forms miniature falls 23 over each successive upwardly directed edge 46 of lower wall 12, to form a series of pools 22 in the V-shaped basin between adjacent edges 46. The tilting of column 33 to about 30 degress from the horizontal is sufficient to cause downwardly projecting edges of upper wall 11 to be submerged in respective pools 22. This forms a series of successive vapor spaces 24 above each edge 46 to contain the steam and alcohol vapors moving upwards in channel 10. Because each vapor space 24 is sealed from the next adjacent vapor space 24 by intermediate edge 25 being submerged in pool 24, it is necessary that the vapor develop enough pressure to force its way through the liquid at successive edges 25. This causes a certain amount of bubbling and turbulence 26 around each corner 25 that is advantageous in providing the intimate vapor-liquid contact necessary to produce an efficient separation of volatile matter from the liquid mash.
The structures shown in the drawings are made with angle beams that have legs at 90 degrees apart. This is not a critical angle, but merely a convenience to represent the normal commercially available article. Angle beams with internal angles of greater or less than 90 degrees are operable, although the orientation angle of 30 from the horizontal as applied to the stripping column must be correspondingly modified so as to provide pools 24 with submerged edges 25 as described above.
The distillation column section of this invention may be made of any convenient material, stainless steel being preferred. This column section can be readily cleaned by boiling caustic solution or boiling acid solution since the total head of liquid is small. A pilot-sized experimental column having the following specifications illustrates the invention for a single column section:
______________________________________Width of channel 10 12 inchesThickness of channel 10 0.5 inchesAngle beam legs 3.0 inchesNo. angle beams for one wall 12Approximate length of column 54 inchesAngle with horizontal 30 degreesSteam pressure supplied 5-15 psi20% solids mash velocity 3 ft./sec.Temperature of mash at inlet about 212 degrees F.Alcohol in feedstock 10% by volumeAlcohol in condensate 30-40%; 0.7 lbs./min.Vapor velocity in column 0.5-1.0 ft./sec.Working pressure of column 5-15 psi______________________________________
A similar separation would require about 7-10 trays of a bubble-cap column. The cost of the present equipment is about 50% of that of an equivalent bubble-cap column and the operating expenses are estimated to be about 20% of that of the equivalent bubble-cap column.
The distillation column section of this invention has several dimensions that may be varied to suit individual desires. These are shown in FIGS. 2 and 4 as:
______________________________________Channel thickness 47 1/2"Channel width 48 12"Column length 49 54"Angle beam angle 50 90 degreesAngle beam leg length 51 3"______________________________________
These parameters fix the length and volume of channel 10 in a single column section, which, in turn, permits the operator choices of capacity for the column section, liquid velocity, vapor velocity, separation efficiency, etc. Channel thickness 47 is preferably kept small, e.g., about 3/8"-1/2" so as to maintain continuous, intimate contact between liquid/vapor. Channel width may theoretically be any size, although practicality dictates there may be construction difficulties of maintaining all portions of a large width at exactly the same elevation as all other portions so as to maintain each pool of liquid 22, each fall 23, and each submerged edge 25 at substantially nearly identical elevation across the width 48 of channel 10 so as to prevent any "channeling" of vapor flow along the path of least obstruction, which channeling substantially destroys the distilling efficiency of the column. Widths 48 of up to six feet are preferred. Any required increase in overall capacity for a column can be achieved by using a plurality of column sections in parallel flow pattern. Column length 49 should be maintained within reasonable limits such that the column section can withstand the head of liquid necessary to clean out channel 10 periodically. Preferably, the head should not exceed about six feet which means that the length of column 33 when tilted 30 degrees should be not more than about 12 feet. It is generally preferable to employ short columns which results in correspondingly short heads of liquid in the columns to permit lighter weight construction. This, of course, must be balanced against the use of longer columns to achieve greater separation efficiency. In order to employ a longer channel 10 for a better separation efficiency, two or more columns may be used in series.
Dimensions of the angle beam component employed to construct column 33 are not so critical as the other dimensions described above. Angle beams of stainless steel can be formed commercially in a large number of sizes and angles. Angle 50 is normally 90 degrees. While other angles are operable, such shapes are generally not readily available and do not offer any important advantages over the 90 degrees type. The length 51 of the leg of the angle beam is a matter of choice although larger lengths normally are accompanied by greater thickness and greater weights per unit length of beam. Since increased strength and weight of the beam component are not advantageous, beyond a necessary minimum, it is preferred to employ small beams, e.g., about 3-4" in length for 51.
Materials of construction for the column are important principally for strength and resistance to corrosion. Materials such as stainless steel or titanium, are preferred, although certain combinations of coated metals are also operable, i.e., glass coated, ceramic coated, and Teflon coated steels are acceptable in many embodiments. Stainless steel, e.g., 304 or 316, is preferred for its combination of ready availability, reasonable cost, and excellent corrosion resistance.
In FIG. 6 there is shown an arrangement of several column sections 33 joined together in a parallelogram formation generally symmetrical about a central vertical plane to provide two distilation columns in parallel flow. In the arrangement of FIG. 6 the upper parallelogram 52 serves as a rectifying section of the total distillation column and the lower parallelogram 53 as the stripping section of the column.
Each column section 33 has a thin ribbon zigzag channel 10 connecting an upper receiver 55 to a lower receiver 56, each receiver functioning as a reservior to receive the distilling mixture and distribute it for flow into the next component of the column. There may be additional column sections 33 in parallel arrangement connected to receivers 55 and 56 if greater capacity is desired. A plurality of flow pipes 57 join receivers 55 and 56 with the next component. At the top of the column is vapor collector 58 to receive vapor through pipes 57 from the tops of the two column halves. Vapor leaves collector 58 and enters condenser 60 where it is condensed and drawn off through pipe 65 as the desired product.
Condenser 60 is cooled by a cooling liquid entering through line 64 and leaving through line 62. If the cooling liquid is not to be used elsewhere in this distillation column, it is drawn off through a side outlet (not shown) in line 62. In the arrangement shown here, the cooling liquid is the cold feedstock (fermented mash feed, if the column is used to extract alcohol from such a feed) which is fed into condenser 60 through line 64, absorbs heat in condenser 60 and is then fed into the middle portion of the column into receivers 55 at the top of lower parallelogram 53 for removal of volatile matter while following downward through the appropriate sections 33 of the column.
When the upper parallelogram 52 serves as a rectifying section of the distillation column it is appropriate to return to the upper parallelogram 52 a liquid reflux to increase the column efficiency in producing a high purified product. In this drawing the reflux liquid is returned through line 63 to the lower receiver 56 or to upper receiver 55 in the middle of parallelogram 52.
At the bottom of the column there is a large liquid collector 59 for receiving the spent liquid which has flowed downwardly through the column. This waste liquid is drawn off through line 54, which has a sufficient siphon effect to keep collector 59 filled with liquid at all times. Steam is admitted through line 66 to provide the heat necessary to cause the vapor component to be volatilized in column sections 33.
In order to equalize the pressure in both vertical halves of the column pipes 61 are connected to two respective lower receivers 56 in each of parallelograms 52 and 53. This assures that each vertical half of the column will function similarly to the other vertical half.
It is to be understood that other paralleogram formations of four column sections 33 can be connected to the ones shown in FIG. 6 to add to the capacity or add to the distillation efficiency. If more capacity is needed, an identical parallelogram can be connected in parallel flow pattern to vapor collector 58 and liquid collector 59. If a greater separation efficiency between vapor and liquid is required, one or more additional parallelogram formations can be added in a vertical direction so there are 6, 8 or more column sections 33 in series between collectors 58 and 59.
It is preferred that the construction of parallelogram sections be accomplished by welding after careful leveling of all components so that liquid flow and liquid levels will be substantially identical across the width of every column section 33.
Other uses for the distillation column of this invention include nearly any separation of low boiling components from a mixture of liquids. Separation of petroleum fractions, separation (scrubbing) of solids in gaseous form from other gases, purification of various solvents, recovery of alcohol from solutions, recovery of volatile oils (flavor components) from agricultural commodities, etc., are feasible with the column of this invention. As mentioned previously, the most important use for this column is believed to be the stripping of a valuable vaporizable component from a mixture of liquids and solid plant residues having calcium and magnesium salt components, because of the ease with which this column may be cleaned of encrustations by use of a boiling solvent.
The the invention has been described with respect to certain specific embodiments, it will be appreciated that many modifications and changes may be made by those skilled in the art without departing from the spirit of the invention. It is intended, therefore, by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention.
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A stripping column is comprised of one or more mixing channels situated in parallel arrangement, each channel in the form of a zigzag strip through which liquid cascades in a series of falls alternating with a corresponding series of pools. Simultaneously, vapor travels upwardly in a counter-current manner, intimately mixing with the liquid when forced through each successive pool. The column is especially useful in separating alcohol from fermented mash. The column is preferably employed with three other identical columns in a parallelogram structure to make a distillation unit of greater efficiency and capacity.
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FIELD OF THE INVENTION AND RELATED ART
[0001] The present invention relates to an image forming apparatus which forms an image through an electrophotographic process. In particular, it relates to an image forming apparatus such as a copying machine, a printer, a facsimileing machine, or the like.
[0002] As one of the electrophotographic image forming apparatuses such as a copying machine, a laser beam printer, etc., a full-color image forming apparatus which forms a full-color image by depositing in layers a plurality of monochromatic images different in color, more specifically, yellow (H), magenta (M), cyan (C), and black (Bk) images, has been known.
[0003] For the formation of a high quality image with use of a full-color image forming apparatus such as the above described one, density control is important, which regulates the apparatus in terms of the maximum and intermediary levels of density for monochromatic yellow (Y), magenta (M), cyan (C), and black (Bk) images so that the apparatus will remain consistent in terms of the image density level, regardless of the difference in manufacture tolerance and changes in ambient conditions. Therefore, it is customary to equip a full-color image forming apparatus with a density controlling means for controlling the apparatus in terms of image density.
[0004] There have been proposed various full-color image forming apparatuses equipped with a density detecting means Some of them (for example, one disclosed in Japanese Laid-open Patent Application 2000-231279) are provided with a plurality of image bearing members and a plurality of developing means. Further, at least two of the plurality of developing means are identical in the hue of the developer (toner) therein, but, are different in density (saturation or deepness) of the developer (toner) therein; the developer in one of the two developing means is the same in hue as the developer in the other developing means, but is lower in density than the developer in the other developing means. They employ an image forming method in which each of the plurality of monochromatic images formed to form a single full-color image is formed of a combination of two monochromatic images identical in spectral properties, that is, a monochromatic image formed of the abovementioned developer lower in color density level (which hereinafter will be referred to light color toner), and a monochromatic image formed of the abovementioned developer higher in color density level (which hereinafter will be referred to as deep color toner), using two kinds of lookup tables, that is, a lookup table A for the light color toner, and a lookup table B for the deep color toner, shown in FIG. 13 .
[0005] According to the lookup tables in FIG. 13 , the low density areas of the monochromatic image are primarily formed of the light color toner, and the mid density areas of the monochromatic image are formed of the mixture of the light and deep color toners. Further, the high density areas of the monochromatic image are primarily formed of the deep color toner. Therefore, controlling the image forming apparatus with reference to these lookup tables A and B makes it possible to form an image which does not suffer from the problem that the low density areas of an image appear grainy due the low dot density, and also, to reduce the amount of toner which is consumed for the formation of the high density areas of an image. In other words, controlling the image forming apparatus with reference to these lookup tables improves the image forming apparatus in terms of image quality by reducing the graininess level at which the low density areas of an image are formed. It also effective to expand the range in which an image is accurately formed in terms of color reproduction.
[0006] However, the above described image forming method suffers from the following problem. That is, as a large number of images are formed, that is, the image forming apparatus is repeatedly used for a large number of times, changes occur to various conditions under which an image is formed; changes occur to the developing means in terms of development properties, the thickness of the dielectric layer of the photosensitive drum, the transfer efficiency, etc. Changes also occur to the ambient conditions. As these changes occur, the light color toner and the deep color toner change in the γ properties, and the occurrence of this change in the γ property corresponds to the threshold value for the input video signal, below which the light color toner is used, and above which the deep color toner is used. Therefore, the linearity in the relationship between the values of input video signals and the density level of the corresponding areas of the resultant image is lost. As a result, a defective image is formed; for example, an image defective in that the areas of the image, which are intermediary in density, are unnatural in gradation, and an image defective in that it has pseudo-contours.
SUMMARY OF THE INVENTION
[0007] The primary object of the present invention is to provide an image forming apparatus capable of an image higher in quality than an image forming apparatus in accordance with the prior art.
[0008] Another object of the present invention is to provide an image forming apparatus superior to an image forming apparatus in accordance with the prior art, in that it is capable of an image superior in the reproduction of the transitional areas of the image, transitional in that the image density changes from the level to be reproduced with the use of the light color toner to the level to be reproduced with the use of the deep color toner.
[0009] These and other objects, features, and advantages of the present invention will become more apparent upon consideration of the following description of the-preferred embodiments of the present invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic sectional view of the image forming apparatus in the first embodiment of the present invention, showing-the general structure thereof.
[0011] FIG. 2 is a flowchart which shows the flow of video signals in the image forming apparatus in the first embodiment.
[0012] FIG. 3 is a schematic drawing of an example of a density detecting means in accordance with the present invention.
[0013] FIG. 4 is a graph showing the relationship between the amount of the light color toner on the medium, and the output of the density detecting means, and the relationship between the amount of the deep color toner on the medium, and the output of the density detecting means.
[0014] FIG. 5 is a graph showing the relationship between the values of the input video signals, and the density levels of the images resultant from the input video signals, after the adjustment of the input video signals based on the lookup tables.
[0015] FIG. 6 is a graph showing the effect of the changes in image formation conditions and/or ambient conditions upon the relationship between the value of the input video signals, and the density levels of the images resulting from the input video signals.
[0016] FIG. 7 is a graph showing the relationship between the values of the input video signals generated for the formation of the density level test patches, and the density levels of the images of the test patches resulting from the input video signals for the formation of the density level test patches.
[0017] FIG. 8 is a graph showing the LUT for the light color toner, and the LUT for the deep color toner, in the first embodiment.
[0018] FIG. 9 is a graph showing the relationship between the values of the input video signals generated for the formation of the density level test patches, and the density levels of the images of the test patches resulting from the input video signals for the formation of the density level test patches.
[0019] FIG. 10 is a schematic drawing of the image forming apparatus in the second embodiment, showing the general structure thereof.
[0020] FIG. 11 is a picture of the density level detection test patches in the third embodiment.
[0021] FIG. 12 is a schematic drawing of the image forming apparatus in the fourth embodiment, showing the general structure thereof.
[0022] FIG. 13 is a graph showing the LUT for the light color toner, and the LUT for the deep color toner, for an image forming apparatus in accordance with the prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Hereinafter, the image forming apparatuses in accordance with the present invention will be described in detail with reference to the appended drawings.
Embodiment 1
[0024] Referring to FIGS. 1-9 , the first embodiment of the present invention will be described.
[0025] Referring to FIG. 1 , the image forming apparatus in this embodiment has four processing stations (image forming stations) P (Pa, Pb, Pc, and Pd) as image forming means for forming monochromatic yellow (Y), magenta (M), cyan (C), and black (Bk) images on the four image bearing members, one for one. The four processing stations are aligned straight in the direction in which a recording medium is conveyed. Each processing station has a photosensitive drum 1 ( 1 a, 1 b, 1 c, and 1 d ), a charging apparatus 2 ( 2 a, 2 b, 2 c, and 2 d ), an exposing apparatus 3 ( 3 a, 3 b, 3 c, and 3 d ), a primary developing means 4 ( 4 a, 4 b, 4 c, and 4 d ), a second developing means 5 ( 5 a, 5 b, 5 c, and 5 d ), a cleaning apparatus 6 ( 6 a, 6 b, 6 c, and 6 d ), and a primary transferring means 7 ( 7 a, 7 b, 7 c, and 7 d ) as a transferring means. The image forming apparatus is provided with an intermediary transfer member 12 as a transferring means for transferring, in coordination with the primary transferring apparatuses 7 , the toner images onto a recording medium p. The intermediary transfer member 12 is stretched between the photosensitive drum 1 and primary transferring apparatus 7 , in each processing station, and is circularly moved in the direction indicated by an arrow mark.
[0026] In this image forming apparatus structured as described above, each of the four image forming stations for forming the four monochromatic toner images, that is, the monochromatic yellow (Y), magenta (M), cyan (C), and black (Bk) toner images, one for one, is provided with two developing means, that is, the first and second developing means 4 and 5 ; two developing means are provided per color. More specifically, the first and second developing means are identical in the color (hue) of the toners therein, but are different in the color density of the toners therein. That is, the first developing means 4 is filled with such developer that is the same in hue, but is lighter in color density (saturation) than the toner in the second developing means 5 .
[0027] In other words, the image forming apparatus in this embodiment has two developing means, that is, the deep color developing means 5 and light color developing means 4 , for each of the four colors, that is, yellow (Y), magenta (M), cyan (C), and black ( 8 k). The deep color developing means 5 and light color developing means 4 are the same in the hue of the toner of the developer they contain, but are different in the color density (saturation) of the toner of the developer they contain; the color of the toner in the second developing means 5 is darker (deeper) than that in the first developing means 4 .
[0028] When it is said that ordinary two toners, which primarily are the mixture of resin and coloring component (pigment), are the same in hue, but different in density (saturation), it usually means that the two toners are practically the same in the spectral characteristics of the coloring ingredient (pigment), but are different in the amount of the coloring component. When one is called “light color toner” of the two toners which are the same in color (hue), the light color toner is the one which is lower in color density (saturation).
[0029] The image forming apparatus in this embodiment uses two toners different in color density in order to form a monochromatic toner image of a given color, and the two toners different in color density used for forming a single monochromatic toner image may sometimes be referred to as “dense (dark) toner” and “light toner”.
[0030] When two toners are said to be the same in hue, it means that the two toners are the same in the spectral characteristics of the coloring component (pigment) as described above. In the following description of the present invention, however, it means that the two toners are the same in terms of the ordinary concept of color. For example, two toners may be said to be the same in hue in that both are of magenta, cyan, yellow, or black color.
[0031] In the following description of the present invention, when one of the two toners of the same hue is referred to as light color toner, it means that when the amount by which this toner is deposited on recording medium is 0.5 mg/cm 2 , the portion of the recording medium covered with this toner is no more than 1.0 in optical density after the image fixation, whereas the portion of the recording medium covered with the other toner, or the deep color toner (toner more saturated in color) is no less than 1.0 in optical density.
[0032] In this embodiment, the amount of the pigment in the deep color toner is adjusted so that when the amount by which the deep color toner is deposited on recording medium is 0.5 mg/cm 2 , the optical density of the recording medium covered with this toner is 1.6, whereas that for the light color toner is 0.8. These two toners different in color density (saturation) are used in various ratios to reproduce a desired level (gradation level) of color density.
[0033] In terms of the direction, indicated by an arrow mark, in which the photosensitive drum 1 is rotated, the first developing means 4 is located on the upstream of the second developing means 5 .
[0034] The normal image forming steps carried out to form an image, by the image forming apparatus structured as described above are as follows:
[0035] In each of the plurality of process stations P, a toner image, which is different in color from the toner images in the other processing stations P, is formed on the photosensitive drum 1 through the electrophotographic process (comprising: charging, exposing, and developing steps).
[0036] First, in each processing station P, the charging step, in which the peripheral surface of the photosensitive drum 1 is uniformly charged by the charging apparatus 2 as a charging means, is carried out.
[0037] Meanwhile, in each processing station P, image formation data are read by an image reading portion 20 , are processed by a controlling means 15 as the controller for controlling the image forming operation, and are transmitted to a laser driver 3 ( 3 a, 3 b, 3 c, and 3 d ), which is a part of the exposing apparatus as a latent image forming means for forming a latent image on the photosensitive drum 1 .
[0038] In this embodiment, an original is read twice by the original reading portion 20 , for each processing station. More specifically, when the original is read for the first time, the obtained image formation data are processed by the controlling means 15 into the video signals for the first developing means 4 , whereas when the original is read for the second time, the obtained image formation data are processed by the controlling means 15 into the video signals for the second developing means 5 . The flowchart which shows the essential steps of this process of outputting the video signals is given in FIG. 2
[0039] First, regarding the first reading of an original for the formation of a latent image (exposure of photosensitive drum 1 ), the original placed on the original reading portion 20 is scanned (si), and the optical data obtained from the original are converted (s 1 ) by a CCD 14 into electrical signals, which are converted (s 3 ) by an A/D conversion apparatus into digital signals. The thus obtained digital signals are processed (s 4 ) by the image formation data processing block, and the R, G, and B signals are converted (s 5 ) in color into CMYK signals. Then, the CMYK signals are subjected to the γ correction step (s 6 ), and are converted (s 7 ) into the video signals for the light color toner, in accordance with the lookup table (which hereinafter will be referred to as “LUT”). Then, the video signals for the light color toner are digitized (s 8 ). The thus obtained digital image formation data are stored (s 9 ), are converted (s 10 ) into analog signals, are transferred to the laser driver 3 , and are used (s 11 ) for image formation. The LUT for the light color toner, which is used in the above described step s 7 , is represented by the line indicated by a referential letter A, in FIG. 8 .
[0040] The electrostatic latent image formed through the exposure in the above described step (s 11 ) is developed by the first developing means 4 which uses the light color toner. Then, the toner image formed by the first developing means 4 is transferred (primary transfer) onto the intermediary transfer belt 12 by the primary transferring apparatus 7 as a transferring means.
[0041] Then, the original is scanned for the second time (s 12 ). In order to form a toner image of the deep color toner after forming a toner image of the light color toner, it is necessary to read (scan) the original again, due to requirement related to the memory. The image formation signals obtained by the second scanning of the original are processed through steps (s 12 -s 17 ) similar to the steps through which the image formation signals obtained by the first scanning of the original are processed, up to the correction step. Thereafter, the signals are converted (s 18 ) into the signals for the deep color toner, in accordance with the LUT for the deep color toner, and then, are digitized (s 19 ). The thus obtained digital image formation data are stored (s 20 ), are converted (s 21 ) into analog signals, are transferred to laser driver 3 , and are used to drive (s 22 ) the laser driver 3 to form an image of the deep color toner. The LUT to be used in the step (s 18 ) to obtain the signals for the deep color toner is represented by the line indicated by a letter B, in FIG. 8 .
[0042] As the above described step s 22 , or the latent image formation step, is carried out, an electrostatic latent image is formed, through the exposure, on the uniformly charged peripheral surface of the photosensitive drum 1 . Next, this electrostatic latent image is developed through the developing step carried out by the second developing means 5 which uses the deep color toner, yielding a toner image formed of the deep color toner The thus obtained toner image is transferred (primary transfer) by the primary transferring apparatus 7 , onto the intermediary transfer belt 12 , onto which the toner image formed of the light color toner has been transferred. As a result, a toner image formed of the deep color toner and light color toner is yielded on the intermediary transfer belt 12 .
[0043] In other words, through the video signal processing steps shown in FIG. 2 , the original is sorted into the areas which are to be reproduced with the use of only the light color toner, the areas which are to be reproduced with the use of both the light and deep color toners, and the areas which are to be reproduced with the use of only the deep color toner, and then, whether only one of the developing means 4 and 5 is to be used, or which developing means is to be used if only one of the developing means 4 and 5 is to be used, is determined based on the results of the sorting.
[0044] As for the transferring means, the intermediary transfer member 12 is circularly moved by the suspensive rollers 12 a and 12 b at the same speed as the rotational velocity of each of the plurality of photosensitive drums 1 , through the contact area (nip) between the primary transferring apparatus 7 and photosensitive drum 1 , in each processing station P (Pa, Pb, Pc, and Pd), with its outwardly facing surface, in terms of the loop which the intermediary transfer member 12 forms, kept in contact with the peripheral surface of the photosensitive drum 1 . Thus, as the intermediary transfer member 12 is moved sequentially through the plurality of primary transfer stations, the toner image formed on the peripheral surface of the photosensitive drum 1 , of the two toner images formed in layers on the peripheral surface of the photosensitive drum 1 , of the two toners different in color density, in each processing station P (Pa, Pb, Pc, and Pd) is transferred in layers onto the intermediary transfer member 12 , yielding a single multicolor image, which is conveyed, while remaining on the intermediary transfer member 12 , to the secondary transfer station 11 , by the circularly movement of the intermediary transfer member 12 .
[0045] The multicolor image formed on the intermediary transfer member 12 , of the plurality of monochromatic toner images formed of the two toners different in color density, in the plurality of processing stations P, one for one, is transferred (secondary transfer) in the secondary transfer station 11 , onto the recording medium p delivered to the secondary transfer station 11 from the sheet feeder cassette 13 , and then, is fixed to the recording medium p by the fixing apparatus 9 . Thereafter, the recording medium p is discharged as a final product (copy) from the image forming apparatus.
[0046] In other words, according to the flowchart given in FIG. 2 , the image formation signals are processed, in the step s 7 , in accordance with the LUT for the light color toner, so that the areas of the image, which are low in color density, are primarily developed with the light color toner. As a result, the latent image is developed so that a monochromatic image, the low color density areas of which are lower in the color density of each dot, will be yielded In other words, the flowchart makes it possible to minimize the shortcoming of a digital image that a digital image appears grainy. Further, another set of image formation signals are processed, in step p 18 , in accordance with the LUT for the deep color toner. In other words, according to the flowchart in FIG. 2 , two monochromatic images different in color density are formed per color component (into which optical image of original is separated), through two sets of image formation steps, that is, the image formation signal processing step, latent image forming step, and developing step, and are transferred in layers onto the intermediary transfer belt 12 , through the primary transfer step, yielding thereby a single monochromatic image formed of two monochromatic images formed of the deep and light color toners, one for one, which are the same in hue and different in color density.
[0047] Described next will be the control to be carried out to form a satisfactory image, regardless of the changes in the apparatus conditions attributable to the usage and the changes in the ambient conditions, through an image forming process such as the one described above, in which two developing means different in the color density of the toners they use are used per color component. In this embodiment, the image forming process is controlled by revising the LUTs used for processing the video signals.
[0048] To describe in more detail, the above described image forming apparatus is reset so that the image formation conditions, such as the conditions under which the photosensitive drums 1 are charged and exposed by the image forming means, the conditions under which a latent image is developed, and the conditions under which a toner image is transferred, are set to the defaults. Then, the data for generating the video signals for forming density level detection test patches, which are stored in the ROM or the like, are read by the means for forming the electrostatic latent images for density level detection test, that is, a density level detection test patch forming means, for example, the controller (controlling means) 15 , and a desired image density level is inputted. Then, the electrostatic latent image for density level detection test, which reflects the inputted image density level is formed, and is developed by the developing means to be used for developing the latent image in accordance with the intended image. As a result, the image of the density level detection test patch (images to be used for devising LUT) is formed, and is transferred (primary transfer) onto the intermediary transfer medium 12 . Then, the color density level of the toner image of the density level detection test patch on the intermediary transfer member 12 is detected by the density detecting means (density sensor) 21 , which is positioned upstream of the second transfer station 11 , in terms of the moving direction of the intermediary transfer member 12 , so that it faces the intermediary transfer belt 12 . The thus obtained density level of the image of the density level detection test patch is used as the output density level.
[0049] Then, based on the relationship between the inputted color density level, and the outputted color density level detected by the color density sensor 21 , the controller 15 as a controlling means adjusts the image formation conditions, as will be described below, in order to yield a satisfactory image. More specifically, the gradation reference, which in this embodiment is the LUT, set in the video signal processing portion of the controller 15 , is revised so that a satisfactory (vivid) image, in terms of gradation, is always formed regardless of the gradational variations.
[0050] Referring to FIG. 3 , the density sensor 21 in this embodiment comprises a light emitting element 23 , a light receiving element 24 such as a photo-diode, Cds, or the like, and a holder 22 to which the light emitting element 23 and light receiving element 24 are attached. The beam of light from the light emitting element 23 is projected onto the image T of the density detection patch (which hereinafter will be referred to patch image T) on the belt 12 , and is partially received by the light receiving element 24 after being deflected (diffused) by the patch image T, in order to measure the density level of the patch image T. Generally, light reflected by a given surface includes the portion literally reflected by the surface and the portion diffused by the surface. In this embodiment, a density sensor of the diffuse light type is used as the density sensor 21 , and the incident angle θ and reflection angle φ are set to 15° and 45°, respectively. The outputs of the density sensor 21 when the light color toner was used, and the outputs of the density sensor 21 when the deep color toner was used, are given in FIG. 4 .
[0051] The controlling means 15 automatically revises the gradation setting, in real time, by changing the values set in the lookup table stored in the γ correcting portion of the video signal processing portion, based on, for example, a LUT revision table, in response to the image density level of the patch image T detected by the density sensor 21 .
[0052] Further, the controlling means 15 stabilizes the image forming apparatus in terms of image quality, by sequentially revising the image formation conditions, that is, the conditions under which the photosensitive drums 1 are charged, the conditions under which the photosensitive drums 1 are exposed, the conditions under which images are transferred, etc., which are set in the video signal processing portion. In other words, the controlling means 15 stabilizes the image forming apparatus in terms of image quality by revising the image formation conditions. Since the image forming apparatus is controlled in image density, based on the LUT revised through the above described steps, the relationship between the input video signals and the density of the image resultant from the inputted video signals becomes linear, as shown in FIG. 5 , making it possible to yield an image satisfactory in terms of density level reproduction. Referring to FIG. 5 , incidentally, the input video signals means the video signals resulting from the reading of the original by the original reading apparatus 20 , and the output image density level means the density level of the image resulting from the input video signals.
[0053] As described above, in this embodiment, the image formation operation is controlled by the controlling means 15 in accordance with the LUT. Therefore, a satisfactory image can be formed.
[0054] However, as a large number of copies are made, that is, the image forming operation is repeated a large number of times, and/or the ambient conditions of the image forming apparatus change, the image formation conditions, such as the developmental properties of the developing means 4 and 5 , the thickness of the dielectric layer of the photosensitive drum 1 , the transfer efficiency or the like in the secondary transfer station 11 , change. As a result, the light and deep color toners change in the γ property, making nonlinear the relationship between input image density level and output image density level, roughly at the density level (which hereinafter will be referred to as mid image density level) where the light color toner and deep color toner begin to be used in mixture, as shown in FIG. 6 . Therefore, it becomes unlikely for an image satisfactory in terms of color density reproduction to be formed. Instead, an unsatisfactory image, for example, an image unnatural in gradation across the areas where color density is in the mid range, an image suffering from pseudo-contours, or the like, is likely to be yielded.
[0055] In this embodiment, therefore, the image density levels to be inputted for forming the images of the density level detection test patches for revising the LUT are selected so that the detection of the density levels of the patch images, the density levels of which are at, or in the adjacencies of, the mid image density level, is prioritized.
[0056] In this embodiment, as the values for the video signals to be inputted to form the patch images for determining the relationship between the input signal level and the output density level, 16 , 48 , 80 , 112 , 120 , 128 , 136 , 144 , 176 , 208 , and 240 are selected from among the 255 values (that is, 256 gradation levels) used to indicate the density level of an image of a solid color. FIG. 7 , in which the abovementioned values for the video signals inputted for patch formation, and the corresponding density levels of the patch images, are plotted, shows the relationship between the input signals and output signals in terms of the image density. As will be evident from this graph, the values for the input video signal are selected so that the interval between the adjacent two values is smaller, near 128 ; in other words, the detection of the density level is concentrated to the values near 128 .
[0057] More specifically, the abovementioned values are selected in consideration of the following facts (problems). That is, not only is it difficult to confirm whether or not the relationship between the input video signal and the density level of the resultant image is linear in the areas of the image, where the density is in the mid range, but also, if the larger the interval between the adjacent two density levels selected for the density level detection test patches, the more unclear the changes in the γ property, whereas the narrower the interval, the greater the number of the patch images to be formed to detect the relationship between the input video signals and the density level of the resultant image, and therefore, the longer the down time, or the time spent to detect the relationship, and also, the greater the toner consumption, and therefore, the higher the image formation cost.
[0058] More specifically, the number by which the patch images, which are formed of the mixture of the light and deep color toners, and the image density levels of which are in the adjacencies of the borderline density level between the density level range in which patch images are formed of the light color toner alone, and the density level range in which patch images are formed of the mixture of the light and deep color toners, are formed, and the number by which the patch images, which are formed of the mixture of the light and deep color toners, and the image density levels of which are in the adjacencies of the border line density level between the density level range in which patch images are formed of the mixture of the light and deep color toners, and the density level range in which patch images are formed of the deep color toner alone, are formed, are made greater than the number by which the patch images which are formed with the use of the deep color toner alone, and the density levels of which are in the mid to high portion of the density level range in which patch images are formed of the deep color toner alone, are formed, and the number by which the patch images, which are formed of the light color toner alone, and the density levels of which are in the low to mid portion of the density level range in which patch images are formed of the light color toner alone, are formed.
[0059] As described above, it is desired that the patch images, the image density levels of which fall within the adjacencies of the mid density level at which the toner used for forming a monochromatic image is switched from the light color toner to the mixture of the light and deep color toners, are formed by a greater number than the patch images, the image density levels of which do not fall within the abovementioned range, and their actual density levels are detected.
[0060] Referring to FIG. 8 , in which in order to make it easier to understand the abovementioned mid density levels, the overall range of the values for the input video signals are divided into an image density range R 1 in which only the light color toner is used, an image density range R 2 in which the mixture of the light and deep color toners are used, and an image density range R 3 in which only the deep color toner is used, the abovementioned mid density level means the borderline between the image density ranges R 1 and R 2 .
[0061] In other words, the patch images, the theoretical density levels of which fall within the adjacencies of the borderline between the image density ranges R 1 and R 2 , are formed by a larger number than the patch images, the theoretical density levels of which do not fall therein, and their actual density levels are detected by the density sensor 21 to more precisely determine the relationship between the input density and output density. Therefore, it is possible to keep linear the relationship between the input density level and output density level. In other words, it is possible to satisfactorily control the image density.
[0062] Referring to FIG. 9 , regarding one of the characteristic features of this embodiment of the present invention, the image density can be even more satisfactorily controlled by forming, by a greater number, the patch images, the theoretical density levels of which fall within the adjacencies of the borderline between the image density ranges R 2 and R 3 , in addition to the patch images, the theoretical density levels of which fall within the adjacencies of the borderline between the image density ranges R 1 and R 2 , than the patch images, the theoretical density levels of which do not fall therein.
[0063] The reason not only are the patch images, the image density levels of which fall within the adjacencies of the intermediary density level, that is, the borderline between the image density ranges R 1 and R 2 , that is, the borderline between the image density range in which only the light color toner is used, and the image density range in which the light color toner is used in combination with the deep color toner, but also, the patch images, the image density levels of which fall within the adjacencies of the intermediary density level, that is, the borderline between the image density ranges R 2 and R 3 , are formed by a greater number than the patch images, the density levels of which do not fall in the adjacencies of the borderline between the image density ranges R 1 and R 2 , and the adjacencies of the image density range R 2 and R 3 , is that the effects of the changes which occur to the developing means through the usage, upon the γ property, and the effects of the changes in the ambient conditions, upon the γ property, are larger when the image density level of the portion of the image being formed is at or in the adjacencies of these borderlines.
[0064] As will be evident from the above description of this embodiment, in the case of the image forming apparatus in this embodiment, in which each of the plurality of monochromatic images, different in color, formed to form a single multicolor image, is formed of two toners, that is, light and deep color toners, which are the same in hue, but, are different in color density, and the image density is controlled by revising the LUT in response to the output of the density sensor which detects the image density levels of the images of the density level detection test patches, the formation of the patch images, the image density levels of which fall in the adjacencies of the image density level at which the toner used for the formation of the monochromatic image is switched from the light color toner to the mixture of the light and deep color toners, is prioritized, and the density levels of the resultant patch images are detected by the density sensor. Therefore, even if the processing conditions of the image forming apparatus change due to the formation of a large number of images (copies), and/or the ambient conditions change, the relationship between the video signals and the density level of the image resulting from the video signals remains linear, making it possible to always form a color image of high quality.
Embodiment 2
[0065] Next, referring to FIG. 10 , the second embodiment of the present invention will be described.
[0066] In this embodiment, the image formation stations Pb and Pc for forming the magenta (M) and cyan (C) images are provided with both the first and second developing means 4 and 5 in the above described first embodiment, and the image formation stations Pa and Pd for forming the yellow (Y) and black (Bk) images are provided with only the second developing means 5 , that is, the developing means which uses the deep color toner.
[0067] Yellow (Y) color is higher in brightness. Therefore, the graininess of the yellow areas of an image is difficult to visually detect, even if the areas are low in density. Thus, the effect of the usage of the light yellow toner is insignificant.
[0068] As for black (Bk) color, it is rare that photographic image or the like images, which require high quality, have black areas which are low in density. Further, a letter or the like image usually is solid. Therefore, effect of the usage of the light black toner is insignificant.
[0069] In this embodiment, the process of forming a magenta (M) image and the process of forming a cyan (C) image are controlled in the manner similar to that in the first embodiment. As a result, the relationship between the input video signal and the density level of the resultant image can be kept linear, making it possible to yield a color image of high quality, in terms of the density of the magenta and cyan color areas of the image, regardless of the changes in the ambient conditions, even after the developing apparatuses change in properties through the usage.
[0070] Moreover, the component count of the developing means is smaller than that in the first embodiment, and also, the memory capacity necessary for the LUT can be reduced. Therefore, it is possible to provide an image forming apparatus, which is smaller, lower in cost, and simpler to control.
Embodiment 3
[0071] Next, referring to FIG. 11 , the third embodiment of the present invention will be described. The general structure of the image forming apparatus in this embodiment is the same as that of the image forming apparatus in the first embodiment, and therefore, the same referential numbers and symbols as those used for the designation of the components, means, etc., of the image forming apparatus in the first embodiment are used to designate the corresponding component, means, etc., of this image forming apparatus.
[0072] In this embodiment, the density of the patch image formed to control the image forming apparatus in terms of image density is detected by the density sensor 21 positioned next to the intermediary transfer member 12 , facing the intermediary transfer member 12 . In this embodiment, however, the density level of the test patch image is detected by the original reading portion 20 after the test patch image is transferred onto the recording medium p, and the control is carried out in response to the thus detected image density level of the test patch image.
[0073] Referring to FIG. 11 , a test pattern print 30 contains four rows of color patches, that is, the row of the eleven yellow color patches, row of the eleven magenta color patches, row of the eleven cyan color patches, and row of the eleven black color patches. The eleven color patches in each row of color patches are different in density level (gradation level). Out of the 256 levels of density (gradation level), which this image forming apparatus is enabled to reproduce, the mid density value and the values close thereto are primarily selected as the values for the density levels for the density level detection test patches, and the images of the density level detection test patches, the density levels of which fall in the low density range, or high density range, are formed by a substantially smaller number than the number by which the images of the density level detection test patches, the density levels of which fall on or within the adjacencies of the mid density value.
[0074] Thus, the images of the density detection test patches are not formed by an excessive number. Therefore, it is possible to control the image forming apparatus in terms of the density level at which the toner used for the formation of a monochromatic image is switched from the light color toner to the mixture of the light and deep color toners, while reducing the toner consumption and the time required for forming the test prints.
[0075] As for the image density levels of the eleven test patches in each of the four rows of test patches, the density level of the test patch, which is deepest in density, is represented by a value of 255, and the values of the density levels of the eleven test patches for each color are 16 , 48 , 80 , 112 , 120 , 128 , 136 , 144 , 176 , 208 , and 240 , as they were in the first embodiment. The video signals for forming the images of these eleven test patches, the density levels of which have the above listed values, one for one, are generated with the use of the test patch generating means.
[0076] After the formation of the groups of patch images, the groups of patch images on the test print 30 are read by the original reading portion 20 .
[0077] In order to accurately detect the density level of the images of the test patches, the density level of each test patch image was detected at 16 points of the test patch, and the obtained signals are averaged. The value obtained by averaging the 16 values obtained by detecting the density level of each test patch image at 16 different points of the test patch image, RGB signals are converted by the optical density converting method into the density values for Y, M, C, and Sk, and the LOT is revised in response to the thus obtained density values for Y, M, C, and Bk; a new LUT is set up.
[0078] By carrying out the above described image density control, it was possible to maintain linearity in the relationship between the input video signals and the density level of the reproduced image, in spite of the changes in the processing conditions which occurred through an operation for forming a large number of copies, repetition of the image forming operations, and/or changes in the ambient conditions. As a result, it was possible to continuously form images of high quality.
[0079] Further, the test patch images tested for image density control in this embodiment are the test patch images which had been transferred onto the recording mediums p, and had been fixed to the recording mediums p by being put through the fixing device 9 . They are virtually the same in terms of image density level as that of the image to be formed for actual usage. Thus, the image density control in this embodiment is more accurate than that in the first embodiment.
[0080] Referring to FIGS. 1 and 10 , in the first to third embodiments, the density sensor 21 was positioned so that it faced the intermediary transfer member 12 , which was a transfer belt for a multilayer direct image transfer method. Obviously, however, the density sensor 21 may be positioned so that it faces the peripheral surface of the photosensitive drum 1 . Placing the density sensor 21 so that it faces the peripheral surface of the photosensitive drum 1 is just as effective as placing the density sensor 21 so that it faces the intermediary transfer member 12 .
Embodiment 4
[0081] Next, referring to FIG. 12 , the fourth embodiment of the present invention will be described.
[0082] This embodiment is an example of the application of the present invention to an image forming apparatus employing the multilayer direct image transferring method. In this embodiment, a plurality of image formation stations Pa-Pd, similar in structure as those shown in FIG. 1 , are disposed along the transfer belt 12 . The recording medium p from a cassette 13 is borne on the surface of the transfer belt 12 , and is conveyed by the transfer belt 12 through the image formation stations Pa-Pd, in which it remains pinched between the transfer roller 7 as a transferring means, and the photosensitive drum 1 , so that the a plurality of monochromatic toner images are transferred in layers directly onto the recording medium p. After the direct transfer, the recording medium p is conveyed through the fixing device 9 , in which the plurality of monochromatic toner images on the recording medium p are fixed. Thereafter, the recording medium p is discharged frog the image forming apparatus. Obviously, a plurality of image formation stations Pa-Pd, similar to those shown in FIG. 10 , may be disposed along the transfer belt 12 .
[0083] In this embodiment, the images of the density level test patches are formed on the portion of the transfer belt 12 other than where the recording medium p is borne, or on the recording medium p borne on the transfer belt 12 , and then, the test patch images are test for density level by the density sensor 21 . The image control in this embodiment is the same as those in the above described first to third embodiments.
[0084] According to the above described first to fourth embodiments, it is possible to keep linear the relationship between the input video signals and the density levels of the resultant images, even if the condition of an image forming apparatus changes because of the formation of a large number of images, and/or the changes in the ambient conditions. Therefore, it is possible to always form images of high quality.
[0085] Incidentally, in the above, the first to fourth embodiments were described with reference to an image forming apparatus of an inline type However, the number of the photosensitive drum 1 does not need to be limited to the number in these embodiments. For example, a plurality of developing means may be disposed in the adjacencies of the peripheral surface of a single photosensitive drum.
[0086] Further, the measurements, materials, and shapes of the structural components of the image forming apparatus, and the positional relationship among them, in the first to fourth embodiments of the present invention, are not intended to limit the scope of the present invention, unless specifically noted.
[0087] While the invention has been described with reference to the structures disclosed herein, it is not confined to the details set forth, and this application is intended to cover such modifications or changes as may come within the purposes of the improvements or the scope of the following claims.
[0088] This application claims priority from Japanese Patent Application No. 433950/2003 filed Dec. 26, 2003, which is hereby incorporated by reference.
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An image forming apparatus image forming means for forming a toner image using light color toner and dark color toner which have the same hues and which have different densities; detecting means for detecting a density of a toner image for reference which is formed by the image forming means, the reference toner image including a number of portions corresponding to different image density levels; control means for controlling an image forming condition of the image forming means in accordance with an output of the detecting means, wherein a difference between the image density levels corresponding to adjacent ones of the portions in a predetermined image density area including an image density level corresponding to a boundary between an image density area where an image is formed using only the light toner and an image density area where an image is formed using both of the light toner and the dark toner, is smaller than that in a density area other than the predetermined image density area.
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BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to methods and apparatus for an automatic fluid ejector alignment and performance system that has the ability to determine alignment and operation of at least one fluid ejector, and can provide various implementation methods to modify defects or errors in operation.
2. Description of Related Art
Fluid ejector systems, such as drop-on-demand liquid ink printers, including piezoelectric, acoustic, phase change wax-based or thermal printers, have at least one fluid ejector from which drops of fluid are ejected towards a receiving sheet. Within the fluid ejector, the fluid is contained in a plurality of channels. Power pulses cause the droplets of fluid to be expelled as required from orifices or nozzles at the end of the channels.
When the fluid ejector is an ink jet printhead, the fluid ejector may be incorporated into for example, a carriage-type printer, a partial width array-type printer, or a page-width type printer. The carriage-type printer typically has a relatively small printhead containing the ink channels and nozzles. The printhead can be functionally attached to a disposable ink supply cartridge. The combined printhead and cartridge assembly is attached to a carriage that is reciprocated to print one swath of information at a time, on a stationary receiving medium, such as paper or transparencies, where each swath of information is equal to the length of a column of nozzles.
Conventional printing systems step the receiving medium a distance generally equal to or less than the height of the swath to be printed, so that the next printed swath is contiguous or overlaps with the previously printed swath. When there is no data to print in large blocks, the receiving medium may be stepped a larger amount. This procedure is repeated until the entire image is printed.
Optimal performance of a fluid ejector requires the nozzles be properly aligned. When the fluid ejector is a color ink jet printhead, such as a four color printhead (CMYK), proper alignment of the various color heads is necessary and printed test patterns are generally used. Each alignment procedure, including vertical head to head alignment, horizontal head to head alignment, bi-directional alignment, and tilt alignment, requires four test pattern sets to be run for a four printhead printer. Furthermore, if the printhead carriage operates at multiple speeds, such as draft and normal, test pattern sets for some alignment procedures must be run for each speed. Manual procedures for correcting alignment require considerable user labor and are prone to user error. These procedures require the user to run the test pattern sets, visually observe the test pattern sets, visually judge the optimal test pattern set among various alternatives, and choose an adjustment value.
Automatic alignment procedures are also known. U.S. Pat. No. 6,609,777 B2 to Endo, the disclosure of which is incorporated herein by reference in its entirety, discloses technology for printing and determination of an adjustment value for correcting bi-directional misalignment of the dot recording positions. The printing apparatus includes an inspection unit that optically detects the passage of a continuous stream of ink droplets ejected from a printer nozzle. An adjustment value is determined based on the results of the performance of a forward pass test and a reverse pass test, and bi-directional misalignment can be determined without need for human observation.
Fluid ejector system's performance will also be impacted by a fluid ejector's nozzle performance. When the fluid ejector is in an ink jet printhead, fluid ejector performance may be impacted where particle contamination clogs the nozzle, where kogation of the heaters decreases drop velocity, or where damage occurs to the nozzle, such as due to resistor burn-out, or where the printhead brushes against the print medium, or where the nozzle plate becomes worn due to frequent servicing. Other factors may also impact nozzle performance. Fluid ejector performance is often determined by printing a test pattern and visually inspecting the test pattern results.
Automatic methods for detecting fluid ejector performance are also known. U.S. Pat. No. 6,454,380 B1 to Endo, the disclosure of which is incorporated herein by reference in its entirety, discloses a system for inspecting nozzles requiring the jetting of a continuous stream of ink droplets for detecting the clogging of nozzles in a printer wherein timings for printing operations for conducting the inspection are preset with respect to at least two print modes. Similarly, U.S. Pat. No. 6,585,346 B2 to Endo, the disclosure of which is incorporated herein by reference in its entirety, discloses a technique for detecting the presence or absence of inoperative nozzles by comparing a specific threshold with a time interval between successive detection pulses. Similarly, U.S. Pat. No. 6,604,807 to Murcia, the disclosure of which is incorporated herein by reference in its entirety, discloses a method for determining anomalous nozzles in an ink jet printing device.
SUMMARY OF THE INVENTION
Current fluid ejector alignment and performance techniques for determining and modifying fluid ejector alignment and performance have significant disadvantages. For example, a large number of test pattern sets are required to be printed. The user then visually analyzes the test pattern sets and manually enters a value into a computer to modify the fluid ejector alignment or performance. Because of the user involvement, the method is onerous, time-consuming, and prone to error. Thus, the conventional method often has inconsistent results in both determining and modifying fluid ejector alignment and performance.
The methods and apparatus of this invention provide for automatic fluid ejector alignment and performance evaluation and modification in one or multiple planes.
The methods and apparatus of this invention separately provide an automatic fluid ejector alignment and performance evaluation that can determine properties on an individual nozzle basis.
In various exemplary embodiments, a fluid ejector fires a fluid drop through a laser beam emitted from a drop detection module's laser. A shadow is created on the drop detection module's photodiode if the fluid drop impinges the laser beam. A shadow is not created if the firing of the drop either fails to eject a fluid drop, or the fluid drop fails to impinge the laser beam. The shadow or lack of shadow signal is focused by a microscope through an aperture onto a photodiode. The microscope is not essential to the invention and the removal of the microscope will result in a simpler apparatus.
In various exemplary embodiments, the focus of the shadow or lack of shadow on the photodiode is amplified by an amplifier and converted into a signal. The signal is sent to a computer as data. After analyzing the data, the computer makes a compensation determination which may then be applied to the fluid ejector to electronically modify the image data to be printed, physically manipulate the fluid ejector nozzle, completely skip the fluid ejector during printing operations or in some other way modify the fluid ejector or image data such that error in the printed image due to fluid ejector mis-alignment or performance error is reduced.
Throughout this application, the decision by the computer on how to modify the fluid ejector such that error induced by the fluid ejector on the printed image is reduced, will be referenced to collectively as the compensation determination. Among other determinations, the computer may make a compensation determination to modify the image data to be printed, to physically manipulate a fluid ejector, or to completely skip a fluid ejector during the printing process.
The compensation determination determines the preferred method of using the selected fluid ejectors to create the printed image. An example of a compensation determination to modify an image to be printed in order to correct for fluid ejector alignment or performance errors may include rotating an image. Similarly, a determination to physically manipulate a fluid ejector in order to compensate for error may include wiping or priming a fluid ejector, or changing the voltage to a fluid ejector.
In various exemplary embodiments, the compensation determination may be made by an on-board diagnostic tool, such as a controller, that allows the apparatus to self-check and modify fluid ejector metrics on a regular basis.
Other objects, advantages and features of the invention will become apparent from the following detailed description taken in conjunction with the attached drawings, which disclose exemplary embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described with reference to the following drawings in which like reference numerals refer to like elements and wherein:
FIG. 1 illustrates one exemplary embodiment of a fluid ejector system drop detection module according to the invention;
FIG. 2 illustrates one exemplary embodiment of a fluid ejector device usable with various exemplary systems and methods according to this invention;
FIG. 3 is a view of a fluid ejector device from a first direction;
FIG. 4 is a view of a fluid ejector device from a second direction;
FIG. 5 is a graph showing an output drop signal from a photodiode over time;
FIG. 6 is a block diagram of an exemplary fluid ejector alignment and performance system according to the invention;
FIG. 7 is a flowchart outlining one exemplary embodiment of a method for automatically determining fluid ejector alignment and performance according to the invention;
FIG. 8 is a flowchart outlining one exemplary embodiment of a method for using the drop detection module to determine and, if necessary, modify fluid ejector alignment and performance according to the invention;
FIG. 9 is a flowchart outlining one exemplary embodiment of a method for using the drop detection module to determine and, if necessary, electronically compensate, horizontal printhead alignment according to the invention;
FIG. 10 is a flowchart outlining one exemplary embodiment of a method for using the drop detection module to determine and, if necessary, electronically compensate, vertical printhead alignment according to the invention;
FIG. 11 is a flowchart outlining one exemplary embodiment of a method for using the drop detection module to determine and, if necessary, electronically compensate, printhead tilt according to the invention;
FIG. 12 is a flowchart outlining one exemplary embodiment of a method for using the drop detection module to determine and, if necessary, electronically compensate, bi-directional alignment according to the invention;
FIG. 13 is a flowchart outlining one exemplary embodiment of a method for using the drop detection module to determine and, if necessary, modify fluid ejector performance for ejector problems, such as blocked or non-firing jets according to the invention; and
FIG. 14 is a flowchart outlining one exemplary embodiment of a method for using the drop detection module to determine and, if necessary, modify fluid ejector performance for ejector problems such as kogation, re-fill, and maximum frequency problems, according to the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The following detailed description of various exemplary embodiments of the fluid ejection systems according to this invention may refer to one specific type of fluid ejection system, an ink jet printer, for sake of clarity and familiarity. However, it should be appreciated that the principles of this invention, as outlined and/or discussed below, can be equally applied to any known or later developed fluid ejection systems, beyond the ink jet printer specifically discussed herein.
FIG. 1 shows an exemplary embodiment of a fluid ejector system drop detection module 200 that incorporates the systems and methods of the invention. A fluid ejector or emitter 305 is housed in a printhead 300 . A computer 400 signals the laser 205 to fire a drop detection module laser beam 210 . The computer 400 may also signal the printhead 300 to fire a drop 310 from fluid ejector 305 . A microscope 215 captures the laser beam 210 and focuses the laser beam 210 through an aperture 220 onto a photodiode 225 . The signal from the photodiode 225 may be amplified by amplifier 230 and sent to the computer 400 . The drop detection module 200 and its components are provided to detect the passage of individual drops 310 from emitter 305 for purposes of alignment and/or performance monitoring.
For simplicity and clarification, the operating principles and design factors of various exemplary embodiments of the systems and methods according to this invention are explained with reference to one exemplary embodiment of a carriage-type ink jet printer 100 , as shown in FIG. 2 , and one exemplary embodiment of a printhead 300 as shown in FIGS. 1–3 . The basic explanation of the operation of the ink jet printer 100 and the printhead 300 is applicable for the understanding and design of any fluid ejection system that incorporates this invention. Although the systems and methods of this invention are described in conjunction with the ink jet printer 100 and the printhead 300 , the systems and methods according to this invention can be used with any other known or later-developed fluid ejection system.
FIG. 2 shows a carriage-type thermal ink jet printing device 100 . A linear array of droplet producing channels is housed in a printhead 300 mounted on a reciprocal carriage assembly 105 . A number of ink droplets 310 are propelled towards a receiving medium 110 , such as a sheet of paper, that is stepped by a motor 115 a preselected distance in a process direction, indicated by the arrow 120 , each time the printhead 300 traverses across the receiving medium 110 along the scan axis perpendicular to the process direction. The receiving medium 110 can be stored on a supply roll 125 and stepped onto a take up roll 130 by the motor 115 or other means well known to those skilled in the art. For example, the receiving medium may be individual sheets of paper indexed in process direction 120 .
In the exemplary embodiment shown in FIG. 2 droplets 310 are fired horizontally from the printhead 300 toward the receiving medium 110 . However, the droplets 310 may also be propelled vertically or diagonally. Thus, although the systems and methods of this invention, as shown in exemplary embodiment FIG. 2 , are described with reference to droplets 310 being fired horizontally, the systems and methods according to this invention can include droplets 310 being fired vertically or diagonally.
The printhead 300 is fixedly mounted on a support base 135 of the carriage assembly 105 , which reciprocally moves along two parallel guide rails 145 . The printhead 300 may be reciprocally moved by a cable or endless belt 150 and a pair of pulleys 155 , one of which is powered by a reversible motor 160 . The printhead 300 is generally moved across the receiving medium 110 perpendicular to the direction that the receiving medium 110 is moved by the motor 115 . Of course, any other known or later-developed structure usable to move the carriage assembly 105 can be used in the ink jet printing device 100 .
Alternatively, the linear array of droplet producing channels may extend across the entire width of the receiving medium 110 , as is well known to those of skill in the art. This is typically referred to as a full-width array. See, for example, U.S. Pat. No. 5,160,403 to Fisher et al. and U.S. Pat. No. 4,463,359 to Ayata et al., each of which is incorporated herein by reference in its entirety.
An encoder 165 is located such that the location or position of the printhead 300 can be determined with respect to the carriage assembly and/or ink jet printing device 100 . Exemplary encoders 165 may include a linear strip encoder or a rotary encoder. However, any known or later-developed structure usable to determine the position of the printhead 300 or fluid ejectors 305 can be used in the ink jet printing device 100 .
In various exemplary embodiments, two drop detection modules 200 are located within the ink jet printing device 100 , each preferably being provided to detect fluid droplets in a different plane. For example, in the embodiment illustrated, one is vertically aligned and one is horizontally aligned. However, the present invention is not limited to this. Moreover, while two modules are shown, only one drop detection module 200 is necessary for some embodiments of the present invention. The drop detection module 200 includes a laser 205 , microscope 215 , aperture 220 , photodiode 225 , and amplifier 230 . As shown in FIG. 2 , it is preferable that at least one drop detection module 200 is capable of movement in at least one plane.
In the exemplary embodiment, movable drop detection modules 200 may have the laser 205 mounted on a reciprocal carriage assembly 235 and the photodiode 225 and amplifier 230 mounted on a reciprocal carriage assembly 240 . The reciprocal carriages 235 , 240 may move along two parallel guide rails 245 , 250 , respectively. The reciprocal carriages 235 , 240 may be moved by a cable 255 , 260 , respectively; and a pair of pulleys 265 , 270 , respectively. The reciprocal carriages may be powered by a reversible motor 275 , 280 , respectively. It is preferable that the movable drop detection module 200 is moved across the printhead 300 in a direction parallel to the direction that the receiving medium 110 is moved by motor 115 . However, in some embodiments, one or more drop detection modules may be moved in a different direction, such as a direction perpendicular to the direction that the receiving medium 110 is moved by motor 115 . Furthermore, in some embodiments, the drop detection module's laser may be capable of rotation and the photodiode capable of movement. With respect to the drop detection module's movement, and the rotation of the laser and the movement of the photodiode, any known or later-developed structure usable to move the drop detection module 200 , or similarly, rotate the laser and move the photodiode may be used in the ink jet printing device 100 .
In the exemplary embodiment, a second drop detection module 200 includes a laser 205 fixedly mounted on the ink jet printer 100 , and a corresponding photodiode 225 and amplifier 230 also fixedly mounted on the ink jet printing device 100 . In the exemplary embodiment shown in FIG. 2 , this second drop detection module 200 is placed outside the paper path along the side of the paper, where generally there is more space. However, the drop detection module 200 may also be placed off the face of paper, and directly between the face of the paper and the printhead.
Each drop detection module 200 is oriented in a plane such that laser beam may be fired by laser 205 across printhead 300 and received by a corresponding photodiode 225 and, thus provide an indication of whether droplets 310 are ejected from individual nozzles of the printhead 300 .
FIG. 3 shows one exemplary embodiment of four printheads 300 each including an array of fluid ejectors 305 . A plurality of such ejectors 305 are found in a typical ink jet printhead 300 . The systems, methods and architectures according to this invention may be used with side-shooter type ejectors, roof-shooter type ejectors, or other ejectors.
FIG. 3 is a view from a first direction showing a front face 315 of four exemplary printheads 300 . In this exemplary embodiment, each printhead 300 is shown for illustrative purposes with seven rows of ejectors 305 and two columns of ejectors 305 on the face 315 . In an exemplary embodiment, the ejectors 305 are sized and arranged in linear arrays of 300 to 1200 or more of the ejectors per inch. Other arrangements and dimensions can be used in other exemplary embodiments, as known to those skilled in the art. Of course, fluid ejectors need not be structured on the printhead in rows or columns or include multiple ejectors.
The face of the printhead may include a single printhead color, or may contain multiple color nozzles, such as a four color printhead (CMYK), including a cyan ink ejector group, a magenta ink ejector group, a yellow ink ejector group, and a black ink ejector group.
The printheads 300 may be capable of movement in the scanning direction. The scanning direction is perpendicular to the process direction. Similarly, at least one drop detection module 200 may be capable of movement in a direction other than the scanning direction. Furthermore, as in the exemplary embodiment shown, at least one other drop detection module 200 may be fixedly attached to the ink jet printing device 100 . In the illustrative embodiment, one drop detection module is oriented horizontally while a second drop detection module is oriented vertically.
FIG. 4 is a view of a fluid ejector device from a second direction, perpendicular to the view of FIG. 3 . In use fluid, such as a drop (not shown), is emitted from ejectors 305 . The fluid travels generally perpendicular to beam 210 toward recording medium 110 . The individual droplets are then sensed by the drop detection module 200 .
FIG. 5 is a graph showing two plots. Plot 421 is a plot showing an output drop signal from a photodiode 225 over time using the printhead 300 and drop detection modules 200 of FIGS. 2–4 . Plot 422 is a plot of the current sent to a heater of a fluid ejector 305 , in order for a fluid ejector 305 to fire a drop.
In general, the graph shown in FIG. 5 may be generated as follows. A controller signals a fluid ejector 305 on a printhead 300 to fire at least one drop 310 such as by sending a current burst or pulse 422 to the heater of a fluid ejector 305 . If the drop 310 , fired by the fluid ejector, impinges laser beam 210 , fired by drop detection module 200 , a shadow is created. The shadow signifies the failure of the photodiode 225 to receive the laser beam 210 . The shadow is focused by the microscope 215 through the aperture 220 onto the photodiode 225 . The microscope 215 is not essential to the present invention, however it may increase the spatial resolution of the drop detection module 200 . The shadow or lack of shadow signal 421 once received by the photodiode 225 may be amplified by an amplifier 230 and transmitted to the computer 400 . The amplifier is not essential to the present invention, however it strengthens the signal 421 transmitted to the computer 400 .
The signal 421 , from the photodiode 225 , is plotted on the graph shown in FIG. 5 . The spikes in the plot 421 coincide with individual drops 310 that impinged the laser beam 210 . Coincidentally, the spikes in plot 422 coincide with where a current burst was sent to a fluid ejector as the signal to fire a drop. Thus, by monitoring the drop signal 421 and selectively ejecting fluid from each of the ejectors 305 , it is possible to detect the firing of very small quantities of liquid from individual ejectors. In fact, by use of the laser/photodiode arrangement, determination of droplets as small as 1 picoliter can be detected and resolved.
In the exemplary embodiment shown in FIG. 5 , the drop signal (y value) ranges in voltage (V) from 0 to 8 and the time signal (x-value) ranges in seconds (s) from 0 to 277.8×10 −6 . However, other values and ranges for current and time may also be used in the systems and methods according to this invention.
FIG. 6 shows one exemplary embodiment of a fluid ejector alignment and performance system 410 that controls fluid ejector alignment and performance according to this invention. This system may be housed in computer 400 . As shown in FIG. 6 , the fluid ejector alignment and performance system 410 includes an input/output interface 415 , a controller 420 , a memory 425 , an alignment and performance determining circuit, routine or application 430 , a position determining circuit, routine or application 445 , an alignment and performance modifying circuit, routine or application 450 , a position modifying circuit, routine or application 460 , a timer 465 , and a counter 470 interconnected by one or more control and/or data busses and/or application programming interfaces 475 . I/ 0 interface 415 may receive data signals, such as an image signal as an input for ejector firing, from a datasource (DS) 500 .
As shown in FIG. 6 , the fluid ejector alignment and performance system 410 is, in various exemplary embodiments, implemented on a programmed general purpose computer. However, the fluid ejector alignment and performance system can also be implemented on a special purpose computer, a programmed microprocessor or microcontroller and peripheral integrated circuit elements, an ASIC or other integrated circuit, a digital signal processor, a hardwired electronic or logic circuit such as a discrete element circuit, a programmable logic device such as a PLD, PLA, FPGA or PAL, or the like. In general, any device, capable of implementing a finite state machine that is in turn capable of implementing the flowchart shown in FIGS. 7–15 , can be used to implement the fluid ejector alignment and performance system.
In FIG. 6 , alterable portions of the memory 425 are, in various exemplary embodiments, implemented using static or dynamic RAM. However, the memory 425 can also be implemented using a floppy disk and disk drive, a writable optical disk and disk drive, a hard drive, flash memory or the like. In FIG. 6 , the generally static portions of the memory 425 are, in various exemplary embodiments, implemented using ROM. However, the static portions can also be implemented using other non-volatile memory, such as PROM, EPROM, EEPROM, an optical ROM disk, such as a CD-ROM or DVD ROM, and disk drive, flash memory or other alterable memory, as indicated above, or the like.
As shown in FIG. 6 , the memory 425 can be implemented using any appropriate combination of alterable, volatile or non-volatile memory or non-alterable, or fixed, memory. The alterable memory, whether volatile or non-volatile, can be implemented using any one or more of static or dynamic RAM, a floppy disk and disk drive, a writable or re-rewritable optical disk and disk drive, a hard drive, flash memory or the like. Similarly, the non-alterable or fixed memory can be implemented using any one or more of ROM, PROM, EPROM, EEPROM, an optical ROM disk, such as a CD-ROM or DVD-ROM disk, and disk drive or the like.
It should be understood that each of the various embodiments of the fluid ejector alignment and performance system 410 can be implemented as software executing on a programmed general purpose computer, a special purpose computer, a microprocessor or the like. It should also be understood that each of the circuits, routines, applications, objects or managers shown in FIG. 6 can be implemented as portions of a suitably programmed general-purpose computer. Alternatively, each of the circuits, routines, applications, objects or managers shown in FIG. 6 can be implemented as physically distinct hardware circuits within an ASIC, using a digital signal processor (DSP), using a FPGA, a PLD, a PLA and/or a PAL, or using discrete logic elements or discrete circuit elements. The particular form of the circuits, routines, applications, objects or managers shown in FIG. 6 will take is a design choice and will be obvious and predictable to those skilled in the art. It should be appreciated that the circuits, routines, applications, objects or managers shown in FIG. 6 do not need to be of the same design.
Further, it should be appreciated that the programming interfaces 475 connecting the memory 425 to the computer 400 can be a wired or wireless link to a network. The network can be a local area network, a wide area network, an intranet, the Internet, or any other distributed processing and storage network.
The fluid ejector alignment and performance system may not only be run to check alignment and/or performance manually, it may also be run automatically. If the system is manually operated, the user inputs a request to start the system. If the system is set to automatically run, the system is set to run by the controller 420 . If the fluid ejector alignment and performance system is automatically run, various exemplary embodiments of the present invention may allow the system to be run based on either a print count counter 470 or a timer 465 . For example, it could be run at start up, after a predetermined number of print jobs, or after replacement of any of the printheads. Of course, any other know or later developed method to automatically run the fluid ejector alignment and performance system may be employed in the present invention.
If the fluid ejector alignment and performance system is automatically run, the controller 420 selects the at least one fluid ejector to be tested and, if necessary, modified. Alternatively, a routine may be implemented to select multiple fluid ejectors. For example, a routine may be selected to select multiple fluid ejectors, such that the drop detection module may ripple through each fluid ejector in a column or row of the printhead, until all ejectors have been fired and tested.
A particular fluid ejector or group of fluid ejectors may be automatically selected based on the results determined by the use of a drop detection module to determine a fluid ejector's operating properties in a different plane. Other automatic methods for selecting fluid ejectors may include a routine that selects an arbitrary fluid ejector based on the image or type of image to be printed, fluid ejectors selected based on a timer 465 , or fluid ejectors selected based on a print count counter 470 . Of course, any other known or later developed method of selecting a fluid ejector may be employed in this invention.
If timer 465 is used to control the running of the fluid ejector alignment and performance system, controller 420 automatically selects fluid ejectors for alignment and performance testing and, if necessary, modification, based on an internal clock.
Similarly, if a print count counter 470 is used to control the running of the fluid ejector alignment and performance system, controller 420 may automatically select fluid ejectors for alignment and performance testing and, if necessary, modification, based on a print count of the selected fluid ejector.
Once the group or set of fluid ejectors to be tested has been selected, a first fluid ejector of the set is selected for determining alignment and/or performance operating properties and, if necessary, modification.
The alignment and/or performance determining control, routine, or application 430 employs at least one drop detection module to determine an operating alignment and/or performance property of a selected fluid ejector.
The alignment and/or performance modifying control, routine, or application 450 may employ various methods, to make compensation determinations. These compensation determinations may then be applied to a fluid ejector or otherwise used to modify the alignment or performance properties of a selected fluid ejector.
FIG. 7 is a flowchart outlining one exemplary embodiment of a method for automatically determining fluid ejector alignment and performance. In step S 1000 , the routine begins. The routine continues to step S 6000 .
In step S 2000 , a fluid ejector or set of fluid ejectors is selected to be tested for either or both alignment and performance. This fluid ejector's alignment and/or performance may also be modified in this routine.
After at least one fluid ejector has been selected, the control routine continues to step S 3000 .
In step S 3000 , the control routine applies an increment counter to count which fluid ejectors of a selected set have been tested.
In step S 4000 , the drop detection module control routine is run. In this step, a method for using at least one drop detection module to determine fluid ejector alignment and performance is applied to the selected fluid ejector. Furthermore, in this step, the fluid ejector alignment and performance may be modified by applying an alignment and/or performance determining and modifying control, routine, or application to the selected fluid ejector. Various exemplary modes for using the drop detection module for determining fluid ejector alignment and performance are possible and several exemplary modes will be described later in the specification in more detail.
After step S 4000 has been applied to a selected fluid ejector, the control routine continues to step S 5000 . In step S 5000 , a determination as to whether all of the selected fluid ejectors have been tested is made. If the determination in step S 5000 is that all selected fluid ejectors have been tested, the routine continues to step S 6000 where the routine ends. If the determination in step S 5000 is that not all of the selected fluid ejectors have been tested, the routine returns to step S 2000 where a next fluid ejector is selected. Accordingly, the routine continues from step S 2000 through step S 5000 until all fluid ejectors have been tested.
FIG. 8 is a flowchart outlining one exemplary embodiment of a method for using the drop detection module to determine and, if necessary, modify fluid ejector alignment and performance. In step S 4005 , the routine begins.
In step S 4010 , a first drop detection module is set in a first plane. In step S 4015 , a second drop detection module is set in a second plane, wherein the second plane is different from the first plane.
In various exemplary embodiments, the drop detection module may be set in planes different than the planes described in the specification or shown in the drawings. The plane within which the drop detection module is positioned determines the fluid ejector alignment the module may test for. For example, for fluid ejector alignment in one plane, such as vertical or horizontal alignment with respect to the scanning direction (face of the printhead), a drop detection module may be positioned in a plane parallel or perpendicular to the scanning direction, respectively.
After the drop detection modules are set, the routine continues to step S 4020 where the lasers on the drop detection modules are fired. The lasers need not be fired simultaneously. The lasers are fired with respect to the plane in which fluid ejector alignment or performance information is desired to be obtained. In various exemplary embodiments, a light emitter, such as an LED, may be substituted for a laser.
In step S 4025 , a position determining control, routine, or application is applied to the selected fluid ejector to determine the fluid ejector's position relative to a fiducia on the ink jet printing device.
The fluid ejector offset can also be determined from the position determining control, routine, or application. The position determining control, routine, or application may use the drop detection module to determine the position of a fluid ejector based on when a drop fired by a fluid ejector impinges the laser beam.
In step S 4030 , the selected fluid ejector fires a drop.
After the drop has been fired, the routine continues to step S 4035 where a determination is made whether the drop impinged the laser beam of one or more of the respective drop detection modules operating in the routine. If the drop impinged the laser beam, the routine continues to step S 4050 where the routine ends. However, if a determination is made that the drop did not appear to impinge at least one laser beam, the routine continues to step S 4040 .
In step S 4040 , the compensation determination is calculated automatically by the alignment and/or performance modifying control, routine, or application. A compensation determination is calculated for the fluid ejector nozzles that fail to have at least one drop impinge the laser beam. This compensation can be performed after individual nozzle firing, or after completion of an array of nozzle firings.
After the compensation determination, the routine continues to step S 4045 . In step S 4045 , the selected fluid ejector is modified in accordance with the compensation determination made by the alignment and/or performance modifying control, routine, or application. The compensation determination can then be applied by the alignment and/or performance modifying control, routine, or application to modify the fluid ejector alignment and/or performance electronically. Where a fluid ejector cannot be adequately modified electronically, a different compensation determination, such as compensation value, may be calculated and applied to the image data. This value is applied to the image data to modify the image data such that the printed product does not reflect the apparent fluid ejector alignment or performance error. Other methods for modifying fluid ejector alignment and performance will be discussed further in the specification.
After step S 4045 , the control routine continues to step S 4050 where the control routine ends. In various exemplary embodiments, step S 4050 may also contain a further routine where steps, including steps S 4010 through step S 4050 , are re-applied to the selected fluid ejector to determine whether the alignment and/or performance control, routine, or application has sufficiently modified the selected fluid ejector.
As discussed above, the plane within which the drop detection module is positioned determines the fluid ejector alignment the module may test for. For example, FIG. 9 and FIG. 10 show two exemplary embodiments of a method to determine horizontal alignment and vertical alignment, respectively.
FIG. 9 is a flowchart outlining one exemplary embodiment of a method for using the drop detection module to determine, and if necessary, modify fluid ejector horizontal head alignment and performance. In step S 4105 , the routine begins.
In step S 4110 , a drop detection module is set in a plane perpendicular to the carriage motion.
In step S 4115 , one or more selected fluid ejectors fire a drop from the printhead. This may, for example, be a middle ejector in the array. After the drop has been fired, the control routine continues to step S 4120 where the signal generated by the photodiode is monitored. After step S 4120 the control routine continues to step S 4125 .
In step S 4125 , a determination is made as to whether the column of ejectors selected has been detected. If the determination is that the column of selected fluid ejectors has not been detected, the control routine proceeds to step S 4130 . In step S 4130 , the printhead carriage incrementally moves across the laser beam and steps S 4115 , S 4120 , and S 4125 are repeated until the column of selected fluid ejectors is detected. Alternatively, drop module 200 may be incremented while the printhead remains fixed.
If a determination is made that the column of selected fluid ejectors has been detected, the control routine continues to step S 4135 where the horizontal offset of this printhead and/or column of ejectors is determined from the position of the carriage when a drop impinged the laser beam. The horizontal offset of each printhead and/or column of ejectors may be a relative or absolute offset amount. It may be based on the determination of the position of the carriage relative to drop module when the fluid ejector drops impinge the laser beam and/or based on known distances between nozzles. After step S 4135 has been completed, the control routine continues to step S 4140 .
In step S 4140 , a determination is made as to whether each column of ejectors has completed steps S 4115 through S 4135 . If the determination is that a column has not completed steps S 4115 through S 4135 the control routine returns to S 4115 where the next column completes the steps S 4115 through S 4135 . Otherwise, the control routine continues to step S 4145 .
In step S 4145 , error due to the horizontal offset of each printhead nozzle can be compensated for electronically by known or subsequently developed methods, such as delayed firing, print mask compensation, etc.
After step S 4145 , the control routine continues to step S 4150 where the control routine ends. In various exemplary embodiments, step S 4150 may also contain a further routine where steps, including step S 4110 through step S 4145 , are re-applied to the selected fluid ejector to determine whether the alignment and/or performance control, routine, or application has sufficiently modified the selected fluid ejector.
Similarly, FIG. 10 is a flowchart outlining one exemplary embodiment of a method for using a drop detection module to determine and, if necessary, modify fluid ejector vertical head alignment and performance. In step S 4205 , the routine begins.
In step S 4210 , a drop detection module is set in a plane such that the laser beam is parallel to the carriage motion.
After the drop detection module is set, the routine continues to step S 4220 where the control routine selectively fires one, some, or all of the fluid ejectors. After step S 4220 , the control routine continues to step S 4225 .
In step S 4225 , the control routine monitors the drop output signal generated by the photodiode. This step includes the photodiode alerting the controller when a drop either impinges or fails to impinge the laser beam. After step S 4225 has been completed, the control routine continues to step S 4230 .
In step S 4230 , a determination is made of whether at least one ejector from each column and/or printhead has been detected. If ejectors from all columns and/or printheads have not been detected, the control routine returns to step S 4220 , where steps S 4220 through step S 4230 are re-applied after selecting different ejectors and/or moving the drop detection module with respect to the printhead. If a determination is made that ejectors from all columns and/or printheads have been detected, the control routine continues to step S 4235 where the vertical offset of each column and/or printhead is determined by analysis of which of the fluid ejector's drops impinged the laser.
After step S 4235 is completed, the control routine continues to step S 4240 . In step S 4240 the vertical offset of each printhead can be compensated for electronically.
After step S 4240 , the control routine continues to step S 4245 where the control routine ends. In various exemplary embodiments, step S 4245 may also contain a further routine where steps, including steps S 4210 through step S 4240 , are re-applied to the selected fluid ejector to determine whether the alignment and/or performance control, routine, or application has sufficiently modified the selected fluid ejector.
Besides fluid ejector alignment in the vertical or horizontal direction with respect to the face of the printhead, fluid ejector tilt alignment and bi-directional alignment may also be determined and modified, if necessary, by using at least one drop detection module with the alignment determining and modifying control, routine, or application.
To determine tilt alignment, at least two fluid ejectors are tested and the drop detection module is positioned such that the position of at least two fluid ejectors can be determined. It is preferred that the fluid ejectors selected be at opposite ends of the printhead. Each fluid ejector separately fires a drop and the drop detection module separately records the signal generated by each respective drop. Once the drop detection module has sent each respective signal to the computer, the fluid ejector offset for each fluid ejector can be determined from the position determining control, routine, or application.
Next, a compensation determination can be generated by the alignment and/or performance routine or application. A compensation value to be applied to the image data can be generated and applied to modify the image data prior to printing. Thus, once the image data is printed, the apparent error due the printhead tilt offset is reduced because of the compensation value applied to modify the image data. Generally, compensation values can be generated to modify printhead tilt offsets of greater than one pixel.
FIG. 11 is a flowchart outlining one exemplary embodiment of a method for using the drop detection module to determine and, if necessary, modify fluid ejector tilt alignment and performance. In step S 4305 , the routine begins.
In step S 4310 , drop detection module is provided such that the laser beam fired from the drop detection module is in a plane perpendicular to the carriage motion.
After the drop detection module is set, the routine continues to step S 4315 where a first selected fluid ejector fires a drop. After step S 4315 , the control routine continues to step S 4320 .
In step S 4320 the output signal generated by the photodiode is monitored to determine whether the drop fired impinged the laser beam. After step S 4320 , the control routine continues to step S 4325 .
In step S 4325 , a determination is made of whether at least two fluid ejectors have been tested. If the selected number of fluid ejectors has not been tested, the control routine returns to step S 4315 where the next fluid ejector is fired. Preferably, the selected ejectors span the entire column of drop ejectors being aligned for improved accuracy. As such, steps S 4315 through step S 4325 are applied to the next fluid ejector. If instead, in step S 4325 a determination is made that the selected number of ejectors has been tested, the control routine continues to step S 4330 where the printhead tilt is determined.
Once the printhead tilt has been determined, the control routine continues to step S 4335 where a compensation value can be determined and applied to the image data to compensate for printhead tilt.
After step S 4335 , the control routine continues to step S 4340 where the control routine ends. In various exemplary embodiments, step S 4340 may also contain a further routine where steps, including steps S 4310 through step S 4335 , are re-applied to the printhead to determine whether the alignment and/or performance control, routine, or application has sufficiently modified the image data appropriately.
Fluid ejector bi-directional alignment may also be determined and modified in a similar manner. FIG. 12 is a flowchart outlining one exemplary embodiment of a method for using a drop detection module to determine and, if necessary modify fluid ejector alignment and performance. In step S 4405 , the control routine begins.
In the exemplary embodiment shown in FIG. 12 , in step S 4410 a drop detection module is provided perpendicular to carriage motion. Next, in step S 4415 , the drop detection module is set at, or close to the paper plane. The drop detection module does not have to be above the paper itself, but may be placed outside the paper path. The drop detection module should be located such that the laser beam is perpendicular to the carriage motion. The drop detection module should also be positioned with respect to a fiducia, such that the drop detection module position is known relative to both the paper and printhead.
After step S 4415 has been completed, the control routine continues to step S 4420 where a timer is set. After the timer has been set, the control routines continues to step S 4425 . In step S 4425 , the laser on the drop detection module is fired. The printhead is then moved in the scanning direction and the fluid ejector's position is determined relative to a fiducia on the ink jet printing device. While the printhead is moving, a selected fluid ejector fires a drop and, simultaneously, a timer controlled by a controller is activated.
After the fluid ejector fires a drop and the timer is activated, in step S 4430 the timer is stopped when the drop impinges the laser beam.
Once the drop has impinged the laser beam, the routine continues to step S 4435 where the drop transit time from drop ejection until when the drop impinged the laser beam is calculated.
After step S 4435 has been completed, the control routine continues to step S 4440 where the fluid ejector velocity due to printhead movement in the scanning direction, while the drop was in transit between the nozzle and impingement of the laser beam, is calculated. This information may be calculated using signals from position encoder.
Next, in step S 4445 , the drop offset from the position the drop was projected to impact the paper is determined based on the transit time and printhead velocity. After the offset and drop position have been calculated, the control routine continues to step S 4450 .
In step S 4450 , steps S 4420 to S 4445 are repeated with the printhead moved in the direction opposite to the direction the printhead was initially moved. The printhead was initially moved in step S 4425 .
In step S 4455 , a compensation value can be determined to control the firing times of the fluid ejectors, or the image data can be modified so that errors in image quality, due to bi-directional alignment error, can be reduced or, at least, be visually less apparent.
Next, as shown in step S 4455 , the compensation value can be applied to the image data to electronically compensate for bi-direction alignment error.
After step S 4455 , the control routine continues to step S 4460 where the control routine ends.
When determining and modifying bi-directional alignment, it is important that the drop detection module be adequately located with respect to the printhead and paper. If positioning of the drop detection module is difficult, such that the transit time of the drop to he paper cannot be directly measured, then an additional step may be added to the bi-directional alignment routine.
In this step, the transit time of drops from the same fluid ejector is determined at two different distances from the printhead. This requires that the drop detection module or portions thereof be moved a known distance between printhead and paper. The drop detection module or portions thereof can be moved with a motor. The approximate drop speed can be determined from the change in transit time and the change in distance. Then, knowing the nominal distance between printhead and paper allows the approximate determination of the transit time of the drop to the paper.
As discussed above, the alignment and performance modifying control, routine, or application calculates the preferred method of using the selected fluid ejectors to create the printed image. For example, among other compensation determinations, the routine may result in the calculation of a compensation value by which to rotate or stretch an image, or result in a decision to wipe or prime a selected fluid ejector, change the voltage to a selected fluid ejector, or skip a fluid ejector during the printing process. Automatic modification of a fluid ejector for either alignment and/or performance may also include any other known or later developed method for modifying a fluid ejector.
For instance, as shown in FIG. 13 , various exemplary embodiments of the present invention may include the detection and modification of a fluid ejector whose performance has deteriorated due to extended idle times. In the exemplary embodiment shown in FIG. 13 , the recovery modification procedure can be employed after a selected fluid ejector has been exposed to an extended idle time. The recovery modification procedure may include modification techniques for modifying a fluid ejector, such as firing fluid through the ejector into a waste container, priming the fluid ejector, wiping the fluid ejector, heating the fluid ejector, or other methods familiar to those skilled in the art. After the recovery modification procedure, the fluid ejector may again be tested for alignment and/or performance.
FIG. 13 is a flowchart outlining one exemplary embodiment of a method for using the drop detection module to modify a fluid ejector. In step S 4505 the control routine begins.
In step S 4510 a determination is made as to whether there was an extended idle time for a fluid ejector or printhead. If the determination is that there was, the control routine continues to S 4515 , otherwise the control routine continues to step S 4545 where the control routine ends.
In step S 4515 , a drop detection module is set in a first plane such that the laser on the drop detection module may scan across selected fluid ejectors. After the drop detection module is set, the routine continues to step S 4520 where the selected fluid ejector fires a drop.
In step S 4525 , a determination is made of whether the fluid ejector drop impinged the laser beam of the drop detection module. If the drop impinged the laser beam, the routine continues to step S 4540 . However, if a determination is made that the drop did not appear to impinge the laser beam, the routine continues to step S 4530 .
In step S 4530 , a determination is made of a modification method to be applied to the selected fluid ejector. As discussed above, the modification method may include wiping or priming the fluid ejector or any other modification method known to those skilled in the art.
After a modification method has been determined, the routine continues to step S 4535 where the modification method is applied to the selected fluid ejector.
After step S 4535 , the routine continues to step S 4540 where a determination is made as to whether all fluid ejectors have been tested. If so, the control routine continues to step S 4545 where the routine ends. If a determination is made that not all fluid ejectors have been tested, the control routine returns to step S 4520 and repeats steps S 4520 through step S 4540 until all fluid ejectors have been tested.
In various exemplary embodiments, step S 4545 may also contain a further routine where steps, including steps S 4510 through step S 4540 , are re-applied to the selected fluid ejector to determine whether the alignment and/or performance control, routine, or application has sufficiently modified the selected fluid ejector.
As discussed above, many modification procedures may be used with the present invention. For instance, modification procedures may be employed to correct kogation, refill problems and frequency problems. If the fluid ejector has kogation or threshold voltage variation problems, drop speed variations may be adjusted with different enable trains or main pulse length. After a modification procedure has adjusted an enable train or main pulse length, the fluid ejector can be re-tested and the enable train re-modified until the fluid ejector drop speed is within acceptable tolerances.
Other problems with fluid ejectors such as refill problems and maximum frequency problems may also be confronted by modification procedures. For instance, if a filter clogs causing firing before re-fill and/or exceedingly fast drops such as spears occur, the fluid ejector and printer can be modified for lower frequency jetting to modify the problem.
FIG. 14 is a flowchart outlining one exemplary embodiment of a method for using the drop detection module to determine and, if necessary, modify fluid ejector alignment and performance. In step S 4605 , the routine begins.
In step S 4610 , a drop detection module is set in a first plane to scan selected fluid ejectors.
After the drop detection module is set, the routine continues to a step S 4615 where a timer is set. After the timer has been set, the control routine continues to step S 4620 where a first fluid ejector fires a drop. Simultaneously, the timer is activated.
After the drop has been fired and the timer activated the routine continues to step S 4625 where the drop speed is analyzed. The transit time of drops from the same fluid ejector is determined at two different distances from the printhead. This requires that the drop detection module or portions thereof be moved a known distance between the printhead and paper. The drop detection module or portions thereof can be moved with a motor or the like. The approximate drop speed can be determined from the change in transit time and the change in distance.
After step S 4625 has been completed, the routine continues to step S 4630 where a determination is made of whether the drop speed is within acceptable product tolerances. If the drop speed is determined to be outside specific product tolerances, the routine continues to step S 4635 where an electronic compensation can be determined and applied to a selected fluid ejector to compensate for drop speed. This compensation may include adjusting with different enable trains or adjusting the frequency of jetting. Once an electronic compensation has been applied to a selected fluid ejector, the routine continues to a step S 4640 .
However, if it is determined in step S 4630 that drop speed is within acceptable product tolerances, the routine continues from step S 4630 to step S 4640 .
In step S 4640 a determination is made as to whether all fluid ejectors have been tested. If so, the control routine continues to step S 4645 where the control routine ends. If, on the other hand, a determination is made that not all fluid ejectors have been tested, the control routine returns to step S 4615 , and repeats steps S 4615 through step S 4640 until all fluid ejectors have been tested.
Of course, in various exemplary embodiments, step S 4645 may also contain a further routine where steps, including steps S 4610 through step S 4640 , are re-applied to the selected fluid ejector to determine whether the alignment and/or performance control, routine, or application has sufficiently modified the selected fluid ejector.
In various exemplary embodiments, the apparatus of the invention may also include a modifying device. The modifying device may be used for wiping the fluid ejector's nozzle or other manipulation of the fluid ejector in order to modify the performance or alignment of the fluid ejector.
Alternatively, or in the event modification fails to adequately modify the fluid ejector's alignment or performance, defects in the image printed can be avoided through smart image processing or alternative print modes. Furthermore, if the modification process fails to adequately modify a selected fluid ejector the fluid ejector may be skipped during image processing.
While the invention has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications, and variations, will be apparent to those skilled in the art. For instance, while one skilled in the art of printing will apply the systems and methods to printing with ink, it is noted that the systems and methods of the invention apply to fluids other than ink. Accordingly, the exemplary embodiments of the invention as set forth above are intended to be illustrative and not limiting. Various changes may be made without departing from the spirit and scope of the invention as described herein.
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Methods and apparatus provide for automatic fluid ejector alignment and performance evaluation and modification in one or multiple planes. A fluid ejector fires a drop through a drop detection module. A signal indicating drop presence or absence is sent to a computer. The computer analyzes the data, and makes a compensation determination of a preferred method of using the fluid ejector. The compensation determination may include electronically modifying the image data to be printed, physically manipulating the fluid ejector, completely skipping the fluid ejector during printing operations, or in some other way modifying the fluid ejector or image data such that apparent printed image error due to fluid ejector alignment or performance error is reduced.
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CROSS-REFERENCE(S) TO RELATED APPLICATIONS
[0001] The present application claims priority of Korean Patent Application No. 10-2010-0024306, filed on Mar. 18, 2010, which is incorporated herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates to a nano particle used to coat an electrode of a dye-sensitized solar cell.
[0004] 2. Description of Related Art
[0005] With the recent growing concerns on the global warming, development of technologies utilizing environment-friendly energy has been drawing much of public attentions. Solar cell, being one of the most intriguing energy sources as such, study on this field has been diversified including silicon-based solar cells, thin film solar cells using inorganic materials such as copper indium gallium selenide (Cu(InGa)Se 2 ; CIGS), dye-sensitized solar cells, organic solar cells, and organic-inorganic hybrid solar cells. Of them, the dye-sensitized solar cell, which is inexpensive and being drawn close to commercial application, has been highlighted in the fields of building-integrated photovoltaics (BIPV) and portable electronics.
[0006] Unlike other solar cells, the dye-sensitized solar cell absorbs visible light and produces electricity through a photoelectric conversion mechanism. In general, patterning of the titanium dioxide working electrode used in the dye-sensitized solar cell is prepared by a screen printing process. Screen printing is a printing technique in which a screen is placed on a work table and a paste is applied on a substrate as it is being passed through a patterned mesh using a rubber blade called the squeegee. The screen printing process is, however, disadvantageous in that it requires a great amount of expensive paste and it is applicable only to a flat substrate. Especially, the control of pattern intervals is important since the efficiency of the solar cell increases in proportion to the light receiving area. The limitation in the control of linewidth between electrodes has been pointed out as the shortcoming of the screen printing technique.
[0007] Recently, there has been proposed to form electrode by inkjet printing. This method has advantages that it reduces material loss and has secured control of narrow linewidths and its process is simple. The inkjet-based patterning process looks promising as a direct printing technique applicable not only to flat-panel displays but also to solar cells and other applications.
[0008] The inkjet process is advantageous in that, since a wanted pattern can be directly formed on a substrate using an inkjet head having small nozzles, the number of processes and material consumption decrease as compared to the screen printing technique and a desired pattern can be created using a simple computer software. However, because a highly viscous paste cannot be used in the inkjet method, printing has to be performed several times to accomplish an electrode coating with a predetermined thickness.
[0009] The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.
SUMMARY
[0010] The present invention relates to a titanium dioxide nano particle modified by a surface stabilizer, a nano ink comprising the same, and a dye-sensitized solar cell produced using the same.
[0011] An object of the present invention is to make ink-jetting in an inkjet printing procedure easy by capping the surface of a titanium dioxide nano particle with a surface stabilizer.
[0012] Another object of the present invention is to provide a titanium dioxide nano ink comprising the titanium dioxide nano particle modified by a surface stabilizer, as well as additives such as an interfacial dispersant and a solvent, a substrate patterned using the titanium dioxide nano ink, and a dye-sensitized solar cell produced using the titanium dioxide nano ink.
[0013] The present invention provides a titanium dioxide nano particle coated with a surface stabilizer by chemical bonding so as to provide good compatibility with an ink composition, and a method for preparing the same. The surface stabilizer may be represented by any one of Chemical Formulae 1 to 3. The surface stabilizer has an acid functional group and also has a hydrophobic moiety capable of providing stable dispersion in other materials.
[0000]
[0014] In Chemical Formulae 1 to 3, R 1 , R 2 and R 3 independently represent hydrogen, C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 2 -C 20 alkynyl or C 6 -C 30 aryl.
[0015] The present invention also provides a nano ink comprising the titanium dioxide nano particle capped with the surface stabilizer, a dispersant and a solvent.
[0016] The present invention further provides a substrate coated with the nano ink by inkjet printing, and a solar cell with an electrode layer printed using the nano ink. The substrate or the electrode is free from the clogging problem because of minimized cohesion and minimized surface tension on the nozzle, conferred by the surface stabilizer capped on the nano particle surface. Unlike the titanium dioxide thin film prepared by screen printing process, pattern cracking during sintering may be minimized because the particles are uniformly distributed, which leads to maximized diffusion and transition of electrons and improved efficiency of a solar cell. Further, it is advantageous in that it is applicable to a curved substrate since the inkjet process can be used.
[0017] The titanium dioxide nano particle of the present invention resolves the clogging problem since the capped surface stabilizer minimizes cohesion and minimized surface tension on the nozzle. The nano ink comprising the titanium dioxide nano particle of the present invention may improve efficiency of a solar cell since occurrence of pattern cracking during sintering is minimized and diffusion and transition of electrons produced by a photoelectric conversion are maximized. Further, it is applicable to a curved substrate since the inkjet process can be employed.
BRIEF DESCRIPTION OF THE DRAWING
[0018] The above and other objects, features and advantages of the present invention will become apparent from the following description of preferred embodiments given in conjunction with the accompanying drawing, in which:
[0019] FIG. 1 shows a image of a nano ink comprising the titanium dioxide prepared in accordance with the present invention printed by ink-jetting.
DETAILED DESCRIPTION
[0020] The advantages, features and aspects of the invention will become apparent from the following description of the embodiments with reference to the accompanying drawings, which is set forth hereinafter.
[0021] The present invention provides a titanium dioxide nano particle coated with a surface stabilizer by chemical bonding so as to provide good compatibility with an ink composition. The surface stabilizer may be represented by any one of Chemical Formulae 1 to 3. The surface stabilizer has an acid functional group and also has a hydrophobic moiety capable of providing stable dispersion in other materials.
[0000]
[0022] In Chemical Formulae 1 to 3, R 1 , R 2 and R 3 independently represent hydrogen, C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 2 -C 20 alkynyl or C 6 -C 30 aryl.
[0023] The titanium dioxide nano particle capped with the surface stabilizer may be obtained by reacting the surface stabilizer with titanium isopropoxide, a precursor used to prepare a titanium dioxide nano particle. The solvent may be an alcohol, glycol, polyol, glycol ether, or the like. More specifically, methanol, ethanol, propanol, isopropanol, butanol, pentanol, haxanol, dimethyl sulfoxide (DMSO), dimethylformamide (DMF), glycerol, ethylene glycol, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol dimethyl ether, ethylene glycol diethyl ether, propylene glycol, propylene glycol propyl ether, etc., may be used alone or in combination of two or more thereof. The proportion of the titanium isopropoxide, the surface stabilizer and the solvent may be 5 to 8 vol %, 0.1 to 1 vol % and 91 to 94 vol %. Preferably, thus produced titanium dioxide colloid solution has a titanium dioxide content from 10 to 15 vol %. By evaporating the solvent from the titanium dioxide colloid solution, a titanium dioxide nano particle having a size of about from 3 to 30 nm may be obtained.
[0024] The present invention further provides a nano ink comprising the titanium dioxide nano particle capped with the surface stabilizer, a dispersant and a solvent.
[0025] The dispersant is compatible with the surface structure of the nano particle and makes the nano particle disperse well in the solvent without precipitating easily. The dispersant may be a non-ionic surfactant. More specifically, it may be a polyethylene oxide-polypropylene oxide block copolymer or a polyethylene oxide-polystyrene block copolymer represented by Chemical Formula 4 or 5.
[0000]
[0026] In Chemical Formulae 4 and 5, n and m independently represent an integer from 1 to 30.
[0027] The copolymer represented by Chemical Formula 4 or 5 provides improved lubrication at the interface with the titanium dioxide nano particle and thus is effective in improving dispersibility when it has a polyethylene oxide (CH 2 CH 2 O) content from 30 to 80 wt % based on the total weight of the copolymer.
[0028] The solvent for the titanium dioxide nano ink may be an alcohol, glycol, polyol, glycol ether, etc. More specifically, it may be methanol, ethanol, propanol, isopropanol, butanol, pentanol, haxanol, dimethyl sulfoxide (DMSO), dimethylformamide (DMF), glycerol, ethylene glycol, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol dimethyl ether, ethylene glycol diethyl ether, propylene glycol, propylene glycol propyl ether, or a mixture thereof.
[0029] In the titanium dioxide nano ink of the present invention, the proportion of the titanium dioxide nano particle, the dispersant and the solvent may be about 10 to 70 parts by weight, about 0.1 to 10 parts by weight and about 20 to 82 parts by weight. If the content of the titanium dioxide nano particle is less than 10 parts by weight, the number of inkjet printing has to be increased. Meanwhile, if it exceeds 70 parts by weight, the ink may be inappropriate for inkjet printing because of too high viscosity. If the content of the dispersant is less than 0.1 part by weight, a desired effect may not be attained. Meanwhile, if it exceeds 10 parts by weight, the ink may be inappropriate for inkjet printing because of too high viscosity.
[0030] The titanium dioxide nano ink of the present invention may have a viscosity from about 1 to 50 cps at room temperature. If necessary, the ink of the present invention may be heated to about 80° C. or below during application to reduce viscosity. By heating to 80° C. or below, the viscosity may be reduced to about 1 to 20 cps. The nano ink of the present invention may further comprise a viscosity modifier. The viscosity modifier serves to modify the viscosity of the nano ink to be appropriate for printing.
[0031] The present invention further provides a solar cell with an electrode layer printed using the titanium dioxide nano ink. After applying the titanium dioxide nano ink on a substrate, the substrate may be sintered to form an electrode pattern. The electrode pattern may be formed by inkjet printing. The inkjet printing method is advantageous in less material loss, easier control of narrow linewidths, a simpler process, or the like. Non-limiting examples of the substrate include a glass substrate, a transparent polymer substrate and a flexible substrate. The sintering may be performed at about 300 to 500° C. for several minutes to several hours. During the sintering process, organic compounds included in the titanium dioxide nano ink such as the dispersant and the solvent are decomposed and destroyed, and the remaining titanium dioxide nano particles form a porous electrode.
EXAMPLES
[0032] The examples and experiments will now be described. The following examples are for illustrative purposes only and not intended to limit the scope of the present invention.
Example
Preparation of Titanium Dioxide Nano Particle and Manufacture of Solar Cell Using the Same
[0033] Toluenesulfonic acid (1.72 mL) was dissolved in butanol (25 mL). After mixing butanol (150 mL) with Millipore water (5 mL) and adding titanium isopropoxide (12 mL), the resultant mixture was added to the toluenesulfonic acid solution. The mixture was reacted at room temperature for 1 hour and then at 110° C. for 6 hours. The reaction was proceeded further by adding phenylsulfonic acid.
[0034] The solvent was evaporated from the resultant titanium dioxide colloid solution to adjust the volume to about 120 mL.
[0035] Polyethylene oxide-polypropylene oxide copolymer (40:60, based on weight, 10 g) was added to the solution and then mixed. 1 hour later, the solution was treated with a tip-type sonicator for 10 minutes. FIG. 1 shows an image of thus prepared titanium dioxide nano ink printed by ink-jetting. It can be seen that the titanium dioxide nano particles are dispersed well with an interval of 200 μm.
[0036] The prepared nano ink was injected into a printer head and an electrode was applied on a glass substrate. After heating at 300° C. for 1 hour, the substrate was sintered at 500° C. for 3 hours. After adsorbing a dye (N3, Solaronix) on thus prepared electrode for 24 hours at room temperature, it was bonded with a platinum counter electrode substrate (Surlyn, DuPont) at 120° C. After injecting an electrolyte through a previously prepared hole, a dye-sensitized solar cell was completed by blocking the injection hole with Surlyn.
Comparative Example
[0037] A dye-sensitized solar cell was prepared according to a commonly employed method. A titanium dioxide paste (Solaronix) for screen printing was coated on a fluorine-doped tin oxide (FTO)-coated glass substrate using a screen printing apparatus. After heating at 300° C. for 1 hour, the substrate was sintered at 500° C. for 3 hours. After adsorbing a dye (N3, Solaronix) on thus prepared electrode for 24 hours at room temperature, it was bonded with a platinum counter electrode substrate (Surlyn, DuPont) at 120° C. After injecting an electrolyte through a previously prepared hole, a dye-sensitized solar cell was completed by blocking the injection hole with Surlyn.
[0038] Current density (J sc ), voltage (V oc ), fill factor (FF) and energy conversion efficiency of the dye-sensitized solar cells according to the Example and Comparative Example were evaluated and compared, as summarized in Table 1. It can be seen that the present invention provides improved energy efficiency. Besides, the present invention is advantageous in that it lowers production cost due to the decreased ink consumption, has simplified process and applicability to a curved substrate.
[0000]
TABLE 1
Energy
Current
Fill factor
conversion
Samples
density (J sc )
Voltage (V oc )
(FF)
efficiency (%)
Example
4.09
0.623
0.679
1.73
Comparative
3.95
0.622
0.655
1.61
Example
[0039] While the present invention has been described with respect to the specific embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims.
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Disclosed are a titanium dioxide nano ink having such a strong dispersibility as to be applicable by inkjet printing and having adequate viscosity without requiring printing several times, and a titanium dioxide nano particle modified by a surface stabilizer included therein. Inkjet printing of the titanium dioxide nano ink enables printing of a minute electrode. In addition, efficiency of a solar cell may be maximized since occurrence of pattern cracking is minimized.
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BACKGROUND
[0001] 1. Field
[0002] The present invention relates to pool safety valves that bleed air into the pool's drain line to relieve excessively high vacuum levels causing the pool's pump to lose prime and more particularly to such valves that include provisional to adjust on site the trip level at which air is bled into the pool's drain line.
[0003] 2. Prior Art
[0004] There have been numerous cases of serious injuries and deaths caused by high vacuum levels at a pool's drain port which holds an individual to the drain port and in some cases causes disembowelment. When such an incident occurs, the vacuum level in the drain line leading from the drain port to the pool's pump rises sharply.
[0005] Various safety valves have been developed in which the high vacuum level occurring during such incidents is sensed and used to trip the valve and allow air to bleed into the drain line, causing the pump to lose prime. Although such valves function to some degree, they generally exhibit two problems. The first is they are often set at the factory to a predetermined trip level which does not always correspond to an appropriate level for a particular pool. Variations in pumps, pipe diameters, pipe length and the number of turns and pitches in a pipe line, all affect the vacuum level at which a safety valve's trip level should be set. This setting is best done at the pool site.
[0006] The second problem is related to the valve's reliability. Virtually all valves include gaskets which must remain sealed if the valve is to function properly. If a gasket becomes dislodged from its seat, it can allow air to leak around the closure elements of the valve, causing the pump to lose prime when there is no emergency. This effectively shuts down the pool and can only be remedied by removing the valve and having it repaired, which often requires the valve to be returned to the factory.
[0007] A safety valve is needed which can be easily adjusted in the field by a service technician to a trip level that is appropriate for each site. For improved reliability, a safety valve is needed that overcomes the leakage past gaskets that often occurs because the gasket becomes unseated. These needed improvements are provided by the valve of the present invention described in the following sections.
BRIEF DESCRIPTION OF THE FIGURES
[0008] [0008]FIG. 1 is a prospective view of the present invention showing it to include a safety valve housing, a connection to the pool's drain line, a lock out pin release, an end cap, an air vent, and a vacuum gage.
[0009] [0009]FIG. 2 is an exploded view of the present invention showing the internal elements of the valve.
[0010] [0010]FIG. 3 is an enlarged cross sectional view of the valve's end-cap showing the valve closure elements including a gasket, an “O”-ring and a cone shaped plunger which is designed to engage the “O”-ring to close the valve.
SUMMARY
[0011] An object of the present invention is to provide a pool safety valve which can be adjusted on site to a selected trip level to accommodate the varying vacuum level found at different pools.
[0012] An object of the present invention is to provide a valve with a cone-shaped plunger element that adjusts for wear to extend the operating life of the valve.
[0013] An object of the present invention is to provide a pool safety valve which prevents air leakage about the valve closure elements to further extend the opening life of the valve.
[0014] The present invention is a safety valve for swimming pools that senses and then instantly relieves excessively high vacuum levels in the pool's drain line. Such high vacuum levels occur when an individual becomes trapped by the suction at the pool's drain port. The drain port is connected to the pool's pump by way of the drain line. The valve relieves the high vacuum levels in the pool's drain and the suction at the drain port by bleeding air into the drain line, causing the pump to lose prime. The valve is equipped with means for adjusting the vacuum level at which it actuates to accommodate varying vacuum levels found at different pools.
[0015] The valve closure element includes a cone-shaped plunger which engages a sealing O-ring. Wear or ageing of these elements is accommodated by the cone shaped plunger which simply moves further into the O-ring as the opening in the O-ring increases to insure closure of the valve. Another failure which occurs with some valves with age is in a gasket seal which is usually positioned behind the O-ring. If the gasket becomes separated from its seat, air is then allowed to leak about the O-ring, which will cause valve failure. In the present invention, the gasket is clamped in place, preventing it from loosening its position and preventing air from leaking past the O-ring. The valve life is significantly improved by these features.
[0016] The pressure applied to keep the valve elements closed determines the vacuum level at which the valve will open or be tripped. In the present invention, a screw adjustment which increases the spring pressure placed against the valve closure elements is accessible from outside of the valve to allow the valve to be easily set at each pool site by the installer to a different trip level as necessary to accommodate the different vacuum levels found at each pool site.
DETAILED DESCRIPTION OF THE INVENTION
[0017] [0017]FIG. 1 is a prospective view of the present invention 1 , showing it to include a safety valve housing 2 , a coupling section 3 located beneath the housing, a lock out pin release 4 on the lower section of the housing, an end cap 20 located at the left end of the housing, an air vent 6 and a screen 6 A located to the left in the end cap and a vacuum gage 5 located on top of the housing. In the use of this valve, a stub line connected to the drain line by means of a “T” rises upward from the drain line and is connected to the coupling section 3 . This stub couples the vacuum in the drain line to the valve. This vacuum level can be read at the vacuum gage 5 and this reading is used to set the trip level of the valve.
[0018] A security cap 8 on the right side of the housing is removed with a special tool 8 A and a screw driver is inserted, engaged and then rotated to set the trip level. When the valve is tripped, it allows air through vent 6 to pass through the valve and the coupling 3 to the drain line, causing the pump which is connected to the drain line to lose prime and free anyone trapped at the pool's drain port. Once the valve has been tripped, it is locked in the open or venting position by a lock out pin until it is manually released by pressing the lock out pin release 4 .
[0019] [0019]FIG. 2 shows the valve in an exploded view of the internal components of the valve which include from right to left in this Figure, a security cap 8 , a second “O”-ring 9 , an adjustment screw 10 , a sleeve for the main piston 11 , a spring guide retainer 12 , a screw 12 A which holds the retainer to the sleeve, a main spring 13 , a main piston 14 , a bearing ring 15 , a cone-shaped plunger 16 , a sealing bushing 17 , a gasket 18 , a first “O”-ring 19 , a third “O”-ring 19 A, the end cap 20 , a compression bushing 21 and interconnected threads 22 of the sealing bushing 17 and compression bushing 21 . These components are placed together within the safety valve in the same order as they are listed above. The security cap 8 is used to close the right end of the housing and discourage unauthorized adjustment of the valve's trip level.
[0020] [0020]FIG. 3 is an enlarged cross sectional view of the valve's end cap 20 showing the valve's closure elements including the gasket 18 , the first “O”-ring 19 , and the cone shaped plunger 16 . The plunger is designed to engage the “O”-ring 19 and close the valve. The cone shaped plunger 16 is in reality a truncated cone. The flattened area at the truncation is designed to permit the plunger to contact the “O”-ring without receiving interference from the sealing bushing 17 , located just to the left of the “O”-ring in this Figure.
[0021] In the operation of the closure elements, the tapered edges 16 A of the plunger are pushed into engagement with the “O”-ring to make contact with the “O”-ring and seal off the air from a passageway 23 which passes through the center of the end cap. When the valve is opened, air flows through the screen 6 A at the vent 6 on the left of the end cap, through the passageway 23 , and the coupling 3 and then on to the pool's drain line. The screen 6 A, located over the vent is designed to keep debris and insects from entering and clogging the valve. As the “O”-ring wears with age, the tapered edges of the cone shaped plunger simply move further into the “O”-ring to maintain contact with the “O”-ring, thereby extending the life of the valve.
[0022] A second factor extending the life of the valve is in the design of the gasket 18 , the sealing bushing 17 , and the compression bushing 21 , all of which are located in the end cap 20 , as shown in FIG. 3. The gasket 18 is formed of two parts, a vertical or flat gasket portion and a horizontal web portion which is attached at its right end to the first “O”-ring 19 .
[0023] In some prior art valves, the gasket only has a horizontal web portion which is located in a round slot in the end cap. If the web is dislodged or simply separated from the wall of the slot, air from the passageway 23 will find its way about the web and leak past the closure elements, the “O”-ring and plunger, to defeat the valve. In this case, the valve appears to be open when it is intended to be closed. The pump loses prime and the pool cannot be operated.
[0024] To overcome this problem in the present invention, the flat gasket portion is clamped between the sealing bushing 17 and compression bushing 21 . This prevents any air from leaking around the bushing. These two bushings are threaded together to clamp the flat gasket between them. The intermeshed threads of these bushings is at location 22 , as can be seen in FIG. 3.
[0025] The way in which the closure elements are drawn together to close the valve and the force used to open the valve is best explained with reference to FIG. 2. The closure elements are urged into contact by the force of the spring 13 that presses against the main piston which in turn presses against the plunger 16 . The plunger 16 is attached to the main piston and is pressed against the “O”-ring to close the valve
[0026] The “O”-ring 19 in this Figure is actually attached to the flat gasket as shown in FIG. 3. When an excessive vacuum occurs in the drain line, it is transmitted through the coupling 3 into the housing and through holes in the main piston 14 , drawing the plunger back which, in this case, is to the right in FIG. 3. That action draws the plunger back and away from the “O”-ring. The result of this action is the opening of the closure elements which allows air in the passageway 23 to flow past the closure element to the coupling section and the drain line.
[0027] The pressure applied by the spring can be varied to adjust for the normal operating vacuum level found at different pool sites. This is done by first removing the security cap, which is simply threaded out of the housing. A screw driver is applied to the adjustment screw 10 which has t threads on it periphery that engage the housing. As the adjustment screw 10 is advanced into the housing, it passes through a central hole in the sleeve 11 and presses against the spring, increasing the spring's pressure against the main piston and the cone plunger 16 . Threading the adjustment screw in the opposite direction has the opposite effect, resulting in reducing the pressure on the plunger.
[0028] At a particular site, the actual required spring adjustment can be determined by installing the safety valve and adjusting the spring tension until no air leakage occurs through the vent 6 . Once properly set, vacuum levels above “normal” operating will cause the plunger to pull back and the valve is opened.
[0029] Once the valve is opened, it must be locked in the open position to allow individuals trapped at the drain port to leave the vicinity of the drain port. This is done by means of a lock out pin 7 which rides on a bearing ring 15 The bearing ring is mounted on the main piston 14 . As the piston 14 is pulled back by the excess vacuum, the pin first rides on the ring 15 and then falls in front of the main piston 14 , preventing it and the plunger, to which it is attached, from returning to a closure position against the first “O”-ring 19 . The only way that the piston can be released is by manually releasing it. This is done by pushing the lock pin release 4 on the lower side of the pump housing. This is only done after any individual that has been trapped at the drain port is well clear of the port.
[0030] It should be noted that the bearing ring 15 serves an important function other than as a bearing surface for the lock out pin 7 . It is also used to seal the piston about its periphery, preventing air from the passageway 23 from bypassing the main piston. Once the valve closure elements have opened, the air presses against the main cylinder forcing it back to the position where it is locked by the lock pin.
[0031] A portion of the air pressing on the face of the piston is allowed to pass through holes 14 A and 14 B and on through the coupling section 3 to cause the pool pump to lose prime. These holes are large enough to allow sufficient air to pass to cause the loss of prime, but are small enough to allow the pressure of the air to move the cylinder. There is a critical range in hole size that is maintained to accomplish both functions.
[0032] The remaining components shown in FIG. 2 have simple mechanical function and require no further explanation as their functions are obvious from their respective name which are listed in connection with the description of FIG. 2 above.
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A safety valve for swimming pools that senses and then instantly relieves excessively high vacuum levels in the pool's drain line. Such high vacuum levels occur when an individual becomes trapped by the suction at the pool's drain port which is connected to the drain line. The valve relieves the high vacuum level in the pool's drain line and the suction at the drain port by bleeding air into the pool's drain line, causing the pump connected to the drain line to lose prime. The valve is equipped with means for adjusting the vacuum level at which it actuates to accommodate varying vacuum levels found at different pools.
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FIELD OF INVENTION
[0001] The present invention relates to cathode active materials for lithium or lithium ion secondary batteries and a method for preparation thereof In particular, the present invention relates to a cathode active material that enhances high temperature storage properties, cycle life, and safety of the battery by forming an outer layer with amorphous complex lithium cobalt oxides on the surface of complex lithium metal oxides, which are used as the cathode active material, and a method for preparing the same cathode active material.
BACKGROUND OF INVENTION
[0002] In the lithium ion secondary battery, safety and high temperature storage properties, as well as the cycle life at room temperature and at high temperatures, are essential to the application of the battery. The factors that most affect these elements are the characteristics of the cathode active materials and anode active materials. Recently, there has been much development in the field of anode active materials, while there are many problems to be improved upon in the field of cathode active materials. In particular, safety and high temperature storage properties of a battery depend on cathode active materials. As standard cathode active materials for the above lithium ion secondary battery, LiCoO 2 , LiNiO 2 , and LiMn 2 O 4 have been known. Although LiNiO 2 has the highest discharge capacity, problems arise in applying this material to practical use due to difficulties in synthesis and thermal safety. LiMn 2 O 4 is relatively low in price and does not harm the environment, but cannot be used alone, since it has a small specific capacity. LiCoO 2 has been used commercially for it has a high battery voltage and excellent electrode characteristics. However, it has poor storage properties at high temperatures. In order to resolve these problems, much research has been performed. According to Japanese Unexamined Patent Publication No. Hei 11-317230, the cycle life and safety of a battery have been enhanced by a metal oxide coating. In the LiNiO 2 system, structural safety is improved by use of several dopants. In addition, safety of the battery is improved by improving thermal safety. Safety and cycle life of the battery are also improved by adding an additive to an electrolyte. However, such improvements do not affect storage properties and cycle life at high temperatures.
SUMMARY OF INVENTION
[0003] The present invention resolves the problems, which have been raised with respect to cycle life, safety and storage properties of a battery when a cathode active material is subject to room temperature and high temperatures. In order to resolve these problems, the present invention provides a cathode active material that improves cycle life, safety and high temperature storage properties of a lithium ion secondary battery. In order to obtain such a cathode active material, the present invention improves structural safety and electrochemical characteristics of the battery by forming a coating layer on the cathode active material with amorphous complex lithium cobalt oxides.
BRIEF DESCRIPTION OF THE DRAWING
[0004] [0004]FIG. 1 is a graph showing charge and discharge characteristics of complex lithium cobalt oxides that form an amorphous coating layer on a core particle LiCoO 2 . The outer coating layer in the prior art deteriorated in capacity, since it did not contain lithium. However, the present invention prevents such capacity deterioration occurring after coating, by forming amorphous complex lithium metal oxides on the outer layer. The amorphous lithium metal oxides have reversible capacity.
[0005] [0005]FIG. 2 is a graph showing discharge curves in their cycles. IR drop of the discharge curves in their cycles is significantly reduced.
[0006] [0006]FIG. 3 is a graph showing the results of the analysis of a calorific value of the complex lithium cobalt oxides performed by use of a Differential Scanning Calorimeter (DSC). The calorific value is based on the temperature of complex lithium cobalt oxides obtained by decomposing a battery after charging the battery up to 4.2V When coating was performed, the initial temperature upon heat generation was increased and the calorific value was decreased. Therefore, it is possible to improve safety of the battery by inhibiting ignition of the battery, which is caused by heat generation at the cathode.
DETAILED DESCRIPTION OF INVENTION
[0007] The present invention relates to a method of reforming a surface by forming a coating layer on the surface of complex lithium metal oxides in order to achieve the above-mentioned object. This method for the preparation of the metal oxides comprises the following steps:
[0008] 1) providing complex lithium metal oxides;
[0009] 2) after thermal treatment, providing a mixture of coating layer feedstocks which form a coating layer made of amorphous complex lithium cobalt oxides;
[0010] 3) coating the complex lithium metal oxides of step 1) with the mixture of step 2); and
[0011] 4) calcinating the coated complex lithium metal oxides of step 3).
[0012] In addition, the present invention provides a lithium or lithium ion secondary battery that uses complex lithium metal oxides prepared by the above method as a cathode active material.
[0013] The present invention relates to obtaining a cathode active material that comprises core particles capable of absorbing, storing and emitting lithium ions, and a coating layer made of amorphous complex lithium metal oxides, which have low electric conductivity, and thus have low reactivity with an electrolyte. Complex lithium metal oxides, which have a voltage of 3.0V or more for lithium, or complex lithium cobalt oxides (LiCoO 2 ) are used as core particles. The coating layer is amorphous oxides comprising lithium cobalt oxides of formula Li 1+x Co 1−x−y A y O 2 , wherein 0≦x≦0.1, and 0≦y≦0.5. A is selected from at least one of Al, B, Mg, Ca, Sr, Ba, Na, Cr, Gd, Ga, Ni, Co, Fe, V, Cr, Ti, Sn, Mn, Zr and Zn.
[0014] The method for coating the surface of complex lithium metal oxides, which are the core particle, with amorphous complex lithium cobalt oxides can be carried out as follows. A homogeneously mixed solution is prepared by mixing the compounds, which will be used as raw material for forming amorphous complex lithium cobalt oxides, in a desired compositional ratio. At this time, at least one of carbonate, nitrate, oxalate, sulfate, acetate, citrate, chloride, hydroxide, and oxide of the above metallic element or a mixture thereof can be used as raw material for forming the coating layer. In particular, an organic solvent such as alcohol or a water-soluble solvent is preferably used to prepare a homogeneous mixture. At step 2), the amount of the coating layer ranges between 0.01˜10 mol % based on the core particles, assuming that the mixture for forming the coating layer is oxidized after thermal treatment. This coating method produces a slurry by adding a powder of complex lithium metal oxides, which are core particles, to a suspension (sol) of an organic solution or an aqueous solution of the compounds used as raw material for forming amorphous complex lithium cobalt oxides. By applying heat to the slurry during stirring by a stirrer, the compounds for forming amorphous complex lithium cobalt oxides are coated on the surface of the powder of complex lithium metal oxides during vaporization of the solvent. By subjecting the heat treatment to the coated complex lithium metal oxide powder at a temperature ranging from 200° C.˜800° C. in the presence of a mixed gas containing air or 10% O 2 , amorphous complex lithium cobalt oxides are formed on the surface. At this time, the flow rate of the gas ranges between 0.05˜2.0 l/g·h (volume per weight and hour). The heat treatment can be carried out for 0.1˜10 hours, and most preferably 1˜5 hours. The period of time and temperature for the heat treatment can be adjusted within the above-mentioned ranges depending on the situation. A portion of the surface layer can be crystallized depending on the temperature of the heat treatment, and some elements may be doped on the surface of the core particle during the heat treatment.
[0015] In another coating method, a suspension of an aqueous solution or an organic solution, in which a mixture of feedstocks for forming amorphous complex lithium cobalt oxides is dissolved, is sprayed on the surface of the core particles made of complex lithium metal oxides, and then dried to form a coating. By floating and fluidizing the core particles in the air, the suspension of a mixed solution is sprayed to form the coating. At the same time, the coating is dried by adjusting the temperature of the flowing air. By treating the dried coating with heat under the above-mentioned conditions, complex lithium metal oxides coated with amorphous complex lithium cobalt oxides are obtained.
[0016] Dip coating is a more simplified coating method, in which complex lithium metal oxides (i.e., the core particles) are kept in a suspension of an organic solution or an aqueous solution in which dissolved feedstocks for forming amorphous complex lithium cobalt oxides during a predetermined time of period, are dried and coated. By subjecting the coating to the heat treatment under the above-mentioned conditions, complex lithium metal oxides coated with amorphous complex lithium metal oxides are obtained.
[0017] The present invention will be explained on the basis of examples. The following working examples are merely to illustrate the present invention, and not to limit the present invention.
EXAMPLES
Example 1
[0018] In order to prepare core particles made of complex lithium metal oxides, Li 2 CO 3 as a lithium feedstock and Co 3 O 4 as a cobalt feedstock, were weighed in the molar equivalence ratio of Li:Co of 1.02:1. Ethanol was added thereto as a solvent. By use of a ball mill, Li 2 CO 3 and Co 3 O 4 were ground together for 12 hours to be homogenized and then mixed. The mixture was dried for 12 hours in a dryer, and calcinated for 10 hours at 400° C. Then, the mixture was ground and mixed again, and subjected to heat treatment for 10 hours at 900° C. As a result, the core particles LiCoO 2 were obtained. The obtained core particles were coated with amorphous complex lithium cobalt oxides in the following manner. In order to provide Li when forming an amorphous coating layer, LiCH 3 CO 2 .2H 2 O was used. In order to provide Co, Co(CH 2 CO 2 ) 2 .4H 2 O was used. The amount was adjusted in the equivalence ratio of 1.0:1.0. The above feedstocks were dissolved in the ethanol, and stirred for 30 minutes to form a mixture solution containing homogeneous metallic compounds. The amount of the mixture to be formed into a coating layer was adjusted to be 1 mol % for the core particles, assuming that all of the mixture is oxidized after heat treatment. After the mixture to be formed into an amorphous coating layer and the complex lithium cobalt oxides to be formed into core particles were mixed, drying of the solvent and coating of the surface were performed at the same time by subjecting the mixture to heat treatment during stirring. The powder of the coated complex lithium cobalt oxides was subjected to heat treatment by a tube-type furnace at the temperature of 300° C. for 3 hours. The presence of heat treatment was performed in air, and the flow rate of air was 0.1 l/gh.
[0019] A slurry was obtained by dispersing the obtained powder of the complex lithium cobalt oxide together with 10% graphite and 5% polyvinylidene fluoride (PVdF) binder in an n-methyl pyrrolidinone (NMP) solvent. The slurry was coated on an aluminum foil. By heating the foil coated with the slurry, the NMP solvent was vaporized and the foil coated with the slurry was dried. A pressure of 500 kg/cm 2 was applied to the dried electrode. Then, the electrode was compressed and cut into cells. A solution used as an electrolyte contains 1 mole of LiPF 6 dissolved in a solvent containing ethylene carbonate (EC) and ethylmethyl carbonate (EMC) in the ratio of 1:2 by volume.
[0020] A half cell is prepared, wherein an electrode prepared in order to measure the cycle life and the high-rate discharge (C-rate) is a cathode, and a lithium metal is used as an anode. The voltage for charge and discharge ranges from 3 to 4.2V. In order to measure the cycle life, the cell was charged and discharged at 0.2C. In order to measure the high-rate discharge, the cell was charged and discharged several times at 0.2C. Then, the capacities of 0.1C, 0.2C, 0.5C, 1C and 2C were measured. Thermal safety of electrode active materials was tested at a rate of 0.5°/min by use of the DSC by applying an electrolyte to a cathode that was obtained by charging it to 4.2V, and then decomposing the battery. The above process was performed in a glove box in order to avoid any contact with air.
Example 2
[0021] In order to prepare complex lithium metal oxides used as core particles, Li 2 CO 3 and Co(OH) 3 (lithium and cobalt feedstocks, respectively), and Al(OH) 3 to dope Al were used. At this time, they were weighed in the molar equivalence ratio of Li:Co:Al of 1.02:0.95:0.05. Then, these were mixed by adding ethanol as a solvent. By use of a ball mill, the mixture was ground together for 12 hours to be homogenized and then mixed. The mixture was dried for 12 hours in a drier, plasticized for 10 hours at 400° C., and was ground and mixed again. Then, the mixture was subjected to heat treatment for 10 hours at 900° C. to give a core particle made of LiCo 0.95 A 0.05 O 2 . The other conditions were the same as in Example 1.
Example 3
[0022] The complex lithium cobalt oxides obtained in Example 1 were used as core particles. In order to form an amorphous oxide coating layer, Li 2 SO 4 was used as the raw material of Li, and Co(CH 3 CO 2 ) 2 .4H 2 O was used as the raw material of Co. The amount was adjusted to be in the molar equivalence ratio of 1.02:1.0. The process for forming the coating layer and the analysis of the characteristics thereof were performed under the same conditions as in Example 1.
Example 4
[0023] The complex lithium cobalt oxides obtained in Example 1 were used as core particles. In order to form an amorphous oxide coating layer, LiCH 3 CO 2 .2H 2 O was used as the raw material of Li. Al(CH 3 CO 2 ) 3 was used as the raw material of Al, and Co(CH 3 CO 2 ) 2 .4H 2 O was used as the raw material of Co. The amount was adjusted in the molar equivalence ratio of Li:Co:Al of 1.02:0.95:0.05. The process for forming the coating layer and the analysis of the characteristics thereof were performed under the same conditions as in Example 1.
Example 5
[0024] The complex lithium cobalt oxides obtained in Example 1 were used as core particles. In order to form an amorphous oxide coating layer, LiCH 3 CO 2 .2H 2 O was used as the raw material of Li. Al(CH 3 CO 2 ) 3 was used as the raw material of Al, and Co(CH 3 CO 2 ) 2 .4H 2 O was used as the raw material of Co. The amount was adjusted to be in the molar equivalence ratio of Li:Co:Al of 1.02:0.9:0.1. The process for forming the coating layer and the analysis of the characteristics thereof were performed under the same conditions as in Example 1.
Example 6
[0025] Example 1 was repeated, except that complex lithium cobalt oxides (LiCoO 2 :C-10H, Japan Chem.) were used.
Example 7
[0026] Example 1 was repeated, except that the amount of the coating layer had a molar ratio of 5 mol % for the core particles.
Example 8
[0027] Example 1 was repeated, except that complex lithium cobalt oxides (LiCoO 2 :C-10H, Japan Chem.) were used as the core particles, and that the core particles, which were coated with a coating layer having the same composition as that of Example 1, were subject to heat treatment in air for 3 hours at 500° C.
Comparative Example 1
[0028] Example 1 was repeated without coating the core particle obtained in Example 1.
Comparative Example 2
[0029] Example 1 was repeated without coating the core particle obtained in Example 2.
[0030] On the basis of Examples 1-8 and Comparative Examples 1 and 2, the results of 10 the experimentation performed with respect to the capacity (i.e., cycle life) in their cycles are shown in Table 1. Table 2 shows the results of the experimentation performed with respect to the high-rate discharge in the voltage range of 3˜4.2 V
TABLE 1 Capacity in Cycle and Discharge Retention Rate After the Completion of Cycles First First After 50 cycles charge discharge First Discharge Discharge capacity capacity efficiency rate retention rate (mAh/g) (mAh/g) (%) (mAh/g) (mAh/g) Example 1 149.8 144.2 96.3 135.5 94.0 Example 2 149.5 140.8 94.2 135.2 96.0 Example 3 149.8 142.5 95.1 136.5 95.6 Example 4 148.2 142.1 95.9 136.4 96.0 Example 5 149.5 144.3 96.5 136.4 94.5 Example 6 149.5 143.2 95.8 135.3 94.5 Example 7 147.8 140.5 95.1 134.5 95.6 Example 8 149.2 143.2 96.0 135.2 94.4 Comp. 149.8 143.2 95.6 130.4 91.1 Example 1 Comp. 149.5 141.3 94.5 131.2 92.9 Example 2
[0031] [0031] TABLE 2 High-Rate Discharge in the Voltage Range of 3˜4.2 V 0.1 C per capacity (%) 0.1 C 0.2 C 0.5 C 1 C 2 C Example 1 100 99.1 96.8 95.1 91.3 Example 2 100 99.2 96.6 94.7 92.1 Example 3 100 99.1 96.4 95.2 91.7 Example 4 100 99.3 96.7 95.6 91.5 Exam le 5 100 99.2 97.2 94.8 91.6 Example 6 100 99.1 95.4 95.2 91.3 Example 7 100 99 95.8 94.1 91.7 Example 8 100 99.2 94.2 95.1 92.1 Comp. 100 98.7 93.7 91.1 87.4 Example 1 Comp. 100 98.5 94.5 90.2 88.2 Example 2
[0032] Table 1 shows that the coated core particle is superior to those that are not coated with respect to the cycle life. Table 2 shows that the coated surface is superior in high-rate discharge.
[0033] When the complex lithium metal oxides having enhanced cycle life and safety at high temperatures are used as a cathode active material of a lithium or lithium ion secondary battery, cycle life, safety and high temperature storage properties of the battery can be further improved.
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This invention relates to complex lithium metal oxides, which are cathode active materials of a lithium or lithium ion secondary battery with enhanced cycle life and safety, and a process for preparation thereof. The core particles are complex lithium metal oxides capable of absorbing, storing and emitting lithium ions, and a coating layer comprised of amorphous complex lithium cobalt oxides that are formed on the surface of the core particle, which is structurally stable and inactive with electrolytes. Because the amorphous complex lithium cobalt oxides are inactive with electrolytes, the oxides stabilize the surface structure of the complex lithium metal oxide and improve on high temperature storage properties, as well as safety and cycle life.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to removing sulfur species from a hydrocarbon stream, and is specifically directed to a method of removing sulfur components selected from the group consisting of mercaptans, organic sulfides and disulfides from a hydrocarbon stream in the absence of extraneously added hydrogen.
More specifically, the present invention is directed to a process for adsorbing sulfur species, i.e., disulfides, organic sulfides and mercaptans, from an olefinic hydrocarbon stream, e.g., containing propylene and propane, by contacting the hydrocarbon stream with a catalyst capable of adsorbing the sulfur species, i.e., one which preferably contains metal oxides selected from the group consisting of a mixture of cobalt and molybdenum oxides, a mixture of nickel and molybdenum oxides, or nickel oxide, in the absence of extraneously added hydrogen and under conditions suitable for adsorbing the sulfur species from the hydrocarbon stream, i.e., a temperature within the range of about 75° C.-175° C., but preferably about 75° C.; a pressure within the range of 150 psig-1100 psig, but preferably about 175 psig; and a liquid hourly space velocity within the range of about 0.5 v/v/h-10 v/v/h, but preferably about 1 v/v/h to form a resultant hydrocarbon stream containing a reduced amount of the sulfur species, i.e. less than about 20% by weight, relative to the initial content of the sulfur species in the hydrocarbon feedstream.
2. Discussion of Background and Material Information
In the petroleum industry, higher olefin plants typically use a propylene feedstock containing various amounts of propylene, propane, butylenes and butanes, and commonly a mixture of 50% propylene and 50% propane. The typical propylene feedstock normally contains from about 5-50 ppm of various sulfur species. Dimethyl sulfides, methyl ethylsulfides, diethyl sulfides, dimethyl disulfide, methyl mercaptan and ethylmercaptan are the most typical of the sulfur species present in these feedstreams.
During oligomerization, however, the sulfur species tend to become incorporated in the higher olefins. Although higher olefins containing sulfur can be used as feedstock for various chemical processes, the sulfur in the higher olefin hydrocarbon streams typically contribute to the production of resultant product streams which are lower in quality than if sulfur were not present in, or removed from, the olefinic hydrocarbon feedstream.
Prior to the present invention, attempts have been to desulfurize higher olefin products over a sacrificial nickel catalyst; however, such processes also suffer from numerous disadvantages.
A typical example of a known desulfurizing technique which has been proposed for this purpose involves subjecting dimethyl sulfide (DMS) and dimethyl disulfide (DMDS) to a sulfided conventional hydrodesulfurization catalyst, such as cobalt-molybdenum (CoMo) or nickel-molybdenum (NiMo) on alumina. In such a catalyst sulfiding, inactive metal oxides are converted to metal sulfides as described hereinafter. A stream of naphtha or gas oil containing 6,000-20,000 wppm DMS or DMDS is mixed with a stream of hydrogen gas and heated to a temperature within the range of 200° C. to 300° C. As the mixture is passed over the catalyst, in its metal oxide form, the sulfur species are thermally and catalytically decomposed by the hydrogen to produce hydrogen sulfide and methane as follows: CH 3 -S-CH 3 +H 2 >2CH 4 +H 2 S; hydrogen sulfide reacts with metal oxides in the catalyst to form the corresponding sulfides:
CoO+H.sub.2 S→CoS+H.sub.2 O;
3NiO+2H.sub.2 S+H.sub.2 →Ni.sub.3 S.sub.2 +3H.sub.2 O; and
MoO.sub.3 +2H.sub.2 S+H.sub.2 →MoS.sub.2 +3H.sub.2 O.
These metal sulfide catalysts are conventionally used with hydrogen to catalytically convert sulfur in hydrocarbon feedstocks to hydrogen sulfide, thus allowing the sulfur to be removed by simple stripping.
A similar process using hydrogen cannot be used to hydrodesulfurize propylene as these catalysts are well known to catalyze hydrogenation of alkenes. Although not wishing to be bound to any particular theory, it is believed that hydrodesulfurization, using metal sulfide catalysts, would hydrogenate propylene to undesirable propane in combination with or even preferentially over, sulfur removal.
U.S. Pat. No. 2,959,538, WEIKART et al., is directed to a process for hydrodesulfurizing petroleum oil feed containing naphtha, kerosene, and diesel oil fractions which involves passing hydrofined products through a zinc oxide drum which is at a pressure of 200 psig so as to convert the hydrogen sulfide present as a result of the hydrofining to H 2 O and zinc sulfide before passing the desulfurized hydrocarbon and hydrogen vapors and gases to a fractionator.
U.S. Pat. No. 3,063,936, PEARCE, relates to desulfurization of hydrocarbon oils, which are intended to be used for the manufacture of methanol from a mixture of carbon monoxide and hydrogen produced by steam reforming of a straight-run naphtha. The desulfurization occurs in three stages including one wherein vaporized hydrocarbon oil is passed over a contact material comprising zinc oxide, manganese oxide or iron oxide, but preferably zinc oxide, at a temperature between about 350° C. and 450° C., and at a pressure between about 1 and 50 atmospheres, prior to passing the vaporized hydrocarbon, together with hydrogen, at a temperature between 350° C. and 450° C., and at a pressure between about 1 and 50 atmospheres, over a hydrodesulfurization catalyst, followed by contacting the resultant product with a hydrogen sulfide absorbing catalyst. It is disclosed that the contact material comprises zinc oxide, manganese oxide or iron oxide, with zinc oxide being preferred. The hydrodesulfurization catalysts are disclosed as being selected from the group of palladium, platinum or cobalt molybdate, supported on alumina wherein the cobalt molybdate are composed of oxides of cobalt and molybdenum. It is disclosed that any suitable material which is capable of absorbing hydrogen sulfide may be used in the third stage of the process but that absorbing material preferably includes zinc oxide, manganese oxide or iron oxide with zinc oxide is preferred.
U.S. Pat. No. 3,660,276, LACEY, is directed to a process for desulfurizing hydrocarbon distillate oils wherein a mixture of the oil vapor in the carbon dioxide-containing hydrogenating gas is passed over a hydrodesulfurization catalyst and then over a material capable of absorbing hydrogen sulfide and eliminating any carbonyl sulfide present either by absorbing the carbonyl sulfide or by converting it to hydrogen sulfide and absorbing the hydrogen sulfide. It is disclosed that the hydrodesulfurization catalyst may contain molybdenum or nickel or cobalt with a preferred catalyst containing molybdenum which is promoted by the presence of nickel and supported on alumina. Another disclosed example of hydrodesulfurization catalysts is molybdenum coated with cobalt and supported on alumina. Materials which are disclosed as being capable of quantitatively absorbing hydrogen sulfide and also eliminating carbonyl sulfides is zinc oxide, with zinc oxide-copper oxide compositions being disclosed as an alternative.
U.S. Pat. No. 4,088,736, COURTY, is directed to a process for purifying a hydrogen sulfide-containing gas which involves absorbing the hydrogen sulfide onto a mass composed of zinc oxide, alumina, and a Group IIA metal oxide, wherein a large proportion of the Group IIA metal oxide is in the form of aluminate or silicoaluminate. The solid contact materials disclosed as being useful for this purpose are described as being thermally stable and regenerable and contain, by weight, 20-85% of zinc oxide, 0.9-50% of alumina, and 2-45% of oxide of a Group IIA metal with or without additional elements which may be 0.1-30% by weight silica, or one or several oxides of a metal selected from the group consisting of copper, cadmium, titanium, zirconium, vanadium, chromium, molybdenum, tungsten, manganese, iron, cobalt, and nickel wherein the latter oxides are disclosed as making the absorption of H 2 S, COS, CS 2 and the regeneration of the absorption material easier.
U.S. Pat. No. 4,300,999, relates to gas oil purification wherein hydrogen sulfide is absorbed by passing partially vaporized oil, hydrogen-containing gas and hydrogen over zinc oxide, wherein the organic sulfur compounds which are removed are disclosed as being carbonyl sulfides (COS) and carbon disulfide (CS 2 ).
U.S. Pat. No. 4,313,820, FARHA, is directed to the removal of hydrogen sulfide from a fluid stream by contacting the fluid stream which contains hydrogen sulfide with an absorbing composition which is composed of zinc, titanium and at least one promoter selected from the group consisting of vanadium, chromium, manganese, iron, cobalt, nickel, molybdenum, rhenium, and compounds thereof. It is disclosed that if organic sulfur compounds are present in the fluid stream, the absorbing composition acts as a hydrodesulfurization catalyst to convert the sulfur in the organic sulfur compounds to hydrogen sulfide which is subsequently removed from the fluid stream by the absorbing composition. If olefin contaminants are present in the fluid stream, the absorbing composition acts as a hydrogenation catalyst to hydrogenate the olefin contaminants to paraffins.
U.S. Pat. No. 4,533,529, LEE, is directed to the removal of sulfur species from a Claus plant tail gas stream by contacting with zinc oxide in the presence of sufficient reducing equivalents for conversion of sulfur compounds to hydrogen sulfide; alternatively, the sulfur compounds are converted to hydrogen sulfide prior to contacting with the zinc oxide.
U.S. Pat. No. 4,571,445, SLAUGH, is directed to reducing the level of sulfur compounds from liquid conjugated diolefin hydrocarbons by contacting the sulfur compound-bearing hydrocarbon liquids with sorbents prepared by combining particulate alumina with at least one compound decomposable to sodium oxide, barium oxide, calcium oxide, or a salt decomposable to potassium oxide.
U.S. Pat. No. 4,593,148, JOHNSON, is directed to the removal of hydrogen sulfide from gaseous streams by contacting the gas streams with a sorbent material which is composed of copper oxide and zinc .oxide, preferably wherein the absorbent material is prepared by coprecipitating hydroxides of copper and zinc, and subsequently heating the hydroxides so as to convert the hydroxides to CuO ZnO with aluminum oxide being disclosed as being an optional component of the sorbent material.
GB 1,142,339, BADISCHE ANILIN & SODA-FABRIK AKTIENGESELLSCHAFT, is directed to the removal of carbonyl sulfide from gas mixtures using metal oxides.
SUMMARY OF THE INVENTION
In accordance with the present invention, therefore, metal oxides are used to adsorb sulfur species, i.e., mercaptans, organic sulfides, and disulfides, from an olefin stream, such as propylene/propane stream, without using hydrogen to promote decomposition of the sulfur species and thereby avoiding hydrogenation of propylene to undesirable propane.
The process of the present invention involves supplying adsorbent particles, either unsupported metal oxides, or metal oxides on an inert support, to one or more vessels as an adsorbent bed. A stream of propylene/propane containing about 5-100 wppm of sulfur, as various species, but preferably selected from the group consisting of mercaptans, organic sulfides, and disulfides, is then heated or cooled as necessary and passed through the adsorbent bed or beds. Typical operating conditions are: temperatures within the range of about 50° C.-175° C.; pressures within the range about 150 psig-1100 psig; and Liquid Hourly Space Velocities within the range of about 0.5 v/v/h-10 v/v/h. The treated substantially sulfur-free propylene/propane may then be fed into conventional higher olefin processes. The deactivated adsorbent may be regenerated.
More generally speaking, however, the method for removing sulfur components from a hydrocarbon stream involves contacting a hydrocarbon stream including at least one sulfur species selected from the group consisting of mercaptans, organic sulfides, and disulfides with a catalyst capable of adsorbing the sulfur species in the absence of extraneously added hydrogen under conditions suitable for adsorbing the sulfur species from the hydrocarbon stream by the catalyst to form a resultant hydrocarbon stream containing a reduced amount of the sulfur species relative to the amount initially present in the hydrocarbon feedstream.
For purposes of the present invention, the catalysts suitable for this purpose include a metal oxide, preferably selected from the group consisting of cobalt oxide, molybdenum oxide, nickel oxide, zinc oxide and copper oxide, as well as mixtures of cobalt oxide, molybdenum oxide, nickel oxide, zinc oxide and copper oxide. Preferred catalysts include metal oxides selected from the group consisting of a mixture of cobalt and molybdenum oxides, a mixture of nickel and molybdenum oxides and nickel oxide. Preferably, the catalyst includes at least about 10% total weight of the catalyst of the metal oxide.
The olefins processed in accordance with the present invention preferably include members selected from the group consisting of ethylene, propylene, and butylenes, and mixtures of these olefins with ethane, propane and butanes; most preferably, the hydrocarbon stream includes a mixture of propylene and propane.
The sulfur species present in the olefin feedstream processed in accordance with the present invention may be selected from the group consisting of organic sulfides, disulfides, and mercaptans. The mercaptans are selected from the group consisting of methyl mercaptan, ethyl mercaptan, and propyl mercaptan. The organic sulfides may be selected from the group consisting of methyl sulfides, ethyl sulfides and propyl sulfides and mixtures thereof. The disulfide may be selected from the group consisting of dimethyl disulfide, diethyl disulfide, dipropyl disulfide, methyl ethyl disulfide, methyl propyl disulfide, and ethyl propyl disulfides, and mixtures thereof, such as mixtures of dimethyl disulfide, diethyl disulfide, dipropyl disulfide, methyl ethyl disulfide, methyl propyl disulfide, and ethyl propyl disulfides.
The hydrocarbon stream processed in accordance with the present invention may include an amount up to about 100 wppm of the sulfur species, and typically within the range of about 5 wppm-100 wppm, but more typically within the range of about 5 ppm-50 ppm.
The process for adsorbing sulfur species selected from the group consisting of mercaptans, organic sulfides, and disulfides from olefin hydrocarbon streams in accordance with the present invention is conducted in the absence of extraneously added hydrogen under conditions suitable for adsorbing the sulfur species from the hydrocarbon stream which include a temperature within the range of about 50° C. to about 150° C., and preferably within the range of about 50° C. to about 100° C.; a pressure within the range of about 0 psig to about 2000 psig, and preferably within the range of about 150 psig to about 1100 psig; and a liquid hourly space velocity within the range of about 0.1 v/v/h to about 30 v/v/h, and preferably within the range of about 0.5 v/v/h to about 10 v/v/h. Most preferably the process in accordance with the present invention is performed in the absence of extraneously added hydrogen under conditions which include a temperature of about 75° C., a pressure of about 175 psig, and a liquid hourly space velocity of about 1 v/v/h.
In accordance with the present invention, the reduced amount of sulfur species in the resultant hydrocarbon stream is as low as about 1% relative to the amount initially present in the hydrocarbon feedstream. Preferably greater than about 80% sulfur is removed relative to the initial amount of sulfur present in the hydrocarbon stream prior to being treated in accordance with the adsorption process of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart showing a process for removing sulfur from propylene/propane containing an initial amount of sulfur within the range of 5 wppm-100 wppm in accordance with the present invention wherein the adsorption process is conducted at a temperature within the range of about 50° C.-175° C., and a pressure within the range of 175 psig-1100 psig, to produce a resultant product stream of propylene/propane which is substantially sulfur-free.
FIG. 2 is a graph showing sulfur removal from propylene/ propane streams wherein the catalytic adsorption process in accordance with the present invention has been performed at a temperature within the range of about 75° C.-130° C., and at liquid hourly space velocities within the range of about 1 v/v/h and 4 v/v/h.
DETAILED DESCRIPTION
In the present invention, metal oxides are used to adsorb sulfur from a propylene/propane stream without using hydrogen so as to minimize the decomposition of the catalyst species and hydrogenation of the propylene to undesirable propane.
Referring to FIG. 1, adsorbent particles, either unsupported metal oxides or metal oxides on an inert support, are provided in adsorbent beds 1 and 2. An olefin hydrocarbon stream, such as propylene/propane containing 5 wppm-100 wppm of sulfur, is heated to a temperature within the range of about 50° C. to 175° C. and passed at a pressure within the range of about 175 psig-1100 psig and a liquid hourly space velocity of 0.5 v/v/h-10 v/v/h through the adsorbent beds. Subsequently, the substantially suIfur-free propylene/propane resultant stream is fed into a conventional higher olefin process, generally designated as 3.
A preferred higher olefin process useful for purposes of the present invention is disclosed in U.S. Pat. No. 4,675,463, the disclosure of which is hereby incorporated in its entirety by reference thereto herein.
In the conventional higher olefins process, the selected lower olefin is reacted over a solid phosphoric acid catalyst to produce branched mono-olefins of a higher carbon number. These mono-olefins so produced are used as feedstock for hydroformylation to form oxo-aldehydes (which can be subsequently hydrogenated to the corresponding oxo-alcohols and used as intermediates to form phthalate plasticizers, and which can also be employed as detergent intermediates, such as nonyl phenol and dodecyl benzene). The lower olefins which can be used comprise propylene, butenes and pentenes, or mixtures thereof. For example, propylene and butenes from steam cracking and catalytic petroleum cracking are suitable mixtures. Any of the isomeric olefins can be used, alone or as mixtures.
The olefin feedstock is typically first treated to remove deleterious quantities of impurities such as organic sulfur, and diolefins e.g., hydrogen sulfide, mercaptans, methylacetylene, propadiene. Such a feedstock pretreatment can conventionally involve absorption of the impurities with mono- or diethanolamine and caustic wash stages for sulfur removal followed by selective catalytic hydrogenation to reduce the diolefins and acetylenes content.
In addition to the olefins, paraffins and water are also generally introduced. The paraffins comprise propane, butane, and pentane, with the selected paraffin generally comprising a molecule of the same molecular structure as the selected olefin, e.g., propane for propylene feeds, butane for butylene feeds, and the like. The function of the propane is as a diluent of the olefin feed to prevent excessive catalyst temperatures from being achieved within the reactor, and thereby control undesired exotherms. In addition, water is typically employed in the olefin feed, and the water content is maintained at a level which is selected to control the hydration level of the phosphoric acid catalyst. Such a hydration level control is important to maintain activity and life of the phosphoric acid catalyst. Typically, olefin feeds to such an oligomerization reactor will comprise from about 20 wt. % to 60 wt. % olefin, from about 40 wt. % to 80 wt. % paraffin, and from about 0.01 wt. % to 0.07 wt. % water, and more typically from about 30 wt. % to 40 wt. % olefin, from about 60 wt. % to 70 wt. % paraffin, and from about 0.02 wt. % to 0.04 wt. % water. However, the quantity of paraffin and water, and amounts of olefin, can vary widely depending on the olefin selected, the temperature and pressures to be employed in the oligomerization reactor, the precise products which are sought to be formed, the type of reactor which is employed and other factors.
Generally, the oligomerization reaction is conducted at a temperature of from about 150° C. to 230° C., more typically from about 165° C. to 215° C., and at a pressure of from about 4100 kPA to about 8200 kPa, more typically from about 4800 kPa to about 7000 kPa. Again, the precise temperature and pressure employed in the olefin oligomerization reactor will depend on a large number of factors, among them the type of olefin which is fed, the olefin distribution of products which is sought to be formed, and other factors.
The olefins can be passed to the reactor in either the liquid or vapor form, and feed rates are generally in the range of from about 1 to about 3.5 L/kg.h typically from about 2 to about 3 L/kg.h.
Since the oligomerization is exothermic, the desired reaction temperature is conventionally maintained either by quenching with the selected paraffin gas, as by quenching between the catalyst stages when the reactor includes a multi-stage vessel containing catalysts, or by conducting the reaction in a tubular reactor in which the phosphoric acid is contained within a plurality of parallel arranged tubes and around which cooling water is circulated for steam generation in order to remove the desired quantity of heat.
The phosphoric acid catalyst is conventional and can comprise phosphoric acid on silica gel or of other materials of a silicous character, including diatomacous earth, kieselguhr and the like. Such conventional phosphoric acid catalysts are disclosed in U.S. Pat. Nos. 2,586,852 and 2,713,560, the disclosures of which are hereby incorporated herein in their entities by reference thereto.
EXAMPLE I
A propylene/propane stream containing about 40 wppm sulfur, composed of about 30 wppm sulfur from methyl ethyl sulfide, 7 wppm sulfur from diethyl sulfide and 3 wppm sulfur from various other sulfur species, was processed in accordance with the present invention, as shown in FIG. 1, by passing the higher olefin hydrocarbon stream containing the sulfur species through the catalyst beds packed with a commercial CoMo oxide catalyst, i.e., 4% CoO and 15% MoO 3 , in the absence of extraneously added hydrogen at a temperature of 75° C., a pressure of 175 psig and a liquid hourly space velocities of 1 v/v/h. Under such conditions, sulfur removals of greater than 80% and as high as at least 95% relative to the initial amount of the sulfur species present in the feedstream were obtained.
EXAMPLE II
The process of the present invention, as shown in FIG. 1, was repeated for a number of propylene/propane higher olefin hydrocarbon feedstreams containing sulfur species in about the same proportions as in Example I, present at about 16 wppm and at about 40 wppm at conditions specified below in the absence of extraneously added hydrogen. The results of such runs are tabulated below:
TABLE 1______________________________________SULFUR REMOVAL FROM PROPYLENE/PROPANECATALYST: Cyanamide HDS 20 COMO SulfurFeed Temper- Pres- Space Product Re-Run Sulfur ature sure Velocity Sulfur moval# (wppm) (°C.) (psig) (v/v/h) (wppm) %______________________________________1 40 50 710 4.0 20 502 40 50 705 3.8 24 403 40 175 705 1.0 25 384 40 75 175 1.0 2 955 40 75 715 4.0 60 --6 16 175 180 4.2 14 127 16 175 710 1.1 7 568 16 75 700 4.0 3 81______________________________________
EXAMPLE III
The process of the present invention, as shown in FIG. 1, was again repeated for a number of propylene/propane higher olefin hydrocarbon streams containing an initial amount of sulfur species in about the same proportions as in Example I at conditions specified below, in the absence of extraneously added sulfur. The results are tabulated below.
TABLE 2__________________________________________________________________________SULFUR REMOVAL FROM PROPYLENE/PROPANE OVERVARIOUS METAL OXIDE CATALYSTS Feed Temper-Run Sulfur ature Pressure LHSV Sulfur Removal# wppm (°C.) (psig) (v/v/h) CoMo NiMo Ni Support__________________________________________________________________________1. 16-40 75 175 1 90-95 >95 >90 <102. 15-40 75 700 4 0 >90 0 -- (1) 80 -- 80 <10 (2)3. 13-19 175 175 4 <10 <10 <10 --4. 13-40 175 700 1 30-55, 50-60 <10 <10 <10__________________________________________________________________________ (1) When run immediately after condition 1. in the run sequence. (2) When run immediately after condition 4. in the run sequence.
In accordance with the present invention, the metal sulfide catalyst may be subsequently regenerable using a mixture of air and steam at 400° C. The regeneration removes coke from the catalyst surface and re-oxidizes metal sulfides to the corresponding metal oxides. Thus, spent or deactivated adsorbent used to remove the sulfur species from the higher olefin stream, as described above, may be regenerated in situ or the deactivated adsorbent may be removed and regenerated off-site using conventional techniques. As should be apparent from what is illustrated in FIG. 1, the vessel from the lead position in a series can undergo regeneration while the remaining vessels continue to operate. The regenerated bed will then be returned to service as the last vessel in the series.
Substantial regeneration of spent absorbent can be achieved with the following procedure:
The spent adsorbent bed is purged with a sulfur-free and hydrogen-free inert gas such as N 2 , steam, methane, and the like prior to heating the bed to about 200° C. and holding at that temperature for at least 45 min. while continuing inert gas purge. The bed is then cooled to operating temperature while continuing inert gas purge.
Periodically, a more severe regeneration may be required to recover the small portion of capacity lost during the above regeneration. The more severe regeneration involves a reoxidation of the catalyst with air at high temperature. Thus, the bed is purged with air or a mixture of air and an inert gas such as nitrogen or steam so that the purge gas contains 1-20% oxygen, then heating the bed to 400° C.-500° C. The flow of purge gas is then continued at this temperature for 4-72 hrs., until all signs of oxidation are gone. Finally, the bed is cooled and the adsorption mode is restarted.
Although the invention has been described with reference to particular means, materials and embodiments, it should be noted that the invention is not limited to the particulars disclosed, and that the foregoing descriptions that are preferred embodiments of the invention. Thus, the present invention is not limited to the particulars disclosed but extends to all equivalents, and various changes and modifications may be made in the invention without departing from the spirit and scope thereof.
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A method of removing sulfur components from a hydrocarbon stream which involves contacting a hydrocarbon stream including an initial amount of at least one sulfur species selected from the group consisting of mercaptans, organic sulfides, and disulfides with a catalyst capable of adsorbing the sulfur species in the absence of extraneously added hydrogen and under conditions suitable for removing the at least one sulfur species from the hydrocarbon stream by the catalyst to form a resultant hydrocarbon stream containing a reduced amount of the at least one sulfur species.
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BACKGROUND OF THE INVENTION History of the Related Art
Conventional sorption dehumidifiers are usually regenerated in a so-called open system, i.e. the regenerating air is taken from surrounding outside air and returned to the surroundings after it has passed a sorption mass and has driven the moisture out of it.
It is often a disadvantage to need duct connection to the surroundings, and a so-called closed regeneration system is then selected, in which, after the air through the sorption mass, the regenerating air is allowed to pass a cooler or condenser, in which this air is cooled so that the absorbed moisture is dispelled before the air is taken back to the sorption mass via a heater, wherein the temperature of the regenerating air is raised to drive the moisture out of the mass. In its turn the condenser is then cooled by a secondary air stream from the dehumidified enclosure which is then in turn supplied with the heat taken from the regenerating air.
This process is also has disadvantages. One such disadvantage is that the energy requirements compared with the open system will be higher. In addition the amount of heat which is supplied to the dehumidified enclosure via the secondary air through the condenser gives the enclosure a temperature increase, which can be troublesome. In certain cases when the dehumidified enclosure, and thus also the cooling air supplied to the condenser, has a temperature lying below 0° C. there is a risk that the condensate will freeze in the condensor, so that it will become blocked and no longer function.
SUMMARY OF THE INVENTION
The object of the present invention is to remove the above-mentioned disadvantages, by lowering the energy requirement considerably, by reducing the amount of heat transferred from the condensor to the dehumidified enclosure and by allowing condensation to take place at a temperature independent of the temperature in the dehumidified enclosure, this temperature being sufficiently high for preventing the condensate from freezing.
This object is achieved in accordance with the invention by the method and apparatus having been given the distinguishing features disclosed in the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail in connection with an embodiment example illustrated on the drawing, where
FIG. 1 schematically illustrates an embodiment of an apparatus for carrying out a method in accordance with the invention.
FIG. 2 illustrates in a psychrometric chart a dehumidifying and regenerating sequence in the method according to the invention.
FIG. 3 is another dehumidifying and regenerating sequence which can be carried out with the method and apparatus according to the invention.
FIG. 4 is a perspective view of a method of arranging dehumidifying components in the sequence according to FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
It is assumed in the following that the gas which is to be treated in accordance with the invention is air which is to be dried (dehumidified) and also that the regenerating gas is air, although the invention is not restricted in these respects.
FIG. 1 solely illustrates the parts of the apparatus which are vital for explaining the invention, while other parts such as casings, fans etc. are excluded. The sorption apparatus as illustrated in FIG. 1 is thus illustrated as essentially including a regenerative drying rotor containing a mass having the ability to absorb moisture. The rotor can be implemented conventionally, and comprise such as alternatingly flat and corrugated layers of suitable material, e.g. glass fibre "paper" with hygroscopic additives. The layers are reeled one upon one another to form a large number of axial ducts which are open towards the end surfaces of the rotor. A recovery apparatus 12 is also illustrated in FIG. 1, and this apparatus can either be a temperature or a moisture exchanger. This recovery apparatus is not necessary for the function of the regeneration sequence, but lowers the energy requirements considerably, and is included in the sequences illustrated in FIGS. 2 and 3 for this reason. In the sequence according to FIG. 2, the recovery apparatus 12 is a temperature exchanger, and in the sequence according to FIG. 3 it is a moisture exchanger. By "moisture exchanger" is intended here an apparatus of conventional kind, e.g. of the same kind as the drying rotor 10, which can transfer moisture from one air stream to another without notably changing the heat content of the air streams.
In the apparatus illustrated in FIG. 1, outside air is caused by the state denoted by the point or numeral 1 to pass through the drying zone of the rotor 10 for dehumidifying the air, which is then given the state denoted by 2. As will be seen from the psychrometric charts in FIG. 2 and 3 the moisture content of the main air streams will decrease simultaneously as the air temperature increases from the point 1 to the point 2.
After the drying zone, the slowly rotating heat exchanging mass of the rotor 10 comes into a regeneration zone, in which the absorbed moisture is removed with the aid of pre-heated regenerating air, which is in counterflow to the main air stream in the drying zone.
In accordance with the invention a closed regeneration circuit is used for treating the regenerating air and the necessary heating and cooling for the treatment of the regenerating air is achieved with the aid of a heat pump. In the heat pump circuit there is included the vaporizer E and the condenser K as well as remaining parts necessary for the function, such as compressor, valve system etc. (not illustrated).
In the embodiment according to FIG. 2 the regenerating air leaving the regeneration zone of the rotor 10 in the state 6 after having been cooled from the state or point 5 before the rotor 10, i.e. from about 60° C. to about 40° C. (and thus having absorbed a corresponding moisture amount, as will be seen from the psychrometric chart in FIG. 2) is taken to a temperature exchanger 12 in the regeneration circuit. The temperature exchanger 12 is divided into two zones where 40-degree air from point 6 is cooled in a first zone to such as 20° C. (point 7 in FIG. 2) by heat exchange with regenerating air which is cooled in a method which is described in the following. After the point 7 the regenerating air is allowed to pass over the outside of the vaporizer E which is connected in a heat pump circuit of conventional kind and which is therefore not described in any more detail.
In the passage over the vaporizer E, the regenerating air will be cooled to the state at point 3, i.e. to about 10° C., simultaneously as the moisture removed from the rotor 10 is dispelled so that the moisture content of the regenerating air is reduced between the points 7 and as will be apparent from FIG. 2. After the air has left the vaporizer E, it is taken into the second zone of the temperature exchanger 12 and is there heated to the state 4 by heat exchange with the 40-degree air at point 6 as mentioned above. The air temperature is thus raised from 10° C. at point 3 to about 30° C. at point 4, as will be seen from the chart in FIG. 2. With the aid of the schematically illustrated fan or pump 14, which provides the movement in the regenerating air, the air is taken to the above-mentioned condenser K in the heat pump circuit, the air temperature being raised from 30° C. at point 4 to about 60° C. at point 5 by heat exchange in the condenser, before the regenerating air is once again supplied to the drying zone of the drying rotor for dehumidifying the mass in the rotor 10.
The temperature exchanger 12 can be of the regenerative type with a rotor as temperature transferring mass, but it can also be of the recuperative type with a stationary exchanger body.
When the exchanger (recovery apparatus) 12 is a moisture exchanger, it can, as mentioned above, be of the same kind and have the same type of sorption mass and the same operation as the rotor 10. It may then be advantageous to build the two units together into a common rotor, and this is what has been shown in the apparatus according to FIG. 4. Irrespective of whether such building together of the moisture exchanging units takes place or not, the thermodynamic sequence will be the same, i.e. that depicted in the psychrometric chart in FIG. 3. This is therefore described with reference to the mechanical implementation illustrated in FIG. 4.
In the embodiment of an apparatus for carrying out the method of the invention illustrated in FIG. 4, the parts in this figure have been given the same reference characters as like parts in the apparatus according to FIG. 1. The numeral 16 denotes a drying rotor which, as with the rotor 10 in FIG. 1 is used for dehumidifying a main air stream. In contradistinction to the embodiment in FIG. 1, a central part of the rotor 16 is separated from the remainder of it with the aid of suitable partition walls, which also divides this central part into two separate zones 18 and 20. The surfaces on the rotor against which these walls seal are illustrated in the figure by the full lines dividing the rotor into corresponding zones. The central rotor part is used for moisture exchange between the streams of regenerating air before and after it has passed over the outer surfaces of the vaporizer E and has been cooled by it. The sequence in this embodiment is as follows: The main air stream is dried from the state 1 to the state 2 during passage through the drying zone of the drying rotor 16, as will be seen from the psychrometric chart in FIG. 3, and its temperature simultaneously increases by about 8° C. The drying rotor mass is regenerated in the regeneration zone downwards in FIG. 4, preheated regenerated air in the state 5 being humidified to the state 6 simultaneously as it is cooled from about 50° C. to about 34° C. The regenerating air is now led back again through the zone 18 in the central part of the rotor 16 and is there humidified further by moisture exchange between regenerating air which has passed the vaporizer E, as is described in the following. Simultaneously with the humidification there is a further temperature drop from point 6 to point 7, see FIG. 3. The air then passes the vaporizer E, through its lower and upper portion in the illustrated case, this vaporizer being included in a heat pump system described in connection with FIG. 1. During the passage through the vaporizer E there is cooling of the air and deposition of moisture so that the temperature falls and the moisture content decreases, as will be seen from FIG. 3. After passage through the vaporizer E, the air is taken through the zone 20 in the central part of the rotor 16, the moisture content further decreasing by moisture exchange with the air stream in the zone 18, which has been described above, simultaneously as the air temperature is raised between the points 3 and 4. Using a fan or pump 14 to maintain circulation in the closed regeneration circuit, the dehumidified and preheated air is supplied to the condenser K of the heat pump system, this condensor raising the temperature of the regenerating air from state 4 to the state 5, i.e. to about 50° C. In this state the air is taken once again to the regeneration zone of the drying rotor 16 for removing the moisture taken up by the mass in the rotor 16 in the drying zone.
In both the described thermodynamic sequences according to FIGS. 2 and 3, the final temperature of the air is about 10° C. after passage past the vaporizer E. The vaporizing temperature in the vaporizer E is sufficiently high for the risk of freezing to be non-existent. Even though the point 1 were to be displaced towards colder temperatures, the vaporizing temperature remains at a level such that no freezing takes place. The closed regeneration circuit sequence has thus been made independent of ambient climate.
The heat which is taken away in the vaporizer and which, in a conventional system, would be transferred to the dehumidified enclosure, now remains in the regeneration circuit and is utilized via the heat pump arrangement for regenerating the rotor. This results in a heavily lowered energy requirement, as well as avoiding an often undesired heating of the dehumidified enclosure. Lowing the energy requirement compared with a conventional closed regeneration system can be considerable, 3-5 times, when recovery in either of the given types will be utilized.
The invention is, of course, not restricted to the illustrated and described embodiments, but can be varied within the scope of the concept forming its foundation, as defined in the following claims. Accordingly, the sorption apparatus 10 can be of the so-called stationary type, i.e. it can have a sorption mass in one or more stationary containers, which are alternatingly regenerated and utilized for drying.
It is also possible to use the described regenerating method when contaminations other than water vapor are to be removed, e.g. paint solvents and the like.
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Method and device for conditioning of a gas which passes through the treatment zone in a regenerative moisture exchanging apparatus (10, 16) for instance a rotor for exchanging moisture with an absorbing bed in the exchanging apparatus. In order to regenerate the bed, a regenerant gas, such as air is passed through the exchanging apparatus in a further treatment zone which is separated from the first mentioned zone. The regenerant air is passed in a closed circuit (3-7) after the passage through the exchanger apparatus. The circuit comprises an evaporator(E) in a heat pump circuit by means of which the regenerant gas air is cooled and its moisture content is decreased. The regenerant air is then passed over a condenser(K) in the heat pump circuit by means of which the regenerant air is heated before being passed to the regenerating zone of the exchanger apparatus.
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[0001] This application claims priority to United Kingdom (GB) patent application number 0122633.1 filed on Sep. 20, 2001.
BACKGROUND OF INVENTION
[0002] The present invention relates to an inside door release mechanism. More particularly, the present invention relates to an inside door release mechanism for a vehicle.
[0003] Vehicle doors, in particular vehicle passenger doors are provided with a separate inside door engagement means such as a pull handle and inside release means such as an inside release handle. The use of two separate components for these functions increases the part count and door assembly time, and hence the overall assembly cost. It also restricts the design freedom of the inside door trim upon which these components are typically mounted.
[0004] It is known to fit power unlatching systems to vehicles. Some systems merely require a switch to be pressed in order to send an unlatching signal to a corresponding door latch. However, there is a risk of accidental actuation if such switches are mounted at an accessible location in the vehicle interior. This is dangerous for the vehicle occupants, particularly if the vehicle is in motion, since they risk falling out of the vehicle.
SUMMARY OF INVENTION
[0005] The present invention seeks to overcome or at least mitigate the aforesaid problems.
[0006] One aspect of the present invention is an inside door release mechanism for a vehicle comprising first and second input means arranged to be mounted in a mutually spaced relationship on a door inner face and a latch wherein the mechanism is so constructed and arranged to cause the latch to be unlatched when both input means are actuated simultaneously.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which:—
[0008] [0008]FIG. 1 is a perspective view of an inner face of a door incorporating the mechanism of the present invention;
[0009] [0009]FIG. 2 is a schematic view of a vehicle incorporating the mechanism of the present invention; and
[0010] [0010]FIG. 3 is a flow chart illustrating the functioning of the mechanism of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0011] Referring to FIG. 1, a vehicle side passenger door 10 is shown and comprises an interior trim panel 12 having an arm rest 14 mounted thereon. A handle portion 16 is integrally provided with the arm rest 14 and a strain gauge 18 (hereinafter referred to as the handle strain gauge) is provided to mount the front of the handle 16 to the trim panel 12 such that pulling on the handle 16 produces an output, as described in greater detail below. A further strain gauge 20 in the form of a panel (hereinafter referred to as the trim strain gauge) is mounted on the trim panel 12 above and towards the rear of the arm rest portion 14 such that pressing thereon produces an output.
[0012] Gauge 20 is located such that if a vehicle user grasps handle 16 and rests his/her arm on the upper face of arm rest 14 the elbow or lower arm will contact the strain gauge panel 20 . Although the gauges 18 and 20 are visible in FIG. 1, they may in alternative embodiments be hidden for aesthetic reasons. In this embodiment, the strain gauges 18 , 20 comprise first and second input means of door inner release means.
[0013] A power door latch 22 is mounted on the rear face 23 of the door.
[0014] Turning now to FIG. 2, a vehicle 50 incorporating door 10 is illustrated schematically. At the heart of the door release mechanism is a controller 30 which may be a standalone microprocessor incorporated into the door 10 or, as this embodiment, is an overall vehicle ICU that is conventionally located under the bonnet (hood) of the vehicle and is also tasked with controlling other vehicle functions (not shown). The controller receives inputs from the handle and trim strain gauges 18 and 20 as well as an input from the door lock status indicator 26 regarding the current locking status of latch 22 .
[0015] A vehicle motion sensor 28 such as a radar speed detector or the like provides a further input to the controller 30 when the vehicle 50 is travelling in excess of a predetermined speed (e.g. 3 km/h).
[0016] In response to the inputs from the aforesaid components, the controller determines the appropriate state of the door latch 22 and signals a power door latch actuator 24 and/or door lock actuator 25 accordingly. The door lock actuator 25 is capable of communicating its current lock state to lock status indicator 26 . It should be appreciated that similar components and inter connections may be provided for each door provided on the vehicle, and that individual controllers may be provided for each door, or a single controller 30 may control the function of all doors.
[0017] For the avoidance of doubt, following terms relating to latch locking states are now defined:—
[0018] A latch is in an unlocked security condition when operation of an inside release means or an outside release means causes unlatching of the latch.
[0019] A latch is in a locked security condition when operation of an outside release means does not unlatch the latch but operation of an inside release means does unlatch the latch.
[0020] A latch is in a superlocked security condition where operation of an outside or an inside release means does not unlatch the latch. In particular it should be noted that multiple operations of the inside and outside release means, in any sequence, does not unlatch the latch.
[0021] A latch is in a child safety on security condition when operation of an inside release means does not unlatch the latch but operation of an outside release means may or may not unlatch the latch depending on whether the latch is an unlocked or locked condition.
[0022] Override unlocking is a function whereby operation of an inside release means, with the latch in a locked condition, causes unlocking of the latch.
[0023] Note that override unlocking is applicable to a latch in a locked child safety off condition, and is also applicable to a latch in a locked child safety on condition. In particular starting from a locked child safety on condition of a latch having override unlocking, an actuation of the inside release means will unlock the door, but this operation or any subsequent operation of the inside release means will not unlatch the door since the child safety feature is on. Nevertheless, once the latch has been unlocked by actuation of the inside release means, a subsequent operation of the outside release means will unlatch the latch. In particular it should be noted that this situation is different from a superlocked latch since in the former case a particular sequence of release means operations, i.e. operation of the inside release means followed by operation of the outside release means, will unlatch the latch. This is not the case for superlocking.
[0024] One pull override unlocking is a function whereby with the latch in a locked child safety off condition a single actuation of the inside release means results in unlocking of the door and also unlatching of the door.
[0025] Two pull override unlocking is a function, whereby with the latch in a locked child safety off condition a first actuation of the inside release means results in unlocking of the latch but does not result in unlatching of the latch. However, a further operation of the inside release means will then cause the latch to unlatch.
[0026] This embodiment, the latch 22 has a child safety function and one a pull override unlocking function, although in other embodiments, the child safety function may be omitted (e.g. for front driver doors) and the latch may have two pull override unlocking.
[0027] The operation of the mechanism is as illustrated by the flow chart of FIG. 3. In use, a user seated in the vehicle grasps handle 16 and rests his/her forearm along arm rest 14 . Then, by applying an inwardly directed tensile force to handle 16 and an outwardly directed compression force to strain gauge 20 , output signals from both gauges are simultaneously sent to controller 30 . If both signals exceed a predetermined threshold value, the controller 30 then goes on to determine the locked state of latch 22 from lock status indicator 24 . If the latch is superlocked, no unlatching signal is sent to door latch actuator 24 . If child safety is on and the latch is locked, the controller 30 signals the door lock actuator 25 to unlock the latch 22 but not to unlatch it. The door lock actuator 25 signals the lock status indicator 26 to provide an update of its status. Only if the latch 22 is locked or unlocked and the output from the motion sensor 28 is low will unlatching occur. The controller 30 sends the appropriate signal to the door latch actuator 24 in order to achieve this.
[0028] In alternative embodiments, a memory may be associated with the controller 30 to store the current lock status and door lock status indicator 25 may be omitted.
[0029] Thus, is apparent that the arrangement of the strain gauges 18 and 20 substantially prevents the accidental unlatching of latch 22 and that in a preferred embodiment, vehicle occupant safety is further enhanced by integrating a motion sensor into the mechanism so as to prevent accidental unlatching whilst the vehicle is in motion.
[0030] Note that the orientations such an “inner” and “outer” as referred to herein relate to orientations of a door when installed in a vehicle. Nevertheless, such terms should not be construed as limiting.
[0031] It is envisaged that numerous changes may be made within the scope of the present invention. For example, alternative input means, such as switches, force transducers or even a mechanical linkage but may be provided in place of the strain gauges. The positioning of the input means may be altered. For example, one gauge may be provided on the handle so that an output is generates when it is squeezed.
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An inside door release mechanism for a vehicle comprising first and second input means arranged to be mounted in a mutually spaced relationship on a door inner face and an output to a latch wherein the mechanism is so constructed and arranged to be capable of causing the latch to be unlatched when both input means are actuated simultaneously.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of UK Patent Application No. 1400933.6, filed 20 Jan. 2014, the entire contents and substance of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a weight training apparatus, and in particular to a refillable weight lifting bag.
[0004] 2. Description of Related Art
[0005] Weight training is a common form of exercise for developing strength and power through an increase in the strength and size of skeletal muscles. Weight training requires the performance of specific movements involving the contraction of the muscles during which the force generated by the muscles is opposed by a weighted device such as a dumbbell acting under the force of gravity. A wide range of weighted devices are available that enable an even wider range of weight training exercises to be performed.
[0006] Weight training devices require a weighted element to provide the required resistance. This weighted element may be metal such as cast iron, or a flowable material such as sand or metal shot. The weight of this material provides the necessary resistance force, but also makes the apparatus difficult for a user to move, store and transport. For example, it would not be practically possible to carry a weight suitable for weight training while travelling both due to the burden of the weight as well as the significant space consumed by the apparatus. In addition, the weight of such apparatus significantly increases the cost of transport for the manufacturer and hence the cost of the apparatus to the consumer.
[0007] It is known to provide weight training apparatus such as dumbbells that comprise hollow weight sections that may be filled at the point of use with weighted material such as sand. However, dumbbells of this type still comprise a rigid form that is space consuming. It is also known to use rudimentary weight apparatus such as sand bags that may be filled at the point of use, but sandbags are difficult for a user to hold and manipulate during exercise in part due to the fact that they do not maintain a fixed shape and structure.
[0008] It is therefore desirable to provide an improved weighted apparatus for exercise which addresses the above described problems and/or which offers improvements generally.
BRIEF SUMMARY OF THE INVENTION
[0009] According to the present invention there is provided a weight training apparatus as described in the accompanying claims.
[0010] In an exemplary embodiment of the invention there is provided a weight training apparatus reconfigurable between an open configuration and a compact configuration, the apparatus comprising a plurality of storage compartments configured to removably receive and retain a weighted material to increase the weight of the apparatus, the storage compartments being movable relative to each other during reconfiguration and arranged to enable the apparatus to be reconfigured to the compact configuration in a filled condition containing the weighted material. The apparatus can be unfurled in the open configuration and rolled or folded in the closed configuration.
[0011] At least one storage compartment can comprise a sealable opening that is accessible when the apparatus is unfurled. At least one storage compartment can comprise a plurality of pockets.
[0012] The apparatus can further comprise a flexible support sheet, wherein the plurality of pockets are secured to a common surface of the support sheet and arranged such that the support sheet may be rolled into cylindrical form in the compact configuration in which the pockets are contained within the support sheet.
[0013] The plurality of pockets can be configured to receive and retain flowable material and comprise closure means for closing the pockets and sealing the flowable material within the pockets.
[0014] The support sheet can be rolled into cylindrical form when the pockets are filled and empty.
[0015] The plurality of pockets can comprise first and second front panels hingedly connected to each other their distal edges and hingedly connected to the support sheet along their proximal edges, side panels arranged at either side of the first and second front panels connected to the side edges of the front panels and to the support sheet. The plurality of pockets can be arranged such that in the rolled configuration they extend radially inwards from the inner surface of the support sheet.
[0016] The apparatus can further comprise at least one strap extending from one end of the support sheet arranged to extend circumferentially around the outer surface of the apparatus in rolled configuration to hold the apparatus in said configuration. At least one strap includes releasable fastening means to fasten the strap in position when wrapped around the apparatus
[0017] The apparatus can further comprise at least one handle arranged on the opposing side of the support sheet to the pockets such that it is arranged on the outer surface of the apparatus in the rolled configuration to enable the apparatus to be gripped by a user to lift the apparatus.
[0018] The plurality of pockets can define a bellows arrangement in which the second front panel and the side panels are collapsible such that the first front panel is pivotable between a collapsed position in which it is arranged parallel to the inner surface of the support sheet, and an expanded position in which it is angled away from the support sheet.
[0019] The plurality of pockets can be configured such that in the rolled configuration they taper inwardly in the radially inwards direction.
[0020] In another exemplary embodiment of the invention there is provided a weight training apparatus reconfigurable between an open configuration and a compact configuration, the apparatus comprising a plurality of storage compartments, and a flexible support sheet, wherein at least one storage compartment is configured to removably receive and retain a weighted material to increase the weight of the apparatus, wherein at least two storage compartments are movable relative to one another during reconfiguration and arranged to enable the apparatus to be reconfigured to the compact configuration in a filled condition containing the weighted material, wherein the apparatus is unfurled in the open configuration and rolled or folded in the closed configuration, wherein at least one storage compartment comprises a sealable opening that is accessible when the apparatus is unfurled, wherein at least one storage compartment comprises a plurality of pockets, wherein at least one pocket is configured to receive and retain flowable material and comprises closure means for closing the pocket and sealing the flowable material within the pocket, and wherein at least one pocket is secured to a common surface of the support sheet and arranged such that the support sheet can be rolled into cylindrical form in the compact configuration in which the pocket is contained within the support sheet.
[0021] In another exemplary embodiment of the invention there is provided a weight training apparatus reconfigurable between an open configuration and a compact configuration in which the apparatus is packed into a smaller form than in the open configuration. The apparatus comprises a plurality of storage compartments configured to removably receive and retain a weighted material to selectively increase the weight of the apparatus. The storage compartments are movable relative to each other and are shaped and arranged to enable the apparatus to be reconfigured to the compact configuration in a filled condition in which the storage compartments contain weighted material. The apparatus may be configured in the compact configuration without weighted material within the pockets for transport or storage. The absence of any weighted material makes the apparatus lightweight to carry, as well as enabling it to compact to a much smaller size than in the in-use filled configuration. At the location of use the apparatus can be opened and weighted material added into the storage compartments, with the apparatus then being returned to the compact configuration for use. The compact configuration is preferable to the open configuration for use as it enables the apparatus to be handled and manipulated more easily.
[0022] The use of multiple storage compartments enables the shape of the apparatus to be controlled when filled by controlling the size and arrangement of the storage compartments. A single volume fillable device such as a sandbag is provided in a fixed form that must be filled to capacity to provide a form that is suitable for handling, but will still experience sag regardless of how much it is filled, and be difficult to manipulate. The form is difficult to maintain as the weighted material is able to flow throughout the entire body. In contrast, the use of multiple storage compartments enables the weighted material to be localized in discrete pockets enabling a more usable form to be maintained.
[0023] The apparatus is unfurled in the open configuration and furled in the closed configuration. The term unfurled means opened, unrolled, unfolded, or spread out from a furled state such as a rolled or folded state. Rolling or folding the apparatus forms a compact, tightly bound body that resists sagging or other deformation.
[0024] The storage compartments each comprise an opening that is accessible when the apparatus is unfurled. Rolling or folding the apparatus to the compact configuration binds and encloses the pockets thereby enclosing and shielding the weighted material to mitigate the risk of damage and release in use.
[0025] The plurality of storage compartments preferably comprises a plurality of pockets formed of a flexible material. The pockets are preferable provided on a flexible support substrate to fix them in a predetermined relationship to each other.
[0026] The plurality of pockets may be configured to receive and retain flowable material and comprise closure means for closing the pockets and sealing the flowable material within the pockets. The use of flowable material such as sand is advantageous as such material may be present on site, which is the case for example for members of the armed forces based in arid or desert environments, meaning that the weighted material is readily available at the point of use without requiring transportation. By the same token this material may be readily disposed of following use. Flowable material also has the advantage of taking the form of the pockets, without requiring specific manufacture to provide a weighted element configured to fit the pockets.
[0027] The support substrate may be a flexible support sheet or panel. The plurality of pockets are secured to a common inner surface of the support panel and arranged such that the support panel may be rolled into cylindrical form in which the pockets are contained within and surrounded by the support panel. This provides a continuous cylindrical outer surface that may be include handles or other means for gripping the apparatus, with the weighted material housed within the confines of the support panel and shielded from impact thereby minimizing the risk of splitting or other damage to the pockets, as well as preventing the pockets from providing an obstruction to the user during use.
[0028] The support sheet may be rolled into cylindrical form when the pockets are filled with weighted material and may also be rolled into cylindrical form when the pockets do not contained weighted material with the unfilled ‘stowed’ compact configuration having a diameter less than the second filled compact configuration. In the stowed configuration the pockets may be arranged substantially flush with the inner surface of the support panel and the panel is able to be rolled several providing a very compact form when no filling is present in the pockets.
[0029] The pockets may each comprise first and second front panels hingedly connected to each other their distal edges and hingedly connected to the support panel along their proximal edges. Side panels are arranged at either side of the first and second front panels connected to the side edges of the front panels and to the support sheet. The distal and proximal edges of the front panels extend transversely across the support panel.
[0030] The pockets may effectively define a bellows arrangement in which the second front panel and the side panels are formed from a flexible material and are collapsible such that first front panel is pivotable between a collapsed position in which it is arranged parallel to the inner surface of the support panel, and an expanded position in which it is angled away from the support panel. The first front panel may be formed from a flexible material that is stiffer than the second front panel and side panels such that it retains its planer form more readily than the second front panel, with the second front panels and side panels configured to collapse beneath the first front panel.
[0031] The opening to each pocket is preferably arranged proximate to and parallel with the proximal edge of the first front panel. Alternatively the opening may be defined by the proximal edge of the first front panel.
[0032] The pockets are preferably arranged such that in the compact configuration, when the pockets are filled, they extend radially inwards from the inner surface of the support panel. The pockets preferably define a substantially v-shaped wedge when filled. Preferably four pockets are provided and in the compact configuration the pockets extend and taper inwardly and substantially define quarter segments of the circular cross section of the apparatus to fill the central volume of the rolled apparatus with minimal void that could lead to sagging.
[0033] At least one strap may be included that extends from and is preferably secured to one end of the support panel and arranged to extend circumferentially around at least part of the circumference of the apparatus in both compact arrangements to hold the apparatus in said configurations.
[0034] The at least one strap wraps at least partially around the apparatus and preferably includes releasable fastening means to fasten the strap in position when wrapped around the apparatus, which may be Velcro® or similar hook and eye fabric.
[0035] At least one handle may be arranged on the opposing side of the support panel to the pockets such that it is on the outer surface of the apparatus in the compact configurations to enable the apparatus to be gripped by a user to lift the apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] Various features and advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:
[0037] FIG. 1 shows a weight training apparatus in accordance with an embodiment of the invention in the open unrolled configuration;
[0038] FIG. 2 shows a pocket of the apparatus of FIG. 1 ;
[0039] FIG. 3 shows the reverse side of the arrangement of FIG. 1 ;
[0040] FIG. 4 shows the apparatus of FIG. 2 in the stowed filled configuration;
[0041] FIG. 5 shows an end view of the arrangement of FIG. 4 ; and
[0042] FIG. 6 shows the apparatus of FIG. 1 in the filled compact configuration.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0043] To facilitate an understanding of the principles and features of the various embodiments of the invention, various illustrative embodiments are explained below. Although exemplary embodiments of the invention are explained in detail, it is to be understood that other embodiments are contemplated. Accordingly, it is not intended that the invention is limited in its scope to the details of construction and arrangement of components set forth in the following description or examples. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, in describing the exemplary embodiments, specific terminology will be resorted to for the sake of clarity.
[0044] It must also be noted that, as used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural references unless the context clearly dictates otherwise. For example, reference to a component is intended also to include composition of a plurality of components. References to a composition containing “a” constituent is intended to include other constituents in addition to the one named.
[0045] Also, in describing the exemplary 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.
[0046] Ranges may be expressed herein as from “about” or “approximately” or “substantially” one particular value and/or to “about” or “approximately” or “substantially” another particular value. When such a range is expressed, other exemplary embodiments include from the one particular value and/or to the other particular value.
[0047] Similarly, as used herein, “substantially free” of something, or “substantially pure”, and like characterizations, can include both being “at least substantially free” of something, or “at least substantially pure”, and being “completely free” of something, or “completely pure”.
[0048] By “comprising” or “containing” or “including” is meant that at least the named compound, element, particle, or method step is present in the composition or article or method, but does not exclude the presence of other compounds, materials, particles, method steps, even if the other such compounds, material, particles, method steps have the same function as what is named.
[0049] It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Similarly, it is also to be understood that the mention of one or more components in a composition does not preclude the presence of additional components than those expressly identified.
[0050] The materials described as making up the various elements of the invention are intended to be illustrative and not restrictive. Many suitable materials that would perform the same or a similar function as the materials described herein are intended to be embraced within the scope of the invention. Such other materials not described herein can include, but are not limited to, for example, materials that are developed after the time of the development of the invention.
[0051] Referring to FIG. 1 , a weight training apparatus 1 comprises a support sheet or panel 2 formed of a flexible material. The support sheet 2 is a substantially rectangular flexible panel having sides 4 defining the length of the support sheet and ends 6 shorted than the sides. The support sheet 2 is substantially planar in the unfolded condition as represented in FIG. 1 and includes an inner surface 8 and outer surface 10 .
[0052] A plurality of elongate straps 12 are secured to the outer side 10 of the support sheet 2 and extend past one end 6 a . The straps 12 are transversely spaced and extend longitudinally past the end 6 a and include free ends 14 . The straps 12 have an outer surface 16 and an inner surface 18 that includes securing fabric such as one part of a hook and eye fabric arrangement such as Velcro®. Alternatively the straps 14 may be provided with mechanical fasteners.
[0053] A plurality of pockets 18 are provided on the inner surface 8 of the support sheet 2 . Preferably the apparatus 1 comprises four pockets 18 . The pockets 18 are transversely aligned and regularly spaced longitudinally. Each pocket 18 includes a front panel 20 , base panel 22 connected along a common edge, and side panels 24 located transversely either side of the front 20 and base 22 panels and connected to both. The front 20 , base 22 and side 34 panels are formed of a flexible material and preferably of the same material as the base panel 2 . The side panels 24 are substantially triangular and the front panel 20 and base panel 22 are substantially rectangular such that the pockets form a wedge shaped configuration. As the base panel 22 and side panels 243 are flexible they are able to collapse when the pockets 18 are empty in a bellows type arrangement such that the front panel 20 is able to lie substantially parallel with the base panel 2 , and expand when full to the wedge configuration.
[0054] As shown in FIG. 2 , the pockets 18 are stitched, adhered or otherwise permanently secured to the support sheet, with the outer surface of the support sheet 2 contained within the pocket, and the inner surfaces of the front 20 , base 22 and side 34 panels combining to define a sealed enclosure. Each pocket 18 includes an opening arranged to permit access to the interior of the pocket 18 . In the embodiment shown in FIG. 1 the opening is a transversely extending slit 26 formed width-wise across the proximal end of the front panel 20 proximate its intersection with the base panel 2 . A fastener 28 such as a zip is provided along the slit to close and seal the slit 26 .
[0055] FIG. 3 shows the outer surface 10 of the support sheet 2 . The straps 12 extend longitudinally along substantially the whole length of the support sheet 2 , with the portion of the straps overlying the support sheet 2 being secured directly to the support sheet, preferably by stitching and/or adhesion. The outer surface 16 of at least the proximal end 19 includes a Velcro® material configured to be secured to by the corresponding Velcro® sections on the inner surface of the opposing free ends 14 . The Velcro® material on the outer surface 16 may extend fully along the length of the straps 12 or in another alternative as far as the ends of the support sheet 2 . The straps 12 also provide reinforcement for the support sheet 2 in the longitudinal direction. Additional straps 21 extend transversely across the outer surface 10 of the support sheet 2 and extend past the sides 4 to form handles 23 which in use are located at longitudinally opposed ends of the apparatus 1 . Securing eyes 27 and 29 are also located to the end 6 a and sides 4 respectively and enable the apparatus to be suspended in the open configuration. This allows the pockets 18 to be used as storage means when they are not filled with weighted material for use in exercise.
[0056] As shown in FIG. 4 , in a first stowed configuration in which the pockets are empty, the base panel 2 may be rolled length-wise into a substantially cylindrical form. With the empty pockets collapsed a tightly rolled arrangement is possible comprising several concentric spiraled layers. The base panel 2 is rolled from the opposing 6 b to the straps 12 in the direction of the straps 12 . When the base panel 2 is fully rolled the straps 12 are pulled and wrapped around the rolled arrangement. As described above, the inner surface of the straps 18 , which in the rolled configuration face radially inwards, comprise a Velcro® material. A corresponding Velcro material is provided on a portion of the outer surface such that when the straps 12 are pulled tight around the rolled panel 2 the inner surface may be secured to the corresponding portion of the outer surface 16 to hold the straps 12 in position, to clamp and retain the panel 2 in the rolled configuration.
[0057] In use, when the apparatus is to be used to perform weight training exercises, the straps 12 are released and the base panel 2 is unrolled to the flat configuration of FIG. 1 . The pockets 18 are then opened by releasing the zips 28 . The pockets 18 are then filled with a weighted material such as sand or metal shot. The material of the pockets 18 and base panel 2 is selected to be non-porous to ensure that even fine sand particles are retained within the pockets 18 when sealed. As an alternative to sand or shot a waterproof bladder may be provided that is configured to fit within the pockets 18 which may be filled with water to provide the required resistance weight. The bladder may be removable from the pocket 18 to allow it to be offered to a source of water more easily.
[0058] In the filled condition the pockets 18 adopt the wedged configuration. With each of the pockets 18 filled, the apparatus 1 may again be reconfigured to the closed configuration by rolling the support sheet 2 . With the pockets 18 filled the support sheet 2 is no longer able to be rolled into the tight stowed configuration. As the support sheet 2 is rolled, each pocket 18 moves into abutment with the longitudinally adjacent pocket 18 . Again the support sheet 2 is rolled from the lower end 6 b until the lower end 6 b comes into engagement with the upper end 6 a which wraps over the outer surface of the lower end 6 b . In the configuration the apparatus 1 is now substantially cylindrical. Internally, the pockets 18 are in abutment with each other.
[0059] As shown in FIG. 5 , the wedge shape of the pockets 18 is such that when viewed in cross section from the end 30 of the rolled apparatus each of the pockets 18 taper in the radially inwards direction with each of the four pockets 18 substantially forming a quarter segment of the overall circular cross section. Each pocket 18 tapers from a wide base 33 to an apex 35 . In an alternative arrangement including more or less than four pockets the pockets would be sized and arranged to substantially fill the circular cross section to avoid gaps that may lead to sagging.
[0060] In the compact cylindrical form the pockets 18 extend longitudinally along the length of the apparatus. In this way, a circular outer shape is achieved with apparatus being maintained in a cylindrical form having a greater diameter than when in the stowed configuration due the internal presence of the weighted filling material. As the pockets 18 are flexible, they may be selectively filled with varying amounts of material to achieve differing weights. Where the pockets are not completely filled their flexible nature allows them to compact against each other as the support sheet is rolled, with the support sheet 2 being rolled tightly to compress the pockets such that the resultant cylindrical rolled form is retained and the apparatus remains longitudinally rigid, having a diameter less than the completely filled form and greater than the stowed form.
[0061] A plurality of handles 32 are arranged along the length of the outer surface 10 of the support sheet 2 . The straps 32 are arranged transversely such that in the rolled configuration they extend circumferentially around part of the circumference of the apparatus 1 . In use the handles 32 allow the filled apparatus to be gripped by the user to enable it to be manipulated to perform weight training exercises. Further straps 34 extend transversely from the sides of the panel 2 , which in the rolled configuration extend longitudinally away from the ends of the cylindrical body of the apparatus 1 to provide an alternative grip position.
[0062] Following use the zip 28 of each pocket 18 is opened and the filling material may be emptied from the pockets 18 allows the apparatus 1 to be rolled back into the stowed configuration for transit or storage.
[0063] As shown in FIG. 6 , in the compact stowed configuration, the absence of filled weighted material in the pocket 18 means the pockets are able to deform and lie substantially parallel to the inner surface of the support sheet 2 and confirm to the same shape as the sheet 2 as it is rolled. This enables a close compact rolled arrangement in which there is minimal spacing between adjacent concentric layers of the rolled configuration. This optimizes the compact arrangement for storage and transport.
[0064] Whilst endeavoring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.
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A weight training apparatus reconfigurable between an open configuration and a compact configuration in which the apparatus is packed into a smaller form than in the open configuration. The apparatus includes one or more storage compartments configured to removably receive and retain a weighted material to selectively increase the weight of the apparatus. If including more than one storage compartment, each can be movable relative to one other and are shaped and arranged to enable the apparatus to be reconfigured to the compact configuration in a filled condition in which the storage compartments contain weighted material. The apparatus can be configured in the compact configuration without weighted material for transport or storage. The absence of any weighted material makes the apparatus lightweight to carry, as well as enabling it to compact to a much smaller size than in the in-use filled configuration.
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BACKGROUND OF THE INVENTION
The present invention relates to the field of user interfaces, more particularly to using an alternate user interface in place of a drag and drop interface for rearranging configurable Web page components.
Drag and drop interfaces are commonly used for many actions in computing sessions. A drag and drop interface is an interface in which elements on the screen are movable to a different location. The user typically first uses a pointing device (such as a mouse, drawing tablet, or trackball) to “click” or select the item to move. When selecting the item to move, the user does not release the selection mechanism (e.g., a mouse button) until the item is moved to the desired place. The most common example can be users dragging and dropping files to different locations in an operating system. Moving the files to different locations can trigger file operations such as copying, moving, or deleting (when moved to a special location such as a trash/recycle bin). Drag and drop operations are also used to configure components of a Web page.
Drag and drop interfaces can be troublesome for some users to use, such as those with visual or motor skill impairments. For a visually impaired user, it can be difficult to keep a visual map in mind of where moveable components are physically located and where they may be relocated. For a user with motor skill impairments, it may be difficult or impossible to perform the combined operations of moving the mouse and clicking the appropriate buttons.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a schematic diagram of a system for an interface to configure Web pages in accordance with an embodiment of the inventive arrangements disclosed herein.
FIG. 2 illustrates an interface for configuring a Web page in accordance with an embodiment of the inventive arrangements disclosed herein.
FIG. 3 is a flow chart of a method for using an alternate user interface in place of a drag and drop interface in accordance with an embodiment of the inventive arrangements disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
The present invention discloses a solution for users to position configurable components of a Web page. The solution can be an alternative to a drag and drop configuration function, which presents Web page elements in a Hypertext Markup Language (HTML) table and provides an ability to reposition these components. For example, a position selection control can be presented next to each component, which provides a mechanism to position the component within a Web page. The solution can be utilized by any user, but can be particularly advantageous to many disabled users, who may have difficulty utilizing a drag and drop interface.
The present invention may be embodied as a method, system, or computer program product. Accordingly, the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, the present invention may take the form of a computer program product on a computer-usable storage medium having computer-usable program code embodied in the medium. In a preferred embodiment, the invention is implemented in software, which includes but is not limited to firmware, resident software, microcode, etc.
Furthermore, the invention can take the form of a computer program product accessible from a computer-usable or computer-readable medium providing program code for use by or in connection with a computer or any instruction execution system. For the purposes of this description, a computer-usable or computer readable medium can be any apparatus that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device. The computer-usable medium may include a propagated data signal with the computer-usable program code embodied therewith, either in baseband or as part of a carrier wave. The computer usable program code may be transmitted using any appropriate medium, including but not limited to the Internet, wireline, optical fiber cable, RF, etc.
Any suitable computer usable or computer readable medium may be utilized. The computer-usable or computer-readable medium may be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium. Examples of a computer-readable medium include a semiconductor or solid state memory, magnetic tape, a removable computer diskette, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory, a rigid magnetic disk and an optical disk. Current examples of optical disks include compact disk-read only memory (CD-ROM), compact disk-read/write (CD-R/W), digital versatile disk (DVD), Blu-ray Disc™, and the like, which includes any high definition and recordable formats of these optical disks. Other computer-readable medium can include a transmission media, such as those supporting the Internet, an intranet, a personal area network (PAN), or a magnetic storage device. Transmission media can include an electrical connection having one or more wires, an optical fiber, an optical storage device, and a defined segment of the electromagnet spectrum through which digitally encoded content is wirelessly conveyed using a carrier wave.
Note that the computer-usable or computer-readable medium can even include paper or another suitable medium upon which the program is printed, as the program can be electronically captured, via, for instance, optical scanning of the paper or other medium, then compiled, interpreted, or otherwise processed in a suitable manner, if necessary, and then stored in a computer memory.
Computer program code for carrying out operations of the present invention may be written in an object oriented programming language such as Java, Smalltalk, C++ or the like. However, the computer program code for carrying out operations of the present invention may also be written in conventional procedural programming languages, such as the “C” programming language or similar programming languages, which include markup languages (e.g., HTML, XHTML, XML, SGML, XLS, CSS) as well as scripting languages (JavaScript, ECMAScript, Python, Perl, PHP, etc.). The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
A data processing system suitable for storing and/or executing program code will include at least one processor coupled directly or indirectly to memory elements through a system bus. The memory elements can include local memory employed during actual execution of the program code, bulk storage, and cache memories which provide temporary storage of at least some program code in order to reduce the number of times code must be retrieved from bulk storage during execution.
Input/output or I/O devices (including but not limited to keyboards, displays, pointing devices, etc.) can be coupled to the system either directly or through intervening I/O controllers.
Network adapters may also be coupled to the system to enable the data processing system to become coupled to other data processing systems or remote printers or storage devices through intervening private or public networks. Modems, cable modem and Ethernet cards are just a few of the currently available types of network adapters.
The present invention is described below with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function/act specified in the flowchart and/or block diagram block or blocks.
The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
FIG. 1 is a schematic diagram of a system 100 for an interface 110 to configure Web pages in accordance with an embodiment of the inventive arrangements disclosed herein. The interface 110 can tabularly present (or present within any HTML table) Web page components/elements, which can be repositioned using a selectable control 116 . The configuration interface 110 can be used in place of or in addition to a drag and drop configuration interface, which is a standard for many customizable Web pages. The drag and drop standard can be particularly disadvantageous to many users who have relatively low vision acuity and/or motor control impairments that make using a drag and drop interface for configuring a Web page problematic. Further, the interface 110 can be used in many situations lacking convenient pointer manipulation mechanisms (e.g., mice, track pad, etc.). For example, many mobile devices, such as cellular phones, include Web access capabilities, where the devices themselves may make drag and drop motions difficult. The tabular interface 110 as presented can be used intuitively with more primitive input peripherals than a drag and drop interface would require.
In system 100 , user 102 can interact with browser 106 running on computing device 104 . Browser 106 can enable the interaction between user 102 and servers 160 and 180 . Web server 160 can serve Web pages 170 stored on data store 168 to browser 106 for interaction with user 102 . User profiles 172 can be maintained in the data store 168 , which represent a set of user established settings/preferences/options to be applied to served Web pages 170 . Configuration engine 166 can allow for the customization of Web pages 170 . That is, a user 102 can establish/change settings in one of the profiles 172 specific to one of the served Web pages 170 using configuration engine 166 . In one embodiment, the configured Web pages 170 can include a mashup, a portal, or other type of container that includes content for user 102 presentation from multiple sources, which it provides through one of the Web pages 170 having a unique Uniform Resource Identifier (URI). The Web pages 170 will generally be dynamically rendered, but can include configurable content that is relatively static, as well.
In one embodiment, the configuration engine 166 can include a page rearrangement engine 182 , which permits a user 102 to configure one of the Web pages 170 using a tabular interface 110 . In another embodiment, the page rearrangement engine 182 can be provided by a proxy server 180 , which is able to configure the Web pages 170 and/or change settings of one of the user profiles 172 . When present, the proxy server 180 can operate in a Web server 160 transparent fashion and/or can be an optional interface for configuring Web pages 170 . Use of proxy server 180 can permit a user 102 to utilize a consistent tabular interface 110 for configuring Web pages 170 provided by a myriad of different Web servers 160 . For example, a disabled user 102 can utilize the proxy server 180 to configure Web pages 170 through a tabular interface 110 instead of through a default drag and drop configuration interface (provided by configuration engine 166 ). A configuration engine 184 of the proxy server 180 can be configured to transparently interact with numerous server 160 standards, such as interacting through the GOOGLE Application Program Interface (API), the YAHOO API, and XXX.API (representing any defined and published API), and can adjust configuration settings accordingly.
Page rearrangement engine 182 can interact with user 102 and provide an interface for reconfiguring elements of one of the Web pages 170 . Page rearrangement engine 182 can begin by providing user 102 with a prompt to determine which Web page user 102 would like to view. Once user 102 provides a requested Web page address (e.g., URI, domain name, etc.), page rearrangement engine 182 can use configuration engine 184 to determine the reconfigurable page components/elements of the requested page. Configuration engine 184 can interface with configuration engine 166 to determine how Web pages 170 can be reconfigured. Once the reconfigurable page components have been determined, configuration engine 184 can convey the reconfigurable elements to page rearrangement engine 182 . Page rearrangement engine 182 can provide an interface to user 102 , such as the example illustrated by Web interface 110 , to allow user 102 to reconfigure page components in an alternative drag and drop interface. Once user 102 reconfigures the page components and submits their new settings, page rearrangement engine 182 can use configuration engine 184 to communicate the page changes to configuration engine 166 . Configuration engine 166 can save the changes to one of the user profiles 172 associated with the requesting address or user.
Web interface 110 can illustrate a sample interface that proxy server 180 can provide to user 102 to reconfigure page components of one of the Web pages 170 . Web interface 110 can include columns component 112 , current position 114 , and available positions 116 . Component 112 can be a column indicating the reconfigurable component of an associated one of the Web pages 170 . Current position 114 can be a column indicating the current position of the reconfigurable component of the Web page 170 . Available positions 116 can be a column in which can contain a drop-down menu Graphical User Interface (GUI) control in which can list the positions the reconfigurable component can relocate to. A user can select a new location from the drop-down in available positions 116 and then select an apply button 118 to apply the setting change. It is also contemplated that applying location settings for multiple components simultaneously may cause location conflicts, requiring graceful location conflict resolution by the system.
As used herein, computing device 104 can be any computing device able to run browser 106 and communicate with servers 160 and/or 180 via network 150 . Computing device 104 can allow user 102 to view and interact with Web pages 170 stored on Web server 160 's data store 168 . Browser 106 can be executable instruction code that can allow the viewing of Web pages 170 provided by Web server 160 . Browser 106 can be a Web browser, but is not limited to a Web browser and can be any application capable of displaying content provided by servers 160 and 180 . For example, browser 106 can include a rich internet interface, a Web enabled widget, and the like. Computing device 104 can include, but is not limited to, a desktop computer, laptop computer, mobile phone, a media player, an internet appliance, a game console, a kiosk, a navigation device, and/or the like.
Web pages 170 can be any Web content that contains page components that can be reconfigured. In some embodiments, Web pages 170 can include dynamic Web content that can require a language interpreter (not shown) to execute code to generate the dynamic view. Web pages 170 can be customized according to settings stored in one of the user profiles 172 associated with a user. User profiles 172 can be configuration settings that have been configured in accordance with a computing session with Web server 160 . The user profiles 172 can be manually or automatically configured. For example, one of the user profiles 172 can be set in the form of a cookie stored in a client's browser such as browser 106 . This cookie can automatically be set to save options for the next time the user requests the same one of the Web pages 170 . User profiles 172 can also be manually configured in cases where an associated one of the Web pages 170 requires a user account or something similar. Each of the user profiles 172 can be any collection of settings for a user's session on an associated one of the Web pages 170 .
Data store 168 can be physically implemented within any type of hardware including, but not limited to, a magnetic disk, an optical disk, a semiconductor memory, a digitally encoded plastic memory, a holographic memory, or any other recording medium. The data store 168 can be a stand-alone storage unit as well as a storage unit formed from a plurality of physical devices, which may be remotely located from one another. Additionally, information can be stored within each data store in a variety of manners. For example, information can be stored within a database structure or can be stored within one or more files of a file storage system, where each file may or may not be indexed for information searching purposes.
Network 150 can include any hardware/software/and firmware necessary to convey digital content encoded within carrier waves. Content can be contained within analog or digital signals and conveyed through data or voice channels and can be conveyed over a personal area network (PAN) or a wide area network (WAN). The network 150 can include local components and data pathways necessary for communications to be exchanged among computing device components and between integrated device components and peripheral devices. The network 150 can also include network equipment, such as routers, data lines, hubs, and intermediary servers which together form a packet-based network, such as the Internet or an intranet. The network 150 can further include circuit-based communication components and mobile communication components, such as telephony switches, modems, cellular communication towers, and the like. The network 150 can include line based and/or wireless communication pathways.
It should be appreciated that the Web interface 110 represents just one contemplated embodiment of reconfiguring Web components within an HTML table having unique cells for each Web component. An important factor is that the interface 110 can be manipulated utilizing input from a standard keyboard only (not requiring pointing device input). This makes interface 110 an accessibility option in one contemplated embodiment for use by users 102 having difficulty using a drag and drop interface. The positions 116 of interface can refer to Web page locations and/or offsets, but need not. For example, in one embodiment, the “positions” 116 can indicate a relative importance of an associated component, which can be mapped to an actual Web page position. For instance, components presented upon a top left point of a Web page (or a bottom right corner in other countries based upon a countries writing system) can be considered “more important” than positions further from this reference position (top-left).
FIG. 2 illustrates an interface 202 for configuring a Web page in accordance with an embodiment of the inventive arrangements disclosed herein. The content configuration interface 202 can be implemented in context of system 100 . That is, content configuration interface 202 illustrates an alternate to using a drag and drop configuration interface.
In interface 202 , an HTML component of a configurable Web page can be extracted as components, along with a current position, and a set of available positions. Presentation in a tabular 204 manner is contemplated, but is not a limitation of the invention. For example, in another embodiment, the table containing the HTML component (components 210 - 214 ) can be used to drive configuration of HTML components through any of a variety of interfaces. For example, each of the HTML components can be presented in a tiled fashion, where each tile includes a position adjustment control, which can be used to change a position of the element within a customizable Web page.
As shown in interface 202 , table 204 can be a listing of all the reconfigurable page components of a Web page. Table 204 can include pointer 210 , zoom tool 212 , and compass 216 . Pointer 210 can currently be in location A and it can be selected to be moved to location E. Zoom tool 212 can currently be in position B and it can be selected to be moved to location C. Compass 214 can currently be in position C and it can be selected to be moved to location D. Content arrangement preview 216 can illustrate the Web page after the selected changes are saved and the page is updated. Content arrangement preview 216 can include graphical representations of pointer 210 , zoom tool 212 , and compass 214 in their new locations. Interface 202 can also include button 224 , which can be used by the user once they've selected new locations for all components. Activating button 224 can save all of the user's changes and update the Web page.
Content configuration interface 202 can also include options 218 - 222 . Option 218 can toggle the enablement of automatically adjusting placement conflicts. For example, if a user selects more than one component to be moved to the same location, a placement conflict is created. In this situation, if option 218 is enabled, the location of the conflicting component can automatically be readjusted to fit the newly selected option. In other embodiments, a visual or audible indicator can be used to notify the user of a placement conflict. Options 220 and 222 can allow for the automatic placement of the reconfigurable page components. Option 220 can cause the automatic placement in order of importance, descending (highest to lowest). Option 222 can cause the automatic placement in order of importance, ascending (lowest to highest). Importance can be determined by any number of factors, including, but not limited to, how often the user has used the component, how relevant the component is to the subject of the Web page, and the like. The order of the physical positions can be determined according to the directionality of the user's writing system. For example, in some countries, top-left can be perceived as a starting position for writing, while in others, other locations can be perceived as the starting position for writing.
The Web page able to be configured through interface 202 can be any type of Web page including a set of repositionable elements. As shown in preview 216 , the Web page being configured can be a Mashup that includes elements from multiple data sources that can be overlaid within the Mashup in a programmatically definable manner. In another embodiment, the Web page can include a configurable portal, a Web page design interface, and the like.
FIG. 3 is a flow chart of a method 300 for using an alternate user interface in place of a drag and drop interface in accordance with an embodiment of the inventive arrangements disclosed herein. Method 300 can be performed in context of a system 100 and can begin in step 306 , where a user begins a computing session with a proxy server. The proxy server is not a requirement of method 300 , but is consistent with the embodiment of the invention shown in system 100 .
In step 308 , the user can specify a configurable Web page. In step 310 , the proxy server can present the user with an interface in which they can rearrange page components in which normally would use a drag and drop interface. In step 312 , the user can specify a new arrangement of the page components in the proxy server's interface. In step 314 , the user's new specified arrangement can be applied to the page view. Method 300 can complete in step 316 , where the new arrangement can be saved and associated with the user's profile for future sessions.
The diagrams in FIGS. 1-3 illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
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A user interface for repositioning Web page components that includes an HTML table. Each cell of the table can represents a Web page component that is able to be repositioned. Each cell can include an identifier and a user selectable position control. The identifier can identify the Web page component. The user selectable position control can accept user input designating a position of the component within the Web page. An activation control can accept input entered within the user selectable position control when selected. Activation of the activation control can result in the Web page being reconfigured so that the position of the Web page components corresponds to positions specified by the position controls. In one embodiment, the user interface can be an accessibility option for users having difficulty with a drag and drop interface.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. application Ser. No. 13/479,607, filed on May 24, 2012, which is a continuation of U.S. application Ser. No. 12/959,971, filed on Dec. 3, 2010, now U.S. Pat. No. 8,215,076, which is a continuation of U.S. application Ser. No. 11/822,698, filed on Jul. 9, 2007, now U.S. Pat. No. 7,874,119, which is a continuation of U.S. application Ser. No. 09/954,064, now U.S. Pat. No. 7,484,338, filed on Sep. 18, 2001, which is a continuation of Application No. PCT/SE00/00785, filed on Apr. 26, 2000, which claims the benefit of Swedish Application No. 9901574-5, filed on Apr. 30, 1999. The entire contents of each of U.S. application Ser. No. 13/479,607, U.S. application Ser. No. 12/959,971, U.S. application Ser. No. 11/822,698, U.S. application Ser. No. 09/954,064, Application No. PCT/SE00/00785 and Swedish Application No. 9901574-5 are hereby incorporated herein by reference.
TECHNICAL FIELD
[0002] The invention generally relates to the field of mechanical locking of floorboards. The invention relates to an improved locking system for mechanical locking of floorboards, a floorboard provided with such an improved locking system, as well as a method for making such floorboards. The invention generally relates to an improvement to a locking system of the type described and shown in WO 94/26999.
[0003] More specifically, the invention relates to a locking system for mechanical joining of floorboards of the type having a body, opposite first and second joint edge portions and a balancing layer on a rear side of the body, adjoining floorboards in a mechanically joined position having their first and second joint edge portions joined at a vertical joint plane, said locking system comprising
[0004] a) for vertical joining of the first joint edge portion of the first floorboard and the second joint edge portion of the adjoining floorboard mechanically cooperating means in the form of a tongue groove formed in the first joint edge portion and a tongue formed in the second joint edge portion,
[0005] b) for horizontal joining of the first joint edge portion of the first floorboard and the second joint edge portion of an adjoining floorboard mechanically cooperating means, which comprise
[0006] a locking groove which is formed in the underside of said second floorboard and which extends parallel to and at a distance from the vertical joint plane at said second joint edge portion and which has a downward opening, and
[0007] a strip made in one piece with the body of said first floorboard, which strip at said first joint edge portion projects from said vertical joint plane and at a distance from the joint plane has a locking element, which projects towards a plane containing the upper side of said first floorboard and which has at least one operative locking surface for coaction with said locking groove, and
[0008] said strip forming a horizontal extension of the first joint edge portion below the tongue groove.
FIELD OF APPLICATION OF THE INVENTION
[0009] The present invention is particularly suitable for mechanical joining of thin floating floorboards made up of an upper surface layer, an intermediate fibreboard body and a lower balancing layer, such as laminate flooring and veneer flooring with a fibreboard body. Therefore, the following description of the state of the art, problems associated with known systems, and the objects and features of the invention will, as a non-restricting example, focus on this field of application and, in particular, on rectangular floorboards with dimensions of about 1.2 m*0.2 m and a thickness of about 7-10 mm, intended to be mechanically joined at the long side as well as the short side.
BACKGROUND OF THE INVENTION
[0010] Thin laminate flooring and wood veneer flooring are usually composed of a body consisting of a 6-9 mm fibreboard, a 0.2-0.8-mm-thick upper surface layer and a 0.1-0.6 mm lower balancing layer. The surface layer provides appearance and durability to the floorboards. The body provides stability, and the balancing layer keeps the board level when the relative humidity (RH) varies during the year. The RH can vary between 15% and 90%. Conventional floorboards of this type are usually joined by means of glued tongue-and-groove joints at the long and short sides. When laying the floor, the boards are brought together horizontally, whereby a projecting tongue along the joint edge of a first board is introduced into the tongue groove along the joint edge of a second board. The same method is used on both the long and the short side. The tongue and the tongue groove are designed for such horizontal joining only and with special regard to how the glue pockets and gluing surfaces should be designed to enable the tongue to be efficiently glued within the tongue groove. The tongue-and-groove joint presents coacting upper and lower contact surfaces that position the boards vertically in order to ensure a level surface of the finished floor.
[0011] In addition to such conventional floors which are connected by means of glued tongue-and-groove joints, floorboards have recently been developed which are instead mechanically joined and which do not require the use of glue. This type of a mechanical joint system is hereinafter referred to as a “strip-lock system” since the most characteristic component of this system is a projecting strip which supports a locking element.
[0012] WO 94/26999 (Applicant Välinge Aluminum AB) discloses a strip-lock system for joining building panels, particularly floorboards. This locking system allows the boards to be locked mechanically at right angles to as well parallel to the principal plane of the boards at the long side as well as at the short side. Methods for making such floorboards are disclosed in WO 98/24994 and WO 98/24995. The basic principles of the design and the installation of the floorboards, as well as the methods for making the same, as described in the three above-mentioned documents are usable for the present invention as well, and, therefore, these documents are hereby incorporated by reference.
[0013] In order to facilitate the understanding and description of the present invention, as well as the comprehension of the problems underlying the invention, a brief description of the basic design and function of the floorboards according to the above-mentioned WO 9426999 will be given below with reference to FIGS. 1-3 in the accompanying drawings. Where applicable, the following description of the prior art also applies to the embodiments of the present invention described below.
[0014] FIGS. 3 a and 3 b are thus a bottom view and a top view respectively of a known floorboard 1 . The board 1 is rectangular with a top side 2 , an underside 3 , two opposite long sides 4 a , 4 b forming joint edges, and two opposite short sides 5 a , 5 b forming joint edges.
[0015] Without the use of glue, both the long sides 4 a , 4 b and the short sides 5 a , 5 b can be joined mechanically in a direction D 2 in FIG. 1 c . For this purpose, the board 1 has a flat strip 6 , mounted at the factory, projecting horizontally from its long side 4 a , which strip extends throughout the length of the long side 4 a and which is made of flexible, resilient sheet aluminum. The strip 6 can be fixed mechanically according to the embodiment shown, or by means of glue, or in some other way. Other strip materials can be used, such as sheets of other metals, as well as aluminum or plastic sections. Alternatively, the strip 6 may be made in one piece with the board 1 , for example by suitable working of the body of the board 1 . Thus, the present invention is usable for floorboards in which the strip is integrally formed with the board. At any rate, the strip 6 should always be integrated with the board 1 , i.e. it should never be mounted on the board 1 in connection with the laying of the floor. The strip 6 can have a width of about 30 mm and a thickness of about 0.5 mm. A similar, but shorter strip 6 ′ is provided along one short side 5 a of the board 1 . The edge side of the strip 4 facing away from the joint edge 4 a is formed with a locking element 8 extending throughout the length of the strip 6 . The locking element 8 has an operative locking surface 10 facing the joint edge 4 a and having a height of e.g. 0.5 mm. When the floor is being laid, this locking surface 10 coacts with a locking groove 14 formed in the underside 3 of the opposite long side 4 b of an adjoining board 1 ′. The short side strip 6 ′ is provided with a corresponding locking element 8 ′, and the opposite short side 5 b has a corresponding locking groove 14 ′.
[0016] Moreover, for mechanical joining of both the long sides and the short sides also in the vertical direction (direction D 1 in FIG. 1 c ), the board 1 is formed with a laterally open recess 16 along one long side 4 a and one short side 5 a . At the bottom, the recess is defined by the respective strips 6 , 6 ′. At the opposite edges 4 b and 5 b , there is an upper recess 18 defining a locking tongue 20 coacting with the recess 16 (see FIG. 2 a ).
[0017] FIGS. 1 a - 1 c show how two long sides 4 a , 4 b of two such boards 1 , 1 ′ on an underlay U can be joined together by means of downward angling. FIGS. 2 a - 2 c show how the short sides 5 a , 5 b of the boards 1 , 1 ′ can be joined together by snap action. The long sides 4 a , 4 b can be joined together by means of both methods, while the short sides 5 a , 5 b —when the first row has been laid—are normally joined together subsequent to joining together the long sides 4 a , 4 b and by means of snap action only.
[0018] When a new board 1 ′ and a previously installed board 1 are to be joined together along their long sides 4 a , 4 b as shown in FIGS. 1 a - 1 c , the long side 4 b of the new board 1 ′ is pressed against the long side 4 a of the previous board 1 as shown in FIG. 1 a , so that the locking tongue 20 is introduced into the recess 16 . The board 1 ′ is then angled downwards towards the subfloor 12 as shown in FIG. 1 b . In this connection, the locking tongue 20 enters the recess 16 completely, while the locking element 8 of the strip 6 enters the locking groove 14 . During this downward angling the upper part 9 of the locking member 8 can be operative and provide guiding of the new board 1 ′ towards the previously installed board 1 . In the joined position as shown in FIG. 1 c , the boards 1 , 1 ′ are locked in both the direction D 1 and the direction D 2 along their long sides 4 a , 4 b , but can be mutually displaced in the longitudinal direction of the joint along the long sides 4 a , 4 b.
[0019] FIGS. 2 a - 2 c show how the short sides 5 a and 5 b of the boards 1 , 1 ′ can be mechanically joined in the direction D 1 as well as the direction D 2 by moving the new board 1 ′ towards the previously installed board 1 essentially horizontally. Specifically, this can be carried out subsequent to joining the long side of the new board 1 ′ to a previously installed board in an adjoining row by means of the method according to FIGS. 1 a - 1 c . In the first step in FIG. 2 a , beveled surfaces adjacent to the recess 16 and the locking tongue 20 respectively co-operate such that the strip 6 ′ is forced to move downwards as a direct result of the bringing together of the short sides 5 a , 5 b . During the final urging together of the short sides, the strip 6 ′ snaps up when the locking element 8 ′ enters the locking groove 14 ′.
[0020] By repeating the steps shown in FIGS. 1 a - c and 2 a - c , the whole floor can be laid without the use of glue and along all joint edges. Known floorboards of the above-mentioned type are thus mechanically joined usually by first angling them downwards on the long side, and when the long side has been secured, snapping the short sides together by means of horizontal displacement along the long side. The boards 1 , 1 ′ can be taken up in the reverse order of laying without causing any damage to the joint, and be laid again. These laying principles are also applicable to the present invention.
[0021] For optimal function, subsequent to being joined together, the boards should be capable of assuming a position along their long sides in which a small play can exist between the locking surface 10 and the locking groove 14 . Reference is made to WO 9426999 for a more detailed description of this play.
[0022] In addition to what is known from the above-mentioned patent specifications, a licensee of Välinge Aluminum AB, Norske Skog Flooring AS (NSF), introduced a laminated floor with mechanical joining according to WO 9426999 in January 1996 in connection with the Domotex trade fair in Hannover, Germany. This laminated floor, which is marketed under the brand name Alloc™, is 7.2 mm thick and has a 0.6-mm aluminum strip 6 which is mechanically attached on the tongue side. The operative locking surface 10 of the locking element 8 has an inclination (hereinafter termed locking angle) of 80° to the plane of the board. The vertical connection is designed as a modified tongue-and-groove joint, the term “modified” referring to the possibility of bringing the tongue and tongue groove together by way of angling.
[0023] WO 97/47834 (Applicant Unilin) describes a strip-lock system which has a fibreboard strip and is essentially based on the above known principles. In the corresponding product, “Uniclic”, which this applicant began marketing in the latter part of 1997, one seeks to achieve biasing of the boards. This results in high friction and makes it difficult to angle the boards together and to displace them. The document shows several embodiments of the locking system. The “Uniclic” product, shown in section in FIG. 4 b , consists of a floorboard having a thickness of 8.1 mm with a strip having a width of 5.8 mm, comprising an upper part made of fibreboard and a lower part composed of the balancing layer of the floorboard. The strip has a locking element 0.7 mm in height with a locking angle of 45°. The vertical connection consists of a tongue and a tongue groove having a tongue groove depth of 4.2 mm.
[0024] Other known locking systems for mechanical joining of board materials are described in, for example, GB-A-2,256,023 showing unilateral mechanical joining for providing an expansion joint in a wood panel for outdoor use, and in U.S. Pat. No. 4,426,820 showing a mechanical locking system for plastic sports floors, which floor however does not permit displacement and locking of the short sides by snap action. In both these known locking systems the boards are uniform and do not have a separate surface layer and balancing layer.
[0025] In the autumn of 1998, NSF introduced a 7.2-mm laminated floor with a strip-lock system which comprises a fibreboard strip and is manufactured in accordance with WO 9426999. This laminated floor, which is shown in cross-section in FIG. 4 a , is marketed under the brand name of “Fiboloc™”. In this case, too, the strip comprises an upper part of fibreboard and a lower part composed of a balancing layer. The strip is 10.0 mm wide, the height of the locking element is 1.3 mm and the locking angle is 60°. The depth of the tongue groove is 3.0 mm.
[0026] In January 1999, Kronotex introduced a 7.8 mm thick laminated floor with a strip lock under the brand name “Isilock”. This system is shown in cross-section in FIG. 4 c . In this floor, too, the strip is composed of fibreboard and a balancing layer. The strip is 4.0 mm and the tongue groove depth is 3.6 mm. “Isilock” has two locking ridges having a height of 0.3 mm and with locking angles of 40°. The locking system has low tensile strength, and the floor is difficult to install.
SUMMARY OF THE INVENTION
[0027] Although the floor according to WO 94/26999 and the floor sold under the brand name Fiboloc™ exhibit major advantages in comparison with traditional, glued floors, further improvements are desirable mainly by way of cost savings which can be achieved by reducing the width of the fibreboard strip from the present 10 mm. A narrower strip has the advantage of producing less material waste in connection with the forming of the strip. However, this has not been possible since narrower strips of the Uniclic and Isilock type have produced inferior test results. The reason for this is that narrow strips require a small angle of the locking surface of the locking element in relation to the horizontal plane (termed locking angle) in order to enable the boards to be joined together by means of angling, since the locking groove follows an arc having its centre in the upper joint edge of the board. The height of the locking element must also be reduced since narrow strips are not as flexible, rendering snap action more difficult.
[0028] To sum up, narrow strips have the advantage that material waste is reduced, but the drawbacks that the locking angle must be small to permit angling and that the locking element must be low to permit joining by snap action.
[0029] In repeated laying trials and tests with the same batch of floorboards we have discovered that strip locks, which have a joint geometry similar to that in FIGS. 4 b and 4 c , and are composed of a narrow fibreboard strip with a balancing layer on its rear side and with a locking element having a small locking surface with a low locking angle, exhibit a considerable number of properties which are not constant and which can vary substantially in the same floorboard at different points in time when laying trials have been performed. These problems and the reason behind the problems are not known.
[0030] Moreover, at present there are no known products or methods which afford adequate solutions to these problems which are related to
[0031] (i) mechanical strength of the joint of floorboards with a mechanical locking system of the strip lock type;
[0032] (ii) handling and laying of such floorboards;
[0033] (iii) properties of a finished, joined floor made of such floorboards.
(i) Strength
[0034] At a certain point in time, the joint system of the floorboards has adequate strength. In repeated testing at a different point in time, the strength of the same floorboard may be considerably lower, and the locking element slides out of the locking groove relatively easily when the floor is subjected to tensile stress transversely of the joint.
(ii) Handling/Laying
[0035] At certain times during the year the boards can be joined together, while at other times it is very difficult to join the same floorboard. There is a considerable risk of damage to the joint system in the form of cracking.
[0000] (iii) Properties of the Joined Floor
[0036] The quality of the joint in the form of the gap between the upper joint edges of the floorboards when subjected to stress varies for the same floorboard at different times during the year.
[0037] It is known that floorboards expand and shrink during the year when the relative humidity RH changes. Expansion and shrinking are 10 times greater transversely of the direction of the fibres than in the direction of the fibres. Since both joint edges of the joint system change by the same amount essentially simultaneously, the expansion and the shrinking cannot explain the undesirable effects which severely limit the chances of providing a strip-lock system at a low cost which at the same time is of high quality with respect to strength, laying properties, and the quality of the joint. According to generally known theories, wide strips should expand more and cause greater problems. Our tests indicate that the reverse is the case.
[0038] In sum, there is a great need for a strip-lock system which to a greater extent than the prior art takes into account the above-mentioned requirements, problems and wishes. It is an object of the invention to fulfill this need.
[0039] These and other objects of the invention are achieved by a locking system, a floorboard, and a manufacturing method exhibiting the properties stated in the appended independent claims, preferred embodiments being stated in the dependent claims.
[0040] The invention is based on a first insight according to which the problems identified are essentially connected to the fact that the strip which is integrated with the body bends upwards and downwards when the RH changes. Moreover, the invention is based on the insight that, as a result of its design, the strip is unbalanced and acts as a bimetal. When, in a decrease of the RH, the rear balancing layer of the strip shrinks more than the fibreboard part of the strip, the entire strip will bend backwards, i.e. downwards. Such strip-bending can be as great as about 0.2 mm. A locking element having a small operative locking surface, e.g. 0.5 mm, and a low locking angle, e.g. 45 degrees, will then cause a play in the upper part of the horizontal locking system, which means that the locking element of the strip easily slides out of the locking groove. If the strip is straight or slopes upward it will be extremely difficult to lay the floor if the locking system is adapted to a curved strip.
[0041] One reason why the problem is difficult to solve is that the deflection of the strip is not known when the floor is being laid or when it has been taken up and is being laid again, which is one of the major advantages of the strip lock in comparison with glued joints. Consequently, it is not possible to solve the problem by adapting in advance the working measurements of the strip and/or the locking groove to the curvature of the strip, since the latter is unknown.
[0042] Nor is it preferred to solve this problem by using a wide strip, whose locking element has a higher locking surface with a larger locking angle, since a wide strip has the drawback of considerable material wastage in connection with the forming of the strip. The reason why the wider but more costly strip works better is mainly because the locking surface is substantially larger than the maximum strip bending and because the high locking angle only causes a marginally greater play which is not visible.
[0043] The strip-bending problems are reinforced by the fact that laminate flooring is subjected to unilateral moisture influence. The surface layer and the balancing layer do not co-operate fully, and this always gives rise to a certain amount of bulging. Concave upward bulging is the biggest problem, since this causes the joint edges to rise. The result is an undesirable joint opening between the boards in the upper side of the boards and high wear of the joint edges. Accordingly, it is desirable to provide a floorboard which in normal relative humidity is somewhat upwardly convex by biasing the rear balancing layer. In traditional, glued floors this biasing is not a problem, rather, it creates a desirable advantage. However, in a mechanically joined floor with an integrated strip lock the biasing of the balancing layer results in an undesirable drawback since the bias reinforces the imbalance of the strip and, consequently, causes a greater, undesirable backward bending of the strip. This problem is difficult to solve since the bias is an inherent quality of the balancing layer, and, consequently, cannot be eliminated from the balancing layer.
[0044] The invention is also based on a second insight which is related to the geometry of the joint. We have also discovered that a strip lock with a relatively deep tongue groove gives rise to greater undesirable bending of the strip. The reason behind this phenomenon is that the tongue groove, too, is unbalanced. Consequently, the tongue groove opens when, in a decrease of the RH, the balancing layer shrinks to a greater extent than the fibreboard part of the strip, causing the strip to bend downwards since the strip is an extension of the joint edge below the tongue groove.
[0045] According to a first aspect of the invention a locking system is provided of the type which is stated in the first paragraph but one of the description and which, according to the invention, is characterized in that the second joint edge, within an area (P) defined by the bottom of the tongue groove and the locking surface of the locking element, is modified with respect to the balancing layer.
[0046] Said area P, which is thus defined by the bottom of the tongue groove and the locking surface of the locking element, is the area which is sensitive to bending. If the strip bends within this area P, the position of the locking surface relative to the locking groove, and thus the properties of the joint, will be affected. Especially, it should be noted that this entire area P is unbalanced, since nowhere does the part of the balancing layer located in this area P have a coacting, balancing surface layer, neither in the tongue groove nor on the projecting strip. According to the invention, by modifying the balancing layer within this area P it is possible to change this unbalanced state in a positive direction, such that the undesirable strip-bending is reduced or eliminated.
[0047] The term “modified” refers to both (i) a preferred embodiment in which the balancing layer has been modified “over time”, i.e. the balancing layer has first been applied across the entire area P during the manufacturing process, but has then been subjected to modifying treatment, such as milling or grooving and/or chemical working, and (ii) variants in which the balancing layer at least across part of the area P has been modified “in space”, i.e. that the area P differs from the rest of the board with respect to the appearance/properties/structure of the balancing layer.
[0048] The balancing layer can be modified across the entire horizontal extent of the area P, or within only one or several parts thereof. The balancing layer can also be modified under the whole of the locking element or parts thereof. However, it may be preferable to keep the balancing layer intact under at least part of the locking element to provide support for the strip against the underlay.
[0049] According to a preferred embodiment, “modifying” means that the balancing layer is completely or partially removed. In one embodiment, the whole area P lacks a balancing layer.
[0050] In a second embodiment, there is no balancing layer at all within one or several parts of the area P. Depending on the type of balancing layer and the geometry of the joint system, it is, for example, possible to keep the whole balancing layer or parts thereof under the tongue groove.
[0051] In a third embodiment, the balancing layer is not removed completely; it is only reduced in thickness. The latter embodiment can be combined with the former ones. There are balancing layers where the main problems can be eliminated by partial removal of some layers only. The rest of the balancing layer can be retained and helps to increase the strength and flexibility of the strip. Balancing layers can also be specially designed with different layers which are adapted in such a way that they both balance the surface and can act as a support for the strip when parts of the layers are removed within one area of the rear side of the strip.
[0052] The modification can also mean a change in the material composition and/or material properties of the balancing layer.
[0053] Preferably, the modification can be achieved by means of machining such as milling and/or grinding but it could also be achieved by means of chemical working, heat treatment or other methods which remove material or change material properties.
[0054] The invention also provides a manufacturing method for making a moisture-stable strip-lock system. The method according to the invention comprises the steps of [0054] forming each floorboard from a body, [0055] providing the rear side of the body with a balancing layer, [0056] forming the floorboard with first and second joint edge portions, [0057] forming said first joint edge portion with [0058] a first joint edge surface portion extended from the upper side of the floorboard and defining a joint plane along said first joint edge portion, [0059] a tongue groove which extends into the body from said joint plane, [0060] a strip formed from the body and projecting from said joint plane and supporting at a distance from this joint plane an upwardly projecting locking element with a locking surface facing said joint plane, [0061] forming said second joint edge portion with [0062] a second joint edge surface portion extended from the upper side of the floorboard and defining a joint plane along said second joint edge portion, [0063] a tongue projecting from said joint plane for coaction with a tongue groove of the first joint edge portion of an adjoining floorboard, and [0064] a locking groove which extends parallel to and at a distance from the joint plane of said second joint edge portion and which has a downward opening and is designed to receive the locking element and cooperate with said locking surface of the locking element.
[0055] The method according to the invention is characterized by the step of working the balancing layer within an area defined by the bottom of the tongue groove and the locking surface of the locking element.
[0056] The adaptation or removal of part of the balancing layer in the joint system can be carried out in connection with the gluing/lamination of the surface layer, the body, and the balancing layer by displacing the balancing layer relative to the surface layer. It is also possible to carry out modifications in connection with the manufacture of the balancing layer so that the part which will be located adjacent to the locking system will have properties which are different from those of the rest of the balancing layer.
[0057] However, a very suitable manufacturing method is machining by means of milling or grinding. This can be carried out in connection with the manufacture of the joint system and the floorboards can be glued/laminated in large batches consisting of 12 or more floorboards.
[0058] The strip-lock system is preferably manufactured using the upper floor surface as a reference point. The thickness tolerances of the floorboards result in strips of unequal thickness since there is always a predetermined measurement from the top side of the strip to the floor. Such a manufacturing method results in tongue grooves of different depths in the rear side and a partial removal of a thin balancing layer cannot be performed in a controlled manner. The removal of the balancing layer should thus be carried out using the rear side of the floorboard as a reference surface instead.
[0059] It has also been an object to provide a cost-optimal joint which is also of high-quality by making the strip as narrow as possible and the tongue groove as shallow and as strong as possible in order both to reduce waste since the tongue can be made narrow and to eliminate as far as possible the situation where the tongue groove opens up and causes strip-bending as well as rising of the upper joint edge when the relative humidity changes.
[0060] Known strip-lock systems with a strip of fibreboard and a balancing layer are characterized in that the shallowest known tongue groove is 3.0 mm in a 7.2-mm-thick floorboard. The depth of the tongue groove is thus 0.42 times the thickness of the floor. This is only known in combination with a 10.0-mm-wide strip which thus has a width which is 1.39 times the floor thickness. All other such known strip joints with narrow strips have a tongue groove depth exceeding 3.6 mm and this contributes considerably to the strip-bending.
[0061] In order to fulfill the above-mentioned object a strip-lock system is provided which is characterized in that the tongue groove depth of the tongue groove and the width of the strip are less than 0.4 and 1.3 times the floor thickness respectively. This joint affords good joint properties and especially in combination with high rigidity of the tongue groove since it can be designed in such a way that as much material as possible is retained between the upper part of the tongue groove and the floor surface as well as between the lower part of tongue groove and the rear side of the floor while, at the same time, it is possible to eliminate the strip-bending problems as described above. This strip-lock system can be combined with one or more of the preferred embodiments which are disclosed in connection with the solution based on a modification of the balancing layer.
[0062] The opposite joint edge of the board is also unbalanced. In this case, the problems are not nearly as serious since the surface layer is not biased and the unbalanced part is more rigid. However, in this case, too, an improvement can be achieved by making the strip as thin as possible. This permits minimal removal of material in the locking groove part of the joint system, which in turn results in maximum rigidity in this unbalanced part.
[0063] According to the invention there is thus provided a strip-lock system having a joint geometry characterized in that there is a predetermined relationship between the width and thickness of the strip and the height of the locking element on the one hand and the floor thickness on the other. Furthermore, there is provided a minimum locking angle for the locking surface. All these parameters separately and in combination with each other and the above inventions contribute to the creation of a strip-lock system which can have high joint quality and which can be manufactured at a low cost.
BRIEF DESCRIPTION OF THE DRAWINGS
[0064] FIGS. 1 a - c show in three stages a downward angling method for mechanical joining of long sides of floorboards according to WO 94/26999.
[0065] FIGS. 2 a - c show in three stages a snap-action method for mechanical joining of short sides of floorboards according to WO 94/26999.
[0066] FIGS. 3 a and 3 b are a top view and a bottom view respectively of a floorboard according to WO 94/26999.
[0067] FIG. 4 shows three strip-lock systems available on the market with an integrated strip of fibreboard and a balancing layer.
[0068] FIG. 5 shows a strip lock with a small tongue groove depth and with a wide fibreboard strip, which supports a locking element having a large locking surface and a high locking angle.
[0069] FIG. 6 shows a strip lock with a large tongue groove depth and with a narrow fibreboard strip, which supports a locking element having a small locking surface and a low locking angle.
[0070] FIGS. 7 and 8 illustrate strip-bending in a strip lock according to FIG. 5 and FIG. 6 .
[0071] FIG. 9 shows the joint edges of a floorboard according to an embodiment of the invention.
[0072] FIGS. 10 and 11 show the joining of two floorboards according to FIG. 9 .
[0073] FIGS. 12 and 13 show two alternative embodiments of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0074] Prior to the description of preferred embodiments, with reference to FIGS. 5-8 , a detailed explanation will first be given of the background to and the impact of strip-bending.
[0075] The cross-sections shown in FIGS. 5 and 6 are hypothetical, unpublished cross-sections, but they are fairly similar to “Fiboloc™” in FIG. 4 a and “Uniclic” in FIG. 4 b . Accordingly, FIGS. 5 and 6 do not represent the invention. Parts which correspond to those in the previous Figures are in most cases provided with the same reference numerals. The design, function, and material composition of the basic components of the boards in FIGS. 5 and 6 are essentially the same as in embodiments of the present invention and, consequently, where applicable, the following description of FIGS. 5 and 6 also applies to the subsequently described embodiments of the invention.
[0076] In the embodiment shown, the floorboards 1 , 1 ′ in FIG. 5 are rectangular with opposite long sides 4 a , 4 b and opposite short sides 5 a , 5 b . FIG. 5 shows a vertical cross-section of a part of a long side 4 a of the board 1 , as well as a part of a long side 4 b of an adjoining board 1 ′. The body of the board 1 can be composed of a fibreboard body 30 , which supports a surface layer 32 on its front side and a balancing layer 34 on its rear side. A strip 6 formed from the body and the balancing layer of the floorboard and supporting a locking element 8 constitutes an extension of the lower tongue groove part 36 of the floorboard 1 . The strip 6 is formed with a locking element 8 , whose operative locking surface 10 cooperates with a locking groove 14 in the opposite joint edge 4 b of the adjoining board 1 ′ for horizontal locking of the boards 1 , 1 ′ transversely of the joint edge (D 2 ). The locking element 8 has a relatively large height LH and a high locking angle A. The upper part of the locking element has a guiding part 9 which guides the floorboard to the correct position in connection with angling. The locking groove 14 has a larger width than the locking element 8 , as is evident from the Figures.
[0077] For the purpose of forming a vertical lock in the direction D 1 , the joint edge portion 4 a exhibits a laterally open tongue groove 36 and the opposite joint edge portion 4 b exhibits a tongue 38 which projects laterally from a joint plane F and which in the joined position is received in the tongue groove 36 .
[0078] In the joined position according to FIG. 5 , the two adjoining, upper joint edge surface portions 41 and 42 of the boards 1 , 1 ′ define this vertical joint plane F.
[0079] The strip 6 has a horizontal extent W (=strip width) which can be divided into: (a) an inner part with a horizontal extent D (locking distance) which is defined by the joint plane F and a vertical line through the lower part of the locking surface 10 , as well as (b) an outer part with a horizontal extent L (the width of the locking element). The tongue groove 36 has a horizontal tongue groove depth G measured from the joint plane F and inwards towards the board 1 to a vertical limiting plane which coincides with the bottom of the tongue groove 36 . The tongue groove depth G and the extent D of the locking distance together form a joint part within an area P consisting of components forming part of the vertical lock D 1 and the horizontal lock D 2 .
[0080] FIG. 6 shows an embodiment which is different from the embodiment in FIG. 5 in that the tongue groove depth G is greater, and the strip width W, the height LH, and the locking angle A of the locking surface are all smaller. However, the size of the area P is the same in the embodiments in FIGS. 5 and 6 .
[0081] Reference is now made to FIGS. 7 and 8 , which show strip-bending in the embodiments in FIGS. 5 and 6 respectively. The relevant part of the curvature which may cause problems is the area P, since a curvature in the area P results in a change of position of the locking surface 10 . Since the area P has the same horizontal extent in both embodiments, all else being equal, the strip-bending at the locking surface 10 will be of the same magnitude despite the fact that the strip length W is different.
[0082] The large locking surface 10 and the large locking angle A in FIG. 5 will not cause any major problems in FIG. 7 , since the greater part of the locking surface 10 is still operative. The high locking angle A contributes only marginally to increased play between the locking element 8 and the locking groove 14 . In FIG. 8 , however, the large tongue groove depth G as well as the small locking surface 10 and the low locking angle A 2 create major problems. The strength of the locking system is considerably reduced and the play between the locking element 8 and the locking groove 14 increases substantially and causes joint openings in connection with tensile stress. If the play of the boards is adapted to a sloping strip at the time of manufacture it may prove impossible to lay the boards if the strip 6 is flat or bent upwards.
[0083] We have realized that the strip-bending is a result of the fact that the joint part P is unbalanced and that the shape changes in the balancing layer 34 and the fibreboard part 30 of the strip are not the same when the relative humidity changes. In addition, the bias of the balancing layer 34 contributes to bending the strip 6 backwards/downwards.
[0084] The deciding factors of the strip-bending are the extent of the locking distance D and the tongue groove depth G. The appearance of the tongue groove 36 and the strip 6 also has some importance. A great deal of material in the joint portion P makes the tongue groove and the strip more rigid and counteracts strip-bending.
[0085] FIGS. 9-11 show how a cost-efficient strip-lock system with a high quality joint can be designed according to the invention. FIG. 9 shows a vertical cross-section of the whole board 1 seen from the short side, with the main portion of the board broken away. FIG. 10 shows two such boards 1 , 1 ′ joined at the long sides 4 a , 4 b . FIG. 11 shows how the long sides can be angled together in connection with laying and angled upward when being taken up. The short sides can be of the same shape.
[0086] In connection with the manufacture of the strip-lock system, the balancing layer 34 has been milled off both in the entire area G under the tongue groove 36 and across the entire rear side of the strip 6 across the width W (including the area L under the locking element 8 ). The modification according to the invention in the form of removal of the balancing layer 34 in the whole area P eliminates both the bias and the strip-bending resulting from moisture movement.
[0087] In order to save on materials, in this embodiment the width W of the strip 6 has been reduced as much as possible to a value which is less than 1.3 times the floor thickness.
[0088] The tongue groove depth G of the tongue groove 36 has also been limited as much as possible both to counteract undesirable strip-bending and to save on materials. In its lower part, the tongue groove 36 has been given an oblique part 45 in order to make the tongue groove 36 and the joint portion P more rigid.
[0089] In order to counteract the effect of the strip-bending and to comply with the strength requirements, the locking surface has a minimum inclination of at least 45 degrees and the height of the locking element exceeds 0.1 times the floor thickness T.
[0090] In order to make the locking-groove part of the joint system as stable as possible, the thickness SH of the strip in an area corresponding to at least half the locking distance D has been limited to a maximum of 0.25 times the floor thickness T. The height LH of the locking element has been limited to 0.2 times the floor thickness and this means that the locking groove 14 can be formed by removing a relatively small amount of material.
[0091] In more basic embodiments of the invention, only the measure “modification of balancing layer” is used.
[0092] FIG. 12 shows an alternative embodiment for eliminating undesirable strip-bending. Here, the balancing layer 34 has been completely removed within the area P (including area G under the tongue groove). However, under the locking element 8 in the area L the balancing layer is intact in the form of a remaining area 34 ′, which advantageously constitutes a support for the locking element 8 against the subfloor. Since the remaining part 34 ′ of the balancing layer is located outside the locking surface 10 it only has a marginal, if any, negative impact on the change of position of the locking surface 10 in connection with strip-bending and thus changes in moisture content.
[0093] Within the scope of the invention there are a number of alternative ways of reducing strip-bending. For example, several grooves of different depths and widths can be formed in the balancing layer within the entire area P and L. Such grooves could be completely or partially filled with materials which have properties that are different from those of the balancing layer 34 of the floorboard and which can contribute to changes in the properties of the strip 6 with respect to, for example, flexibility and tensile strength. Filling materials with fairly similar properties can also be used when the objective is to essentially eliminate the bias of the balancing layer.
[0094] Complete or partial removal of the balancing layer P in the area P and refilling with suitable bonding agents, plastic materials, or the like can be a way of improving the properties of the strip 6 .
[0095] FIG. 13 shows an embodiment in which only part of the outer layer of the balancing layer has been removed across the entire area P. The remaining, thinner part of the balancing layer is designated 34 ″. The part 34 ′ has been left intact under the locking element 8 in the area L. The advantage of such an embodiment is that it may be possible to eliminate the major part of the strip-bending while a part ( 34 ″) of the balancing layer is kept as a reinforcing layer for the strip 6 . This embodiment is particularly suitable when the balancing layer 34 is composed of different layers with different properties. The outer layer can, for example, be made of melamine and decoration paper while the inner layer can be made of phenol and Kraft paper. Various plastic materials can also be used with various types of fibre reinforcement. Partial removal of layers can, of course, be combined with one or more grooves of different depths and widths under the entire joint system P+L. The working from the rear side can also be adapted in order to increase the flexibility of the strip in connection with angling and snap action.
[0096] Two main principles for reducing or eliminating strip-bending have now been described namely: (a) modifying the balancing layer within the entire area P or parts thereof, and (b) modifying the joint geometry itself with a reduced tongue groove depth and a special design of the inner part of the tongue groove in combination. These two main principles are usable separately to reduce the strip-bending problem, but preferably in combination.
[0097] According to the invention, these two basic principles can also be combined with further modifications of the joint geometry (c) which are characterized in that:
[0098] The strip is made narrow preferably less than 1.3 times the floor thickness;
[0099] The inclination of the locking surface is at least 45 degrees;
[0100] The height of the locking element exceeds 0.1 times the floor thickness and is less than 0.2 times the floor thickness;
[0101] The strip is designed so that at least half the locking distance has a thickness which is less than 0.25 times the floor thickness.
[0102] The above embodiments separately and in combination with each other and the above main principles contribute to the provision of a strip-lock system which can be manufactured at a low cost and which at the same affords a high quality joint with respect to laying properties, disassembly options, strength, joint opening, and stability over time and in different environments.
[0103] Several variants of the invention are possible. The joint system can be made in a number of different joint geometry where some or all of the above parameters are different, particularly when the purpose is to give precedence to a certain property over the others.
[0104] Applicant has considered and tested a large number of variants in the light of the above: “smaller” can be changed to “larger”, relationships can be changed, other radii and angles can be chosen, the joint system on the long side and the short side can be made different, two types of boards can be made where, for example, one type has a strip on both opposite sides while the other type has a locking groove on the corresponding sides, boards can be made with strip locks on one side and a traditional glued joint on the other, the strip-lock system can be designed with parameters which are generally intended to facilitate laying by positioning the floorboards and keeping them together until the glue hardens, and different materials can be sprayed on the joint system to provide impregnation against moisture, reinforcement, or moisture-proofing, etc. In addition, there can be mechanical devices, changes in the joint geometry and/or chemical additives such as glue which are aimed at preventing or impeding, for example, a certain type of laying (angling or snap action), displacement in the direction of the joint, or a certain way of taking up the floor, for example, upward angling or pulling along the joint edge.
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A locking system for mechanical joining of floorboards constructed from a body, a rear balancing layer and an upper surface layer. A strip, which is integrally formed with the body of the floorboard and which projects from a joint plane and under an adjoining board has a locking element which engages a locking groove in the rear side of the adjoining board. The joint edge provided with the strip is modified with respect to the balancing layer, for example by means of machining of the balancing layer under the strip, in order to prevent deflection of the strip caused by changes in relative humidity. Also, a floorboard provided with such a locking system, as well as a method for making floorboards with such a locking system.
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RELATED APPLICATIONS
[0001] This application claims the benefit of prior co-pending U.S. patent application Ser. No. 10/923,889, Paving System Using Arrays of Vertically Interlocking Paving Blocks, by Weiss et al., filed Aug. 24, 2004, incorporated herein by reference.
STATEMENT OF GOVERNMENT INTEREST
[0002] Under paragraph 1(a) of Executive Order 10096, the conditions under which this invention was made entitle the Government of the United States, as represented by the Secretary of the Army, to the entire right, title and interest therein of any patent granted thereon by the United States. This patent and related ones are available for licensing. Contact Phillip Stewart at 601 634-4113.
BACKGROUND
[0003] Heretofore, providing a lateral attachment between laterally adjacent elements in a paving system has been a problem. U.S. Pat. No. 5,054,253, Rigid Grating Mat with Unidirectional Elements, to Bedics, Oct. 8, 1991, describes a system for building a mat that has separate plank-like elements that are joined laterally by a tongue and groove construction. This makes for a complicated extrusion that is difficult to construct and is easily extended laterally only in one direction.
[0004] U.S. Pat. No. 5,429,451, Grid Matrix System Including Interconnected Revetment Blocks, to Pettee, Jul. 4, 1995, describes a grid matrix system that has interconnected revetment blocks. These square or hexagonal blocks have alternate recesses and locking protrusions (or ears). A disadvantage of this construction is that it can be easily vandalized because the individual blocks or elements can be lifted vertically. Further, casting the units in concrete presents problems because the ears and edges of the locking recesses can be relatively easily broken.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1A shows a plan view of a bottom half of embodiments of the present invention as used in a small array.
[0006] FIG. 1B depicts a perspective view of a single unit used in the array of FIG. 1 .
[0007] FIG. 2 depicts how the individual unit of FIG. 1B is inverted onto the array of FIG. 1A to effect an embodiment of the present invention.
[0008] FIG. 3 depicts a top view of three interlocking units inverted over one edge of the array of FIG. 1A as used in an embodiment of the present invention.
[0009] FIG. 4 shows a side view of the relationship of vertically interlocking units of FIG. 1B , showing the edge of the array of FIG. 1 A through 1 - 1 of FIG. 3 .
[0010] FIG. 5 shows the array of FIG. 1A with a connecting means embedded therein.
[0011] FIG. 6 shows how staggering patterns of the array of FIG. 5 permits interlocking of inverted arrays over un-inverted arrays to effect an embodiment of the present invention.
[0012] FIG. 7 illustrates a way to change direction of a pathway using top portions of the arrays of FIG. 5 for illustrative purposes only.
[0013] FIG. 8 depicts an alternative configuration using hexagon and diamond shapes to effect an embodiment of the present invention.
[0014] FIG. 9 illustrates an alternative configuration using squares and right triangle shapes to effect an embodiment of the present invention.
DETAILED DESCRIPTION
[0015] Embodiments of the present invention comprise in part employing a component having a first section with first sides parallel to a first plane containing a first bearing surface and a first thickness in a second plane orthogonal to the first plane, the first thickness of a dimension less than that of any of the first sides and a second section having second sides parallel to both the first plane and a second plane containing a second bearing surface, the second plane parallel to the first plane, the second section contacting the first section uniformly along a part of the first plane, the second section oriented to the first section such that the second sides are contained entirely within the perimeter formed by the first sides.
[0016] One embodiment employs a component having the first sides form a first square and the second sides form a second square set at about a 45° angle to the first square, the second square having sides of a length approximately 0.707 that of the first sides.
[0017] Another embodiment employs a component having the first sides form a hexagon and the second sides form a diamond with the long axis of the diamond extending in a line joining the center of two parallel sides of the hexagon and the short axis of the diamond chosen to be the same width as that formed by two parallel first sides of the hexagon.
[0018] Another embodiment employs a component having the first sides form a square and the second sides form a single right triangle along two adjacent sides of the square.
[0019] In select embodiments of the present invention, employed components may have first and second sections fabricated such that the first and second sections are incorporated inseparably in the component. In select embodiments of the present invention, employed components may have at least one of the first and second sections formed of a lamination of at least two layers. In select embodiments of the present invention, employed components may have at least one of the layers made of a material flexible under compression.
[0020] An embodiment of the present invention may employ an array of any of the components above comprising a first set of four components, each component arranged in a plane to abut a first component along a first axis in that plane and a second component arranged along a second axis in that plane, the second axis orthogonal to the first axis, and a second set of four components arranged as above, the second four components inverted and arranged to interlock vertically with the first four components.
[0021] In select embodiments of the present invention, a configuration of arrays as above may be employed as a plurality of the arrays abutting one to another and arranged to cover a pre-specified area. In select embodiments of the present invention, the above configuration further may be employed as partial components for forming finished edges of the configuration, such as a component cut in half.
[0022] In select embodiments of the present invention, employed configurations may be arranged to form a pathway.
[0023] In select embodiments of the present invention, employed arrays may be joined by flexible means incorporated between the first and second sections during fabrication and extending in a plane approximately parallel to each of the first and second sections so as to permanently connect and position each of the four components in an array. The flexible means may employ material selected from the group consisting essentially of a mesh, a fabric, roving, a web-perforated fabric, a wire mesh, an elastomer, and combinations thereof.
[0024] In select embodiments of the present invention, a plurality of employed connected arrays abutting one to another may be arranged to cover a pre-specified area, such a road or pathway. In select embodiments of the present invention, employed configurations may comprise partial components, such as components cut in half, for forming finished edges of the configuration, e.g., a road or pathway.
[0025] Select embodiments of the present invention provide a method for covering a pre-specified area, comprising leveling the pre-specified area; arranging any of the employed components as described above in an array as described above, abutting a number of arrays to cover the pre-specified area in a first plane, and inverting a second configuration of pre-specified like arrays over the first configuration such that the second configuration interlocks vertically with the first configuration and adding partial components, such as components cut in half, for forming finished edges of the interlocked configurations.
[0026] In select embodiments of the present invention, a method employs components comprising first sides forming a first square, second sides forming a second square set at about a 45° angle to the first square, the second square having sides of a length approximately 0.707 that of the first sides.
[0027] In select embodiments of the present invention, a method employs components comprising first sides forming a hexagon and second sides forming a diamond with the long axis of the diamond extending in a line joining the center of two parallel sides of the hexagon and the short axis of the diamond chosen to be the same width as that formed by two parallel first sides of the hexagon.
[0028] In select embodiments of the present invention, a method employs components comprising first sides forming a square and second sides forming a single right triangle along two adjacent sides of the square.
[0029] In select embodiments of the present invention, a method employs a component comprising first and second sections fabricated such that the first and second sections are incorporated inseparably in the employed component.
[0030] In select embodiments of the present invention, a method employs a component in which at least one of the first and second sections is formed of a lamination of at least two layers. In select embodiments of the present invention, at least one of the layers may be constructed of a material flexible under compression.
[0031] Select embodiments of the present invention provide a method of fabricating components for a vertically interlocking configuration, comprising providing a first mold to form a first section as described above, providing a second mold to form a second section as described above; pouring a fluid mixture of a first material into the first mold to be at least partially hardened in the mold as the first section; permitting the first mixture to at least partially harden in the first mold; placing a second mold over the first at least partially hardened mixture in a pre-specified orientation; pouring a fluid mixture of a second material into the second mold to be hardened in the mold; upon hardening of the first and second mixtures to a pre-specified level, removing both molds and trimming the component as necessary.
[0032] In select embodiments of the present invention, the above method of fabricating may also comprise arranging at least four like components in a pre-specified array and adding a connecting means over at least a portion of each of the first sections of each before placing the second mold so that the connecting means is embedded in each component, both connecting and orienting the components in an array. The employed connecting means may comprise material selected from the group consisting essentially of a mesh, a fabric, roving, a web-perforated fabric, a wire mesh, an elastomer, and combinations thereof. In select embodiments of the present invention, fabrication may employ the same material for the first and second sections.
[0033] In select embodiments of the present invention, the employed sections may be a mixture containing at least some Portland cement. In select embodiments of the present invention, a method may employ different materials for fabricating the first and second sections. In select embodiments of the present invention, a method of fabrication may employ layers of different materials for at least one of the first and second sections such that at least one of the first and second sections is a laminate of at least two layers. In select embodiments of the present invention, at least one material flexible in compression may be employed in at least one of the layers.
[0034] Select embodiments of the present invention may be employed to form a continuous paved traffic way without having to laterally interlock a paving block with its neighbor. One employed embodiment, suitable for quickly forming a pavement, is termed PORTAPAVE™.
[0035] This is achieved in one aspect by employing a paving mat that comprises an array of paving blocks, and means for connecting the paving blocks together in the array. Each paving block includes a bottom part having a first shape, and a top part having a second shape. Neighboring top parts of blocks form a cavity between them having the same shape as the top part of a block so that a second similar array of paving blocks can be turned upside down and overlapped and interlocked with the first array of paving blocks to make a two-layered block paving unit.
[0036] Also provided in an embodiment of the present invention is a method of making a paving mat that comprises: providing a first array of the above described paving blocks and providing means for connecting the paving blocks together in the array. In one embodiment, since neighboring top parts of blocks form a cavity between them having the same shape as the convex top part of a block, in one method a second similar array of paving blocks is turned upside down, thus overlapping and interlocking with the first array of paving blocks to make a two-layered block paving unit.
[0037] Embodiments of the present invention, unlike conventional “articulated concrete mats,” employ overlapping vertically interlocking arrays thus maintaining integrity of the mat. In one embodiment, placement of the employed blocks involves staggering the positions of the blocks so that a block in an upper layer partly covers the intersection of the contacting blocks in the lower layer. This reduces the chance for vegetation to grow through the paving unit. In one embodiment the means for connecting the employed paving blocks together in an array is an opaque material, such as a fabric or an elastomer. This opaque material blocks light and either kills vegetation or confines it.
[0038] In one embodiment runoff water can be controlled by inserting a mesh fabric between layers or providing drain holes in the connecting means. In one embodiment, employed paving units may be moved by lifting upper layers (mats), so that the lower layers (mats) may be separated. In embodiments to be installed permanently, a layer of mortar may be spread over the lower layer and the upper layers bonded thereto. Embodiments of the present invention may facilitate a change in the direction of the pavement by staggering the employed layers (mats) laterally so the track “curves” as needed.
[0039] Embodiments of the present invention employ arrays of vertically interlocking units that may be employed in applications otherwise suitable for conventional individual paving blocks. In embodiments of the present invention, the employed connecting means prevent individual blocks from moving laterally. In conventional systems this is accomplished by attaching the connecting means from one array of blocks to adjacent arrays. A cavity formed between neighboring top parts of the un-inverted units has the same shape as a unit's top section so that a second similar array of units may be inverted and interlocked with the un-inverted array to make a two-layered paving mat, for example. Thus, in embodiments of the present invention, interlocking an un-inverted array with an inverted array of units obviates the need for any “holding” means.
[0040] In embodiments of the present invention, arrays of vertically interlocking units may be employed as “portable” pathways, e.g., pedestrian or vehicle thoroughfares that may be temporary or permanent. Embodiments of the present invention may also be employed on fords where it is necessary to anchor the units on a slope. Embodiments of the present invention may also be used to prevent stream bank erosion, as a base for a waterproof liner, or as a weed-free break to limit or control grass fires.
[0041] Refer to FIG. 1A showing a rectangular array 100 of four abutting units 110 each comprising a bottom section 101 and a smaller raised top section 102 comprising an integral part of a unit 110 . The units 110 may be top and bottom portions of what are termed “pavers” in the construction industry. The units 110 may be constructed of moldable materials such as Portland cement and its variations, any of a variety of plastics, fiberglass, steel, carbon or KEVLAR® fibers (para-aramids), and combinations of these. The two sections 101 , 102 may be formed in a mold as a single entity such that they are not individual parts that may be separated. In the embodiment shown in FIG. 1A , the perimeter of the top section 102 is defined by drawing a line from the middle of a side of the bottom section 101 diagonally across to the middle of an adjacent side of the bottom section 101 and continuing around the sides until the shape of the top section 102 is obtained, as seen in the top (plan) view of FIG. 1A . In one embodiment of the present invention, all such units 110 are identical and symmetrical with respect to top 102 and bottom 101 sections. The symmetry enables the use of like units 110 by inverting an array 100 of units 110 over an un-inverted array 100 of units 110 such that each of the top sections 102 mate in the space created in the un-inverted array 100 where four corners of the units 110 of the un-inverted array 100 come together.
[0042] Refer to FIG. 1B , a perspective view of an employed unit 110 shown in a top view in the array 100 in FIG. 1A . This unit 110 is essentially a “small box-on-large box” arrangement with the top section (small box) 102 being arranged so that each of its corners are at the center of the sides of the bottom section (large box) 101 , resulting in a small box having sides in the plane parallel to the bottom section (large box) of approximately 0.707 that of the sides of the bottom section 101 . Each of the sections 101 , 102 is square in the plane at which they contact and set at approximately 45° with respect to each other in that plane. The thickness, t 1 and t 2 , of each of the employed sections 101 , 102 , respectively is chosen according to structural and esthetic requirements of the user and need not be the same for each section 101 , 102 .
[0043] Refer to FIG. 2 . For clarity, an employed single inverted unit 110 is shown as a shaded area over the array 100 of FIG. 1A in a configuration 200 that highlights the “interlocking” feature of the present invention. The dark shaded portion represents a top section 102 for the inverted unit 110 . The employed un-inverted array 100 of FIG. 1A is shown in FIG. 2 with a perimeter of dashed lines since this un-inverted portion will not be visible in any installation of this embodiment of the present invention, being covered by inverted units 110 that will be placed outwardly in the direction of the arrows 201 . The interlocking occurs at each intersection of the corners of the un-inverted units 110 . At the edges of an intended installation of multiple employed arrays 100 , the inverted units 110 may be cut in half diagonally to make a smooth edge that matches the edges of the un-inverted array 100 on bottom. Alternatively, “half-units” (not shown separately) may be molded at the factory for forming portions of the edges of installations (e.g., pathways or thoroughfares).
[0044] Refer to FIGS. 3 and 4 . A configuration 310 of three employed inverted abutting units 110 is placed over an edge 301 of the employed array 100 of FIG. 1A to further illustrate the interlocking feature of an embodiment of the present invention. An end (edge) view of the resultant configuration as taken with a vertical cut through 1 - 1 of FIG. 3 is shown in FIG. 4 . The “half-squares” of the employed top sections 102 cover the intersection between the two employed abutting un-inverted units 110 below the edge insuring a “double thickness” of coverage above each intersection of the un-inverted units 110 . Conversely, where the employed inverted units 110 abut is at the middle of one of the un-inverted units.
[0045] Refer to FIG. 5 . In one embodiment of the present invention an employed means 501 for connecting together an employed small array 100 of units 110 , such as a web of perforated fabric or a wire mesh of metal or suitable roving, is provided in a configuration 500 for ease in placing and maintaining spacing of the units 110 should one wish to make a permanent installation with mortar and grouting between employed units 110 . The spacing, d, may be adjusted to accommodate performance and esthetic requirements of the user.
[0046] FIG. 6 shows how staggering the pattern of employed inverted units 110 over employed un-inverted units 110 enables interlocking of the configuration 600 and keeps the units 110 from moving laterally with respect to each other. Thus, the units 110 may be kept together without having to manually attach them to each other, forming a two-layered configuration that may be used for such applications as a pathway, a thoroughfare, a ford, or for stabilizing embankments. For a permanent arrangement, embodiments of the present invention may be provided with a spacing to enable mortar or grout to be placed between neighboring units 110 , although they may be useful as installed with only the mechanical interlocking described above. Since individual units 110 cannot be lifted from an installation, it is difficult for vandals to damage the installation by removing units 110 . For illustrative purposes, FIG. 6 also shows a single “half-block” 601 as it may be used on an edge of a pathway or pavement.
[0047] Refer to FIG. 7 , a simplified representation of the employed units 110 of FIG. 1A as arranged in a manner that enables changing direction to establish a desired pathway 701 that results in the configuration 700 . The representation of FIG. 7 is illustrative only, demonstrating that pathways may be made in various configurations enabling changing of direction. For illustrative purposes, FIG. 6 shows a single “half-block” 601 as it may be used on an edge of a pathway to provide a smooth edge to the configuration 700 . FIG. 7 is for illustrative purposes only and depicts only the inverted units 110 with the un-inverted units 110 implied as being installed under the inverted units 110 .
[0048] The employed units 110 may be manufactured in a variety of ways. For example, in one embodiment, bottom sections 101 may be made by filling a first mold or form with a self-hardening mixture such as a Portland cement-based concrete. A connecting means 501 , such as web-perforated fabric or metal wire mesh, may be placed over the uncured mixture in the first form and a second form placed over the connecting means 501 to establish the top section 102 . An additional layer of mixture is cast over the connecting means 501 such that the second mixture bonds to the first mixture through perforations in the connecting means 501 .
[0049] A second way of manufacturing employed units 110 is to pre-cast the top 102 and bottom 101 sections and bond or attach them to opposite sides of the connecting means 501 .
[0050] It is obvious that many modifications and variations of the present invention are possible in light of the above teachings. The basis for getting the employed inverted and un-inverted units 110 to interlock is to use a “regular tessellation” on each of the top and bottom surfaces of the unit 110 . The “large box-small turned box” combination of an embodiment of the present invention is two square tessellations 101 , 102 with the smaller “box” 102 tessellation on the top of the “layer” of units 110 placed on the bottom and rotated 45 degrees with a grid spacing, or side length, that is 0.707 times that of the larger “box” 101 tessellation. Another usable combination would be triangles, but with triangles the orientation of the base and apex of the triangle is important since adjacent triangles are oriented in opposite directions in a regular tiling of triangles. There are exactly three regular tessellations composed of regular polygons tiling a plane. They are hexagons, squares and triangles.
[0051] Refer to FIG. 8 for an example of hexagon sections 810 employed in an array 800 . The bottom section 801 of this array is a hexagon while the top section 802 is a symmetric “diamond” with the long axis of the diamond-shaped top section 802 extending in a line joining the center of two parallel sides of the hexagon of the bottom section 801 and the short axis of the diamond-shaped top section 802 chosen to be the same width as a side of the hexagon-shaped bottom section 802 . The employed array 800 of hexagon-shaped units 810 is also amenable to connection of individual units in small arrays, using a mesh or fabric, such as the four-unit array 500 of FIG. 5 . These small connected arrays, such as array 500 of FIG. 5 , may be connected with or without spacing, d, for mortar or grouting. Unlike the “small box-large box” arrangement of FIG. 1 , the “interlocking” section, i.e., the diamond-shaped top section 802 of the bottom layer of the hexagon array 800 , is exposed in the top layer of the array 800 . Thus, the hexagon array 800 may be chosen for other reasons, such as esthetics.
[0052] Refer to FIG. 9 . A configuration involves overlapping employed units 910 that are squares with an employed raised right triangle 902 covering half of one side of each of the units 910 , leaving a like right triangle 901 that is not raised on the other half of that side of the unit 910 . The configuration of FIG. 9 may consist of employed arrays 900 of individual units 910 each having one raised right triangle section 902 on one side or, alternatively rather than having four individual units 910 making an array 900 , a single large square may be fabricated as the array 900 with four raised right triangles 902 formed on the single large square comprising the array 900 . This alternative “large square” array 900 with four integral raised right triangles 902 on one side would have the benefit of not needing a mesh or other means to hold together the units 910 and would eliminate four seams, two of which are shown between the arrows 903 so that overlapping inverted arrays 900 each would have fewer portions where seams overlapped as compared to using individual units 910 , each with only one raised triangle 902 . To minimize the number of seams exposed, an inverted four-unit configuration 900 could overlap a single small square as indicated by the arrow 904 or overlap half of a bottom layer as indicated along the line represented by the arrow 903 .
[0053] The easiest interlocking units 110 , 810 , 910 to fabricate and install are those involving different sized squares, as described above for the array of FIGS. 1A and 5 , and a combination of squares with raised right triangles on half of one side as depicted in FIG. 9 . The most practical interlocking system may be the small box-large box combination of FIGS. 1A and 5 . It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as described.
[0054] Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures.
[0055] The abstract is provided to comply with the rules requiring an abstract, which will allow a searcher to quickly ascertain the subject matter of the technical disclosure of any patent issued from this disclosure. 37 CFR § 1.72(b). Any advantages and benefits described may not apply to all embodiments of the invention.
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A method for fabricating and forming a continuous covered area, such as a sidewalk or patio, employing vertically interlocking tessellated components. One embodiment, termed PORTAPAVE™, achieves this interlocking via an array of uniquely configured two-sectioned pavers. Each paver has a first section of a first shape and a second section of a second shape impressed upon the first section and bonded together. In one embodiment, first sections of pavers are installed in a bottom layer to form a cavity between them having the same shape as the second section of a paver that is inverted onto the pavers of the bottom layer, thus providing a top layer. Each inverted paver in this top layer is fitted to interlock in that cavity formed between the un-inverted pavers in the bottom layer.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation and claims the priority benefit of U.S. patent application Ser. No. 14/633,019 filed Feb. 26, 2015, issuing as U.S. Pat. No. 9,741,022, which claims the priority benefit of U.S. provisional application 61/945,053 filed Feb. 26, 2014, the disclosures of which are incorporated herein by reference.
BACKGROUND
Field of the Invention
[0002] The present invention generally relates to web services. More specifically, the present invention concerns parental controls.
Description of the Related Art
[0003] Families often separate to enjoy different activities while attending popular attractions such as theme parks, cruise ships, stadiums, sporting venues, and resorts. Parents understandably want to monitor, restrict, or grant permission to their children when they want to view or participate in age or content restricted activities such as watching shows, riding rides, or watching digital content when they are not physically present with their children. Absent being physically present or having some other chaperone, there is no way to ensure proper supervision and restrictions while granting children reasonable freedom and separation.
[0004] There is a need in the art for an improved methodology for parents to monitor and grant or deny permission to their children when they want to access content or activities while physically separated from their parents.
SUMMARY OF THE PRESENTLY CLAIMED INVENTION
[0005] In a first claimed embodiment of the present invention, a method for controlling access to entitlements is disclosed. An entitlement for a first user is detected. An authorization message is then sent to a second user having control of entitlement access for the first user. Authorization for the first user to enjoy the entitlement is then received from the second user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 illustrates a system for increasing customer engagement, including redeeming user entitlements.
[0007] FIG. 2 is a method for redeeming entitlement rights.
[0008] FIG. 3 illustrates an exemplary computing system that may be utilized to implement one or more embodiments of the present invention.
DETAILED DESCRIPTION
[0009] The present invention includes a web service platform to enable the user to remotely authorize a different person's access to content or services when not in the presence of the person requesting access. Mobile and web-based clients enable application users to automatically request authorization, grant or deny access.
[0010] FIG. 1 illustrates a system 100 for increasing customer engagement, including redeeming user entitlements. The system 100 of FIG. 1 includes an ecosystem of data sources 105 such as mobile devices 110 , point-of-sale (POS) or point-of-entry/-exit (POE) terminals 115 , and databases 120 . Communicatively coupled to data sources 105 are back-end application servers 125 . In system 100 , application servers 125 can ingest, normalize and process data collected from mobile devices 110 and various POS or POE terminals 115 . Types of information gathered from data sources 105 and processed by back-end application servers 125 are generally inclusive of identity (e.g., user profiles, CRM data, entitlements, demographics, reservation systems and social media sources like Pintrest and Facebook), proximity (e.g., GPS and beacons), and time (e.g., schedules, weather, and queue length).
[0011] Mobile devices 110 can execute an application on a user mobile device that shares customer engagement data such as current and prior physical locale within a venue as well as wait times and travel times (e.g., how long was a customer at a particular point in a venue and how long did it take the customer to travel to a further point in a venue). Mobile devices 110 are inclusive of wearable devices. Wearable devices (or ‘wearables’) are any type of mobile electronic device that can be worn on the body or attached to or embedded in clothes and accessories of an individual. Processors and sensors associated with a wearable can gather, process, display, and transmit and receive information.
[0012] POS data may be gathered at a sales terminal 115 that may interact with a mobile or wearable device 110 to track customer purchase history at a venue or preference for engagement at a particular locale within the venue. POE terminals 115 may provide data related to venue traffic flow, including entry and exit data that can be inclusive of time and volume. POE terminals 115 may likewise interact with mobile and wearable devices 110 .
[0013] Historical data may also be accessed at databases 120 as a part of the application server 125 processing operation. The results of a processing or normalization operation may likewise be stored for later access and use. Processing and normalization results may also be delivered to front-end applications (and corresponding application servers) that allow for the deployment of contextual experiences and provide a network of services to remote devices as is further described herein.
[0014] The present system 100 may be used with and communicate with any number of external front-end devices 135 by way of communications network 130 . Communication network 130 may be a local, proprietary network (e.g., an intranet) and/or may be a part of a larger wide-area network. Communication network 130 may include a variety of connected computing device that provide one or more elements of a network-based service. The communications network 130 may include actual server hardware or virtual hardware simulated by software running on one or more actual machines thereby allowing for software controlled scaling in a cloud environment.
[0015] Communication network 130 allows for communication between data sources 105 and front-end devices 135 via any number of various communication paths or channels that collectively make up network 130 . Such paths and channels may operate utilizing any number of standards or protocols including TCP/IP, 802.11, Bluetooth, GSM, GPRS, 4G, and LTE. Communications network 130 may be a local area network (LAN) that can be communicatively coupled to a wide area network (WAN) such as the Internet operating through one or more network service provider.
[0016] Information received and provided over communications network 130 may come from other information systems such as the global positioning system (GPS), cellular service providers, or third-party service providers such as social networks. The system 100 can measure location and proximity using hardware on a user device (e.g., GPS) or collect the data from fixed hardware and infrastructure such as Wi-Fi positioning systems and Radio Frequency ID (RFID) readers. An exemplary location and proximity implementation may include a Bluetooth low-energy beacon with real time proximity detection that can be correlated to latitude/longitude measurements for fixed beacon locations.
[0017] Additional use cases may include phone-based, GPS, real-time location (latitude/longitude) measurements, phone geo-fence-real time notifications when a device is moving into or out of location regions, Wi-Fi positioning involving user location detection based on Wi-Fi signal strength (both active or passive), RFID/Near Field Communication (NFC), and cellular tower positioning involving wide range detection of user device location, which may occur at the metro-level.
[0018] Front-end devices 135 are inclusive of kiosks, mobile devices, wearable devices, venue devices, captive portals, digital signs, and POS and POE devices. It should be noted that each of these external devices may be used to gather information about one or more consumers at a particular location during a particular time. Thus, a device that is providing information to a customer on the front-end (i.e., a front-end device 135 ) such as a mobile device executing an application or a specially designed wearable can also function as a data source 105 as described above.
[0019] The system 100 of FIG. 1 provides services to connect venue management with visitors and entertainment consumers while simultaneously providing a messaging platform for consumers. For example, the social network of a consumer may be extended into a map and the physical world associated with the map. Services to extend the social network of a user include finding friends and family and management of proximity based parental controls.
[0020] FIG. 2 is a method for redeeming entitlement rights. The method of FIG. 2 may be performed by an end user with a mobile device 110 in a system 100 like that of FIG. 1 . A web services platform may operate at application server 125 of FIG. 1 either alone or in conjunction with a mobile application or web application executing on mobile device 110 .
[0021] The method of FIG. 2 allows an authorizing user to not be physically present when the entitlements are redeemed while still providing the opportunity for the authorizing user to make a decision whether to grant access. Further, the authorizing user is only contacted to provide access in the event they are not physically present at the location where the entitlements are being redeemed. The method of FIG. 2 may utilize one or more location based services in the context of system 100 .
[0022] Through the method of FIG. 2 , an end user configures parental controls for a child or other minor at step 200 . Configuration includes, but is not limited to, specifying which entitlements will automatically be authorized or rejected, the distance end user must be from their child or minor before they will be notified to grant access, and whether the end user only wants to be notified of entitlement redemptions or wants to grant permission before the entitlement can be redeemed.
[0023] Entitlements can have many manifestations. For example, an entitlement may include a ticket to access a physical location such as an amusement park, show, movie, or sporting event. Entitlements might likewise include rights to use a transportation service or for digital goods including rights to purchase, play, use, watch, or listen to content. Use of content may be on a set-top box, mobile device, kiosk, or other form of entertainment system, including tablet devices.
[0024] The entitlement holder (such as a younger child) may attempt to redeem an entitlement by presenting a physical ticket or displaying a ticket on a mobile device 110 at step 205 . When the entitlement holder presents their entitlement for redemption, an automated ticket reader (e.g., QR Code, RFID reader, Bluetooth beacon) or ticket processing kiosk will at step 210 scan and verify the authenticity of the entitlement. If the entitlement is invalid because it has already been redeemed or for some other reason, access is denied ( 255 ).
[0025] If the entitlement is valid and no parental control restrictions have been assigned to the entitlement or the individual holding the entitlement as determined at step 215 , the user redeeming the entitlement is authorized at step 245 and may proceed to enter the gate or other ticketed area. In the case of content delivery, the user may then begin downloading, playing, watching, or listening to the same.
[0026] If the parental control settings defined in step 200 have assigned restrictions to the entitlement or the entitlement holder (or both), then further authorization is required at step 215 before the entitlement holder is authorized to access the content or proceed into the otherwise ticketed or prohibited area. In the event that permissions are required, the web service will determine whether parent end-user, is currently in the physical presence of the user redeeming the entitlement at step 220 . The location of parental end user may be determined based on location based technology in a mobile device 110 or wearable reporting its location to web services platform executing at application server 135 or through monitoring of the location of end user with proximity technology such as Wi-Fi MAC address harvesting, which would also be reported to web services platform. For entitlements that grant access to a physical location, the location of the entitlement holder may be determined based on the location of the point of sale or gate control system. The entitlement holder's location may also be determined based on mobile technologies like those discussed above.
[0027] At step 220 , if the authorizing end user is in proximity of the user redeeming the entitlement and the preferences defined at step 300 are configured to allow access based on proximity of end user 48 and the entitlement holder, the web service platform will authorize access in step 245 . Indication of authorization may be transmitted to a mobile device, wearable, or other device such as a kiosk or ticket scanning device.
[0028] If the end user is not in the same location as the entitlement holder, the web service platform will require additional permission from the end user before authorizing the entitlement holder to proceed in step 220 . If the entitlement holder is redeeming the entitlement on a mobile device 110 or wearable, the device may display a message or indicator light at step 225 indicating that authorization is required before they can proceed. If the entitlement is being redeemed at a gate using the likes of a point of sale system or kiosk, a message or indicator light may be displayed to the operator that authorization is required before the entitlement holder can proceed.
[0029] In such an event, end user will be contacted at step 230 to grant the entitlement holder access. Contact may take the form of a message sent to a mobile device or wearable. In some embodiments, a phone call may be initiated be a real-person or an automated system. The method of contact can be determined based on the user preferences defined in step 200 .
[0030] If the entitlement redemption is authorized in step 235 , notification may be displayed in the point of sale, gate control system, or kiosk at step 240 . The entitlement is then redeemed at step 245 . If the entitlement redemption is authorized in step 235 , notification of authorization being granted by end user may be displayed to the mobile device of the entitlement holder at step 240 and the entitlement is redeemed at step 245 .
[0031] If the entitlement redemption is denied in step 235 , notification may be displayed in the point of sale, gate control system, or kiosk at step 250 ; access would formally be denied in step 255 . If the entitlement redemption is denied in step 235 , notification of the authorization being denied by end user may be displayed to the entitlement holder by way of their mobile device or wearable at step 250 .
[0032] FIG. 3 illustrates an exemplary computing system that may be utilized to implement one or more embodiments of the present invention. System 300 of FIG. 3 , or portions thereof, may be implemented in the likes of client computers, application servers, web servers, mobile devices, wearable devices, and other computing devices. The computing system 300 of FIG. 3 includes one or more processors 310 and main memory 320 . Main memory 320 stores, in part, instructions and data for execution by processor 310 . Main memory 320 can store the executable code when in operation. The system 300 of FIG. 3 further includes a mass storage device 330 , portable storage medium drive(s) 340 , output devices 350 , user input devices 360 , a graphics display 370 , and peripheral device ports 380 .
[0033] While the components shown in FIG. 3 are depicted as being connected via a single bus 390 , they may be connected through one or more internal data transport means. For example, processor 310 and main memory 320 may be connected via a local microprocessor bus while mass storage device 330 , peripheral device port(s) 380 , portable storage device 340 , and display system 370 may be connected via one or more input/output (I/O) buses.
[0034] Mass storage device 330 , which could be implemented with a magnetic disk drive or an optical disk drive, is a non-volatile storage device for storing data and instructions for use by processor 310 . Mass storage device 330 can store software for implementing embodiments of the present invention, including the method 200 described in the context of FIG. 2 .
[0035] Portable storage medium drive(s) 340 operates in conjunction with a portable non-volatile storage medium such as a flash drive or portable hard drive to input and output data and corresponding executable code to system 300 of FIG. 3 . Like mass storage device 330 , software for implementing embodiments of the present invention (e.g., method 200 of FIG. 2 ) may be stored on a portable medium and input to the system 300 via said portable storage.
[0036] Input devices 360 provide a portion of a user interface. Input devices 360 may include an alpha-numeric keypad, such as a keyboard, for inputting alpha-numeric and other information, or a pointing device, such as a mouse. Input device 360 may likewise encompass a touchscreen display, microphone, and other input devices including virtual reality (VR) components. System 300 likewise includes output devices 350 , which may include speakers or ports for displays, or other monitor devices. Input devices 360 and output devices 350 may also include network interfaces that allow for access to cellular, Wi-Fi, Bluetooth, or other hard-wired networks.
[0037] Display system 370 may include a liquid crystal display (LCD), LED display, touch screen display, or other suitable display device. Display system 370 receives textual and graphical information, and processes the information for output to the display device. In some instances, display system 370 may be integrated with or a part of input device 360 and output device 350 (e.g., a touchscreen). Peripheral ports 380 may include any type of computer support device to add additional functionality to the computer system. For example, peripheral device(s) 380 may include a modem or a router or other network communications implementation (e.g., a MiFi hotspot device).
[0038] The components illustrated in FIG. 3 are those typically found in computer systems that may be suitable for use with embodiments of the present invention. In this regard, system 300 represents a broad category of such computer components that are well known in the art. System 300 of FIG. 3 can be a personal computer, hand held computing device, smart phone, tablet computer, mobile computing device, wearable, workstation, server, minicomputer, mainframe computer, or any other computing device.
[0039] System 300 can include different bus configurations, network platforms, processor configurations, and operating systems, including but not limited to Unix, Linux, Windows, iOS, Palm OS, and Android OS. System 300 may also include components such as antennas, microphones, cameras, position and location detecting devices, and other components typically found on mobile devices. An antenna may include one or more antennas for communicating wirelessly with another device. An antenna may be used, for example, to communicate wirelessly via Wi-Fi, Bluetooth, with a cellular network, or with other wireless protocols and systems. The one or more antennas may be controlled by a processor, which may include a controller, to transmit and receive wireless signals. For example, processor execute programs stored in memory to control antenna transmit a wireless signal to a cellular network and receive a wireless signal from a cellular network. A microphone may include one or more microphone devices which transmit captured acoustic signals to processor and memory. The acoustic signals may be processed to transmit over a network via antenna.
[0040] The foregoing detailed description of the technology herein has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the technology to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. The described embodiments were chosen in order to best explain the principles of the technology and its practical application to thereby enable others skilled in the art to best utilize the technology in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the technology be defined by the claims appended hereto.
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A web service platform to improve end-user engagement in a captive audience environment. Mobile and web-based clients allow application users to authorize and approve usage of entitlements of other users, including their children, based upon preconfigured rules and the proximity between the user requesting and the user approving authorization to use the entitlement.
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This is a continuation of application Ser. No. 07/047,696 filed May 8, 1987, now abandoned.
FIELD OF THE INVENTION
The present invention relates to methods and apparatus for generating images on a cathode ray tube ("CRT") or other display device. More particularly, the present invention relates to methods and apparatus for the accurate rendering of higher order curves and curved surfaces, vectors or objects on a CRT or other display.
BACKGROUND OF THE INVENTION
In many computer systems, it is quite common to represent and convey information to a user through digital images. These images may take a variety of forms, such as for example, alphanumeric characters, cartesian graphs, and other pictorial representations. In many applications, the digital images are conveyed to a user on a display device, such as a raster scan video monitor, printer or the like. Typically, the images to be displayed are stored in digital form, manipulated, and then displayed.
Parametric curves and curved surfaces are common functions which are used in the computer generation of surfaces and objects on a display such as, for example, in mechanical computer aided design ("CAD") applications. Since high speed hardware capable of rendering vectors and polygons is known in the prior art, high speed rendering of curved lines and curved surfaces is usually done by subdividing and rendering them on a CRT as a plurality of straight-lines or planar polygons. (For a more thorough understanding of prior art methods for rendering curves and/or surfaces, see: Bishop, G. and Weimer, D., "Fast Phong Shading" pp 103-106 Computer Graphics Vol. 20, Number 4, August, 1986; Foley, J. D. and Van Dam, A., 1983 Fundamentals of Interactive Computer Graphics, Addison Wesley, Reading, Mass.; Gouraud, H., June 1971. "Continuous Shading of Curved Surfaces." IEEE Transactions on Computers, Vol. 20, No. 6, pp 623-628; Swanson, R. and Thayer, L., "A Fast Shaded-Polygon Renderer," Computer Graphics, Vol. 20, No. 4, pp 95-101, August, 1986.)
However, with respect to the rendering of higher order curves and surfaces, prior art systems employ recursive subdivision methods which are expensive to implement in computer hardware because of the high speed stack memory requirements.
The present invention employs an adaptive forward difference ("AFD") technique which overcomes the problems associated with the prior art, yet requires relatively simple and inexpensive circuitry using ordinary forward differencing (advancing along a parametric curve or surface in constant parameter increments), as well as a new adaptive method superior to prior art adaptive subdivision methods of recursively dividing the object until the resulting pieces are smaller than one pixel. The present invention adapts the forward difference parameter increment so as to advance along the curve or surface with a step size (i.e., the distance between the previously drawn pixel location and the current pixel location of the curve or surface being rendered) which is approximately equal to the distance between two adjacent pixels (hereinafter referred to as a "single or one pixel increment"). This adaptation is performed by transforming the equation of the curve to an identical curve with different parameterization, such that the step size is increased or decreased such that the curve proceeds in substantially uniform increments from one pixel to the next. AFD differs from prior art recursive subdivision methods for rendering curves because it does not require manipulation of the complex prior art stack memory circuitry and therefore is simpler and more efficient. Further, the rendering of the curve, curved surface or object yielded by the present invention is more accurate than it would otherwise be if rendered by the prior art ordinary forward differencing method with piece-wise, straight-line or planar polygon approximation.
SUMMARY OF THE INVENTION
The present invention overcomes the obstacles and drawbacks contained in the prior art through an adaptive forward differencing apparatus for rendering a curve on a display device (such as a "CRT") by actuating display elements defining the curve. The apparatus of the present invention comprises a means for receiving a plurality of data points representative of the display elements which define the images and a means for incrementally rendering the curve in substantially uniform single pixel steps.
The means for incrementally rendering the image in substantially uniform single pixel steps includes X, Y, Z and W Adaptive Forward Differencing Unit "AFDU" circuits for calculating x, y, z and w for a point in homogenous coordinates. The W AFDU circuit is coupled to a l/w circuit that produces the reciprocal l/w of the homogenous coordinate w. The output of the l/w circuit is multiplied by the x, y, z coordinates to yield the rational cubics x/w, y/w and z/w. The AFDU circuits are also coupled to a pixel filter circuit which, in cooperation with the AFDU circuits, implements the AFD technique of the present invention by reparameterizing the x, y, z and w cubic functions such that a curve is generated in substantially uniform one pixel sized increments.
The pixel filter circuit of the present invention compares the current pixel location with the previous pixel location calculated by the AFDU circuits and, if the current x, y pixel location of the display means is greater than a one pixel increment away from the previously defined x, y pixel location, instructs the X, Y, Z and W AFDU circuits to reduce the step size of the curve being rendered.
Similarly, if the calculated x and y increments of the curve being rendered are less than a predetermined portion (i.e. 0.5 pixels), the pixel filter instructs the X, Y, Z and W AFDU circuits to increase the step size of the curve being rendered.
When rendering vectors, the AFDU circuit of the present invention implements the Bresenham algorithm using many of the same circuit components utilized by the Adaptive Forward Difference method. The present invention also provides a means for defining clipping regions on a CRT display, a means for mapping imagery onto curved surfaces and onto curves, and a means for shading and trimming curved surfaces. Other features and advantages will become apparent after a reading of the foregoing specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an overall block diagram view of the present invention;
FIG. 2 is a block diagram of the l/w circuit of FIG. 1;
FIG. 3 is an exploded block diagram view of the X AFDU circuit of FIG. 1;
FIG. 4 illustrates a portion of the circuit shown in FIG. 3 which is used in rendering vectors;
FIG. 5 is a flow chart illustrating a sequence of operations of the circuit of FIG. 4;
FIGS. 6 and 6a illustrate an aspect of the present invention relating to the enabling of pixels on a display; and
FIG. 7 is an exploded view of the pixel filter circuit of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
The present invention disclosed apparatus and methods having particular application for use in a computer system used for the graphic display of images. Although the present invention is described with reference to specific circuits, block diagrams, signals, algorithms, etc., it will be appreciated by one of ordinary skill in the art that such details are disclosed simply to provide a more thorough understanding of the present invention. It will therefore be apparent to one skilled in the art that the present invention may be practiced without these specific details. In other instances, well known circuits are shown in block diagram form in order not to obscure the present invention unnecessarily
In FIG. 1 there is shown an overall block diagram view of the present invention. In order to define images on a CRT display or other display device, it is necessary to manipulate data at a high speed in order to select the pixels of a CRT display that define the curve, curved surface, vector or image that is desired to be displayed. It is well known in the art that the location of each point to be displayed on a CRT often is represented by digital values stored in a memory device which correspond to x, y, z and w homogenous coordinates.
The coefficients of the equations describing curves to be rendered by the circuit of FIG. 1 are calculated and supplied by a CPU 9 and are transmitted to the W, X, Y and Z Adaptive Forward Differencing Unit ("AFDU") circuits 10, 12, 14 and 16 which, in response, output x, y, w and z coordinates, respectively, for each pixel to be drawn on the display. The w coordinate outputted by the W AFDU circuit 10 is coupled to the l/w circuit 18 which, in turn, outputs the current value of l/w. The x, y and z coordinates are divided by the homogenous coordinate w (i.e. multiplied by the current l/w value in order to obtain the ratio of two cubic functions), by the l/w circuit 18 and the three multipliers 20, 22, and 24.
More specifically, the X AFDU circuit 12 outputs the current x coordinate to a multiplier 20, wherein it is multiplied by the corresponding l/w value outputted by the l/w circuit 18, such that a current x/w value is supplied to pixel filter 30. In a similar fashion, y/w and z/w are supplied to pixel filter 30, respectively, by W, Y, and Z AFDU circuits 10, 14 and 16, l/w circuit 18 and by the multipliers 22 and 24. In this fashion the x, y, and z coordinates of the rational cubic functions are inputted to pixel filter 30 and used to select the pixels defining images of the rational cubic functions on a CRT.
The pixel filter 30 of FIG. 1 compares the current x, y and z pixel coordinates which ar fed thereto by multipliers 20, 22 and 24, with the x, y and z pixel coordinates which were fed to the pixel filter 30 one clock cycle previously and instructs the W, X, Y and Z AFDU circuits to "adjust up" (i.e., advance the curve or curved surface in larger increments) by multiplying the parameter t by two or to "adjust down" (i.e., advance the curve or curved surface in smaller increments) by dividing the parameter t by 2, or to "step forward" to the next pixel such that the x, y and z coordinates outputted by pixel filter 30 advance the curve being displayed on the CRT substantially in single pixel increments. The adjustment technique will later be more fully described.
The pixel filter 30 also detects and replaces "elbows" [wherein a curve section having, for example, the coordinates (x 0 , y 0 ), (x 0 , y 1 ) and x 1 , y 1 ), is replaced with a curve section having the coordinates (x 0 , y 0 ) and (x 1 , y 1 ).] This is done to improve the appearance of the rendered curve by eliminating the corner pixel (i.e. pixel x 0 , y 1 .
The pixel filter 30 is coupled, at outputs 33, 35, and 37, to a frame buffer (not shown) which, in turn, is coupled to a CRT display (also not shown) or other appropriate display device, for defining images by enabling, or writing a color value at the pixels defined by the pixel coordinates outputted by pixel filter 30 at outputs 33, 35 and 37.
Arc length output 31 of pixel filter 30 is coupled to a paint section 150 (not shown) which paints pixels in accordance with the arc length value outputted by pixel filter 30 at output 31. The arc length value is employed in the drawing of textured (dashed, dotted, etc.) lines and surfaces. The drawing of textured lines and surfaces does not, however, form an essential part of the instant invention as described and claimed herein and a more detailed explanation thereof is not, therefore, necessary.
In FIG. 2 there is shown an exploded view of the l/w circuit 18 of FIG. 1. The l/w circuit 18 of FIG. 1 is an advancement over prior art circuits for obtaining the reciprocal of w in that the l/w circuit 18 of the present invention yields the reciprocal of w faster, with less computational overhead and less latency than comparable prior art circuits.
Prior art l/w circuits typically use a Newton iteration algorithm employing a single look-up table for the initial approximation of the reciprocal of w. These prior methods require a large multiplier and take several clock cycles to obtain a result. In direct contrast, the present invention requires only one clock cycle for the iteration computation, thereby greatly reducing latency as compared with prior art methods. (For a more complete description of prior art methods for division through divisor reciprocation see: "Computer Arithmetic", Kai Hwang, pp 259-264, John Wiley & Sons, New York, N.Y., 1979.) To achieve the above-described superior results, the present invention uses a truncated Taylor series approximation utilizing two small look-up tables 76 and 78 (i.e. in the preferred embodiment, table 76 has 8K entries and 20 bit output while table 78 has 8 bit output) and minor computation hardware to implement the same in order to derive an approximation of l/w without the costly, slower computations required by the prior art.
As is well known in the art, the Taylor series approximation is used to derive the reciprocal of the homogenous coordinate w. The Taylor series approximation states:
l/w≈(l/w.sub.0)[l-d/w.sub.0 +(d/w.sub.o).sup.2 -(d/w.sub.o).sup.3 +(d/w.sub.o).sup.4 +(d/w.sub.0).sup.5 . . . ]
where w 0 represents a pre-determined quantity of the most significant bits of the w value and where d represents a pre-determined quantity of the least significant bits of the w value. It has been discovered that truncating the above listed Taylor series approximation to include only the first two terms thereof (i.e. l/w 0 -d (l/w 0 2 ) renders a l/w value which is sufficiently accurate for purposes of obtaining the rational cubic functions x/w, y/w and z/w for use in the rendering of images.
The w value outputted by W AFDU circuit 10, in the preferred embodiment of the present invention, comprises 21 bits. The 13 most significant bits (termed herein as "w 0 ") of that 21 bit value are supplied to look-up tables 76 and 78. Look-up table 76 outputs the reciprocal (l/w ) of the thirteen bit value inputted thereto to register 80. Similarly, look-up table 78 outputs a (l/w 0 ) 2 value corresponding to the thirteen most significant bits supplied thereto, to register 82. The eight least significant bits of the 21 bit w value are supplied to an 8-bit delay register 84, which merely delays the eight least significant bits a length of time sufficient to allow the outputting of (l/w 0 ) 2 by register 82, such that multiplier 87 multiplies the eight least significant bits, (termed herein as "d"), times the contents of register 82 such that multiplier 87 outputs d(l/w 0 ) 2 to subtracter 89 where d(l/w o ) 2 is subtracted from (l/w o ) in order to produce at register 90 l/w 0 -d (l/w 0 ) 2 . As stated, l/w o -d(l/w o ) 2 ≈l/w. Register 90, in turn, outputs the value l/w to multipliers 20, 22 and 24 as previously discussed with respect to FIG. 1. Delays 13, 11 and 15 are present to ensure that the x, y and z coordinates outputted, respectively, by X, Y and Z AFDU circuits 12, 14 and 16 arrive at multipliers 20, 22 and 24 substantially coincident with the calculated corresponding l/w value outputted by Register 90.
Multiplier 87 is an 8 bit by 8 bit multiplier. (l/w 0 ) 2 and d are 8 bit terms and are therefore propagated through to subtracter 89 and thus register 90 in only one clock cycle.
From the above discussion, it will be appreciated that by employing the two look-up tables 76 and 78 which yield, respectively, l/w 0 and (l/w 0 ) 2 and computing those values to produce l/w as previously described, the present invention avoids the long latency producing computations which were previously required in the aforedescribed prior art devices, thereby increasing the speed with which l/w is derived. In the preferred embodiment of the l/w circuit, 18 produces a l/w value which has 20 significant bits, however, it will be appreciated that more or less bits may be used as long as the values stored in the look-up tables employed are adjusted accordingly.
In FIG. 3 there is shown an exploded view of the X AFDU circuit 12 of FIG. 1. Y, Z and W AFDU circuits 14, 16 and 10 are identical in circuitry to the X AFDU circuit 12, and therefore a thorough understanding of X AFDU circuit 12 will also fully convey the circuitry and operation of Y, Z and W AFDU circuits 10, 14 and 16.
Each AFDU circuit calculates a parametric cubic function f(t) represented as:
f(t)=aB.sub.3 (t)+bB.sub.2 (t)+cB.sub.1 (t)+dB.sub.0 (t). (1)
For each x, y, z and w coordinate the parametric cubic function f is:
x(t)=a.sub.x B.sub.3 +b.sub.x B.sub.2 +c.sub.x B.sub.1 +d.sub.x B.sub.0
y(t)=a.sub.y B.sub.3 +b.sub.y B.sub.2 +c.sub.y B.sub.1 +d.sub.y B.sub.0
z(t)=a.sub.z B.sub.3 +b.sub.z B.sub.2 +c.sub.z B.sub.1 +d.sub.z B.sub.0
w(t)=a.sub.w B.sub.3 +b.sub.w B.sub.2 +c.sub.w B.sub.1 +d.sub.w B.sub.0
The above functions B 3 (t), B 2 (t), B 1 (t) and B 0 (t) are forward difference basis functions which differ from one another as t varies from 0 to 1 along a curve. The dt step size for t is automatically adjusted so that the curve increments in approximately one pixel steps as explained below. The four forward difference basis functions B 3 , B 2 , B 1 and B 0 are listed below: ##EQU1##
The above cubic functions x(t), y(t), z(t), w(t) are calculated separately by each AFDU circuit. The four coefficients a, b, c, and d which describe a cubic curve are loaded into the four coefficient registers 34, 50, 62 and 72 of each AFDU circuit at initialization by the CPU 9. At each clock cycle, the parameter t increases by dt and the four coefficients are updated to a', b', c', d' while the four AFDU circuits 10, 12, 14 and 16 generate the coordinates which correspond to a particular pixel on the CRT display.
If the x, y coordinate currently calculated by the X and Y AFDU circuits 12 and 14 define a pixel location on the CRT display which is more than a single pixel increment from the previously defined pixel, then pixel filter 30 instructs each AFDU circuit to divide dt by two (adjust down), thereby reducing the x, y increments so that at each clock cycle each AFDU circuit outputs coordinates which define pixels along the curve in substantially single pixel increments. In a similar fashion, if the x, y address step is less than a 1/2 pixel increment from the previously defined pixel, then dt is doubled (adjusted up) to increase the change in the x, y coordinates such that again a substantially one pixel step is incremented at each clock cycle. To reduce dt by half, the cubic functions x(t), y(t), z(t), w(t) are transformed as follows:
x'(t)=x(t/2)=a'.sub.x B.sub.3 +b'.sub.x B.sub.2 +c'.sub.x B.sub.1 +d'.sub.x B.sub.0
y'(t)=y(t/2)=a'.sub.y B.sub.3 +b'.sub.y B.sub.2 +c'.sub.y B.sub.1 +d'.sub.y B.sub.0
z'(t)=z(t/2)=a'.sub.z B.sub.3 +b'.sub.z B.sub.2 +c'.sub.z B.sub.1 +d'.sub.z B.sub.0
w'(t)=w(t/2)=a'.sub.w B.sub.3 +b'.sub.w B.sub.2 +c'.sub.w B.sub.1 +d'.sub.w B.sub.0
The coefficients of the transformed set of cubic functions are given by:
a'=a/8
b'=b/4-a/8
c'=c/2-b/8+a/16
d'=d
In order to double dt, the coordinate cubic functions are transformed by:
x'(t)=x(2t)
y'(t)=y(2t)
z'(t)=z(2t)
w'(t)=w(2t)
In the case of doubling dt, the present invention utilizes the following coefficient transformation:
a'=8a
b'=4b+4a
c'=2c+b
d'=d
If the current step size being used by the AFDU circuits is correct, (i.e. substantially a one pixel increment), then the AFDU circuits generate coordinates corresponding to a new pixel and step forward to that pixel by calculating the following transformation:
x'(t)=x(t+1)
y'(t)=y(t+1)
z'(t)=z(t+1)
w'(t)=w(t+1)
The corresponding coefficient transformation for an increment of one pixel is:
a'=a
b'=b+a
c'=c+b
d'=d+c
Returning to FIG. 3, in order to implement the above transformations (adjust up, adjust down, or forward step) the pixel filter 30 sends control signals to multiplexors 32, 44, 46, 54, 56 and 70 to select an appropriate input into, respectively, adder/subtracter 45, 58, and 66. These multiplexors select the appropriate transformed values for the a', b', c' and d' coefficients. As stated, the values a, b, c and d are initially loaded by the CPU 9 into registers 34, 50, 62 and 72. New coefficient values corresponding to the desired pixel location are updated and loaded into registers 34, 50, 62 and 72 at each clock cycle, thereby incrementally computing the parametric function x(t)=a x B 3 +b x B 2 +c x B 1 +d x B 0 . If the x, y and w coordinates outputted by AFDU circuits 12, 10, and 14 correspond to a pixel location which is greater than a one pixel increment from the previously defined pixel, the coefficients of a', b', c' and d' are selected as a'=a/8, b'=b/4-a/8, c'=c/2-b/8+a/16 and d'=d. The 8a input to multiplexor 32 is wired with a left shift of 3 bits to give the value 8a for use in the above listed equations. Similarly, the input a/8 is right shifted three bits to obtain the value a/8.
In general, dividing or multiplying by an integer power of two is accomplished by a hard wired right or left shift. The coefficients for an adjust down operation are obtained in two clock cycles as follows: First clock cycle, pixel filter 30 places control signals on bus 51, which cause multiplexor 32 to select A/8, multiplexor 4 to select A/8, multiplexor 46 to select B/4, multiplexor 56 to select 0, and multiplexor 54 to select C/2. At the end of this clock cycle, A'=A/8, B'=B/4-A/8, and C'=C/2. During the second clock cycle, pixel filter 30 places control signals on bus 51 which cause multiplexor 32 to select a, multiplexor 44 to select 0, multiplexor 46 to select b, multiplexor 56 to select B/2, and multiplexor 54 to select c. At the end of this clock cycle, the result of the two clock cycle operations is A'=A/8, B'=B/4-A/8, C'=C/2-(B/4-A/8)/2. Adders/subtracters 45 and 58, as well as adder 66, are controlled by pixel filter 30 in order to perform addition or subtraction operations necessary for the above-described transformations.
Similarly, as previously discussed, when a pixel increment calculated by the X AFDU circuit 12 is less than 0.5 of a pixel step, the coefficients a, b, c and d are transformed by: a'=8a, b'=4b+4a, c'=2c+b and d'=d. To perform these transformations, appropriate control signals from pixel filter 30 are asserted at multiplexors 32, 44, 46, 54, 56 and 70 such that the 8a, 4a, 4b, and 2c are clocked into the corresponding registers in conjunction with adder/subtracters 45, 58 and 66.
Alternatively, if the AFDU circuit calculates an x increment between 0.5 and 1 and a y increment between 0.5 and 1, then the a, b, c and d coefficients are selected by multiplexors 32, 44, 46, 54, 56 and 70 by appropriate control signals asserted by the pixel filter 30 such that register 50 is updated by b'=b+a, register 62 is updated by c'=c+b, d register 72 by d'=d+c and a register 34 remains unchanged. It will be appreciated that only the outputs from AFDU circuits X, Y, and W are used by the pixel filter to control the adjustment of all four AFDU circuits since the x/w and y/w coordinates sufficiently define pixel location in such a fashion, the AFDU circuits 10, 12 and 14, in cooperation with the l/w circuit 18, multipliers 20, 22, 24 and pixel filter 30, ensure that the curves rendered are incremented in substantially one pixel increments.
Memory buffers 48, 60 and 68 are used to store a sequence of the last N b, c and d values, respectively, so that the properly delayed b coordinate values associated with the pixel filter 30 control signal are used. This is necessary because pixel filter 30 determines control decisions several clocks after the AFDU generates the pixel addresses. Memory buffers 48, 60 and 68 store a sequence of values so that the b value having a delay equal to the number of clocks between the AFDU and the pixel filter is used to compute b'. No memory buffer is necessary for register 34 since "a" does not change during a forward step AFDU operation.
Another important aspect of the present invention is hereinafter described.
A critical problem which typically occurs in prior art forward differencing methods for rendering curves is overflow or overloading of the registers used for storing the integer of the coefficient values of the parametric cubic function used for calculating the curve. Of course, if a register used for storing a coefficient reaches capacity and overflows, accurate calculation of the parametric cubic function will become impossible. The present invention provides a unique method and apparatus for preventing such overflow from occurring, thereby ensuring continuous accurate implementation of the parametric cubic function for rendering the curve. The following is an explanation of this aspect of the present invention.
In the present embodiment, registers 34 and 50 of FIG. 3 have a capacity for storage of three-integer bits, which, for purposes of convenience, will herein be labelled, respectively, a 1 , a 2 , a 3 and b 1 , b 2 and b 3 . a 1 and b 1 are the most significant integer bits. The most significant fractional bit of register 34 will herein be labeled a 4 . Since Register 62 accumulates, on a forward step, the contents of register 50, it has, in the preferred embodiment, a storage capacity of more than three integer bits. The most significant integer bit of register 62 is termed herein as c 1 . Registers 34, 50 and 62 are coupled to a control circuit 92 of FIG. 7 (a detailed description of the operation of pixel filter 30 and control circuit 92 as shown in FIG. 7 will later be described more fully) within the pixel filter 30 and outputs thereto bits which indicate to the control circuit 92 that the integer storage capacity of registers 34, 50 and/or 62 are in overflow or could possibly overflow with the next calculation. Below are listed the conditions in which registers 34 and 50 send a bit (termed herein as the "warning bit") which instructs the control circuit 92 of the pixel filter 30 that the next adjust up will result in an overflow of the integer storage capacity of registers 34 and 50.
A warning bit is asserted if:
a 1 ≠the sign bit (sb) of register 34 or;
a 2 ≠sign bit of register 34 or;
a 3 ≠sign bit of register 34 or;
a 4 ≠sign bit of register 34 or;
b 1 ≠sign bit of register 50 or;
b 2 ≠sign bit of register 50 or;
b 3 ≠sign bit of register 50.
The pixel filter 30, as stated, sends control signals to multiplexors 32, 44, 46, 54 and 70, which instruct each ADFU circuit to adjust up, adjust down or step forward to the next pixel. When a warning bit is asserted at control circuit 92 of pixel filter 30, pixel filter 30 instructs each AFDU unit to step forward to the next pixel (instead of adjust up) when an adjust up is indicated by calculations made by the pixel filter 30. Adjust down and forward steps are not affected by assertion of the warning bits. Instructing each AFDU circuit to step forward does not cause registers 34 and 50 to overflow, since stepping forward does not require multiplication of the coefficient "a" term by 8 or multiplication of the "b" term by 4. The AFDU circuits are thus prevented from adjusting up until the curve is completed or until the warning bit is de-asserted.
Similarly, the bit which instructs pixel filter 30 that the integer storage capacity of registers 34, 50 and 62 will overflow with next adjust up or forward step (termed herein as the "overflow bit") is asserted whenever a 1 ≠sign bit of a; b 1 ≠sign bit of b or c 1 ≠sign bit of c. When the overflow bit is asserted it instructs control circuit 92 to assert control signals to the AFDU multiplexors which instruct each AFDU circuit to adjust down, whether or not an adjust up or a step forward is indicated by the calculations made by the pixel filter 30. An adjust down relieves the overflow problem in registers 34, 50 and 62, thereby causing de-assertion of the overflow bit. The sign bit of registers 34, 50 and 62 is used so that the warning bit and overflow bits will be asserted if the integer portion of the number stored therein is getting too large in the positive direction or too small in the negative direction in two's complement representation
It will be appreciated to one skilled in the art that registers having a storage capacity for more or less integer values may be used in place of registers 34 and 50 without departing from the concepts of the present invention herein disclosed.
It will also be appreciated from the above description that a critical problem which occurs in prior art forward differencing circuits (i.e. overflow of the curve rendering units) is hereby avoided by the above described features of the present invention.
The above-described functions of the AFDU circuit pertain to the drawing of curves. FIG. 4 shows a simplified circuit diagram of the X AFDU chip 12 (shown in FIG. 3) illustrating only the components which are used for drawing vectors. FIG. 5 is a flow chart illustrating the operation of the circuitry shown in FIG. 4 and performing the example operation of drawing an x major vector using the Bresenham algorithm which is well known in the art.
When the rendering of a vector is initiated, the Bresenham algorithm parameters dx (the change in x), dy (the change in y), Err (the Bresenham error term), Inc 1 (a first increment), and Inc 2 (a second increment), which will later be discussed more fully with references to FIG. 5, are calculated by the CPU 9. The CPU 9 loads registers 34, 38, and 50 with Inc 1, Inc 2, and Err respectively. The CPU 9 also loads register 72 with vector endpoint value x 0 and loads the c register 62 with the value 0. The operation of the circuitry of FIG. 4 in the rendering of an x-major vector in conjunction with the flow diagram of FIG. 5, will now be explained.
A conditional circuit 64 outputs a 1 bit whenever the sign bits of register 50 and 62 are the same. Therefore, circuit 64 will provide a 1 input to adder 69 only when register 50 and 62 have the same sign. As stated, since register 62 is loaded with a zero at initialization time its sign is always 0. As such, circuit 64 will output a 1 to adder 66 whenever the sign bit from register 50 is zero (i.e., the Err is greater than zero). When the rendering of a vector is initiated, the CPU 9 commands the pixel filter 30 to assert a control signal to the AFDU circuits so that multiplexor 44 is control to the sign bit output of register 50. When the sign bit of register 50 is 0, multiplexor 44 then channels through the output of register 38. When the sign bit of register 50 is 1, multiplexor 44 selects the output of register 34.
Turning now to FIG. 5, the Bresenham parameters for a vector between beginning and ending curve coordinates x 0 , y 0 and x 1 , y 1 are initialized by CPU 9, as listed in block 160 of FIG. 5. The error term (Err) is calculated by the equation Err=-1/2 dx+dy wherein dx=x 1 -x 0 and dy=y 1 -y 0 . In block 162, the pixel having the current x and y coordinates (x is stored in register 72 of FIG. 4 and y is stored in the corresponding register of the Y AFDU circuit 14) is written on the CRT display. The flow then proceeds to step 164, wherein it is determined whether or not the Err (the value in register 50) is greater than 0.
If the error is greater than or equal to 0, the sign bit of register 50 is also 0 and the flow then proceeds to step 168 wherein Err is updated by adding Inc 2 to the previously calculated Err. The sign bit of register 50 controls multiplexor 44 such that the Inc 2 (input at multiplexor 44 which is stored in register 38), is selected then clocked through adder/subtracter 45 into register 50 whenever the sign bit of register 50 is zero. In block 168 the x and y coordinates are updated in the X and Y AFDU circuits by adding 1 to the contents of register 72 in X AFDU 12 and the corresponding register in Y AFDU circuit 14. As described above, this addition is performed by adder 66 which adds the output of circuit 64 to the previous contents of register 72 only when the sign bit of register 62 is equal to the sign bit of register 50.
On the other hand, if the Err is less than 0, the flow then proceeds to step 166, wherein the Err is adjusted to be equal to the previously calculated Err (stored in register 50) plus Inc 1 (stored in register 34) and x is incremented by one. [Note: In this example operation, the y coordinate is not incremented in step 166 because the adder in the Y AFDU circuit 14 corresponding to adder 66 adds the output of circuit 64 (which is 0) to the contents of the register in Y AFDU circuit 14 corresponding to register 72.]
Inc 2, which is stored in register 38, is selected by multiplexor 44 and added to the contents of register 50 by adder 45 whenever the Err is greater or equal to 0. When the sign bit of register 50 is positive, adder 66 adds the output of circuit 64 to the contents of register 72 and clocks it through multiplexor 70 into register 72. The flow completes at step 170 when x is greater than x 1 .
In view of the above discussion, it will therefore be appreciated that, when drawing vectors, the AFDU circuit provides a unique method for accurately implementing the Bresenham algorithm, which algorithm is well known in the art. It should also be appreciated in view of the above discussion that with appropriate initialization, the AFDU circuit may also implement the well known generalized version of the Bresenham algorithm which calculates the closest pixel to an ideal line in between the beginning and ending points, yet generates only one pixel location x, y for each unit increment in y. These generalized versions of the Bresenham algorithm are widely used for incrementally stepping along the edge of a polygon in scanline order and in anti-aliasing vector techniques. (See Dan Field, "Incremental Linear Interpolation," ACM Transactions on Graphics, Vol. 4, No. 1, January 1985; Akira Fujimoto and Ko Iwata, "Jag Free Images on a Raster CRT," Computer Graphics Theory and Applications, edited by Tosiyasu Kunii, published by Springer Verlag, 1983.)
In FIG. 7 there is shown an exploded view of the pixel filter 30 of FIG. 1. It is important to note that when drawing vectors, the pixel filter 30 transfers control of the AFDU circuits to perform the Bresenham algorithm, as previously described with reference to FIG. 4. In this case the l/w circuit 18 and the W AFDU 10 are not used. However, when drawing curves, pixel filter 30 controls the X Y, Z and W AFDU circuits 10, 12, 14 and 16 as previously described with respect to FIG. 3 to perform adjustments and forward steps.
Registers 102, 103, 104, 105 and 106 of FIG. 7 store coordinate values x n to x n+4 which are supplied thereto by X AFDU circuit 12 and multiplier 20) (of FIG. 1) in five consecutive previous clock cycles. Similarly, y registers 120, 121, 122, 123 and 124 store y values y n to y n+4 . Likewise, register 134, 135, 136, 137 and 138 store z value z n to z n+4 . Registers 148, 149, 152, 154 and 158, as well as adder 156, and comparator 144, also operate in conjunction with the afore-described components, as will later be discussed.
Register 102-106 store, sequentially, each x coordinate supplied thereto by the X AFDU circuit 12 such that x n+4 is the most recently calculated coordinate. At each clock cycle comparator 94 compares the value x n+3 in register 105 with x n+4 in register 106, and comparator 112 compares the value y n+3 in register 123 with y n+4 in register 124. If the absolute value of x n+4 -x n+3 and the absolute value of y n+4 -y n+3 are both less than 0.5 of a single pixel increment, the controller 92 sends a control signal to all four AFDU circuits instructing the same to increase the step size (adjust up) as previously described with respect to FIGS. 1, 2 and 3. If the absolute value of x n+4 -x n+3 is greater than 1 or the absolute value of y n+4 -y n+3 is greater than 1, the controller then asserts a control signal at all four AFDU circuits which instruct the same to decrease the step size (adjust down), also as previously described with reference to FIGS. 1, 2 and 3.
Values z n+4 and z n+3 stored in registers 138 and 137 are not used to determine whether or not the step size should be adjusted upwardly or downwardly because the x and y coordinates sufficiently define a pixel location on a CRT display. However, registers 138 and 137 function as delay buffers so that values z n+2 , z n+1 and z n (which are stored, respectively, in registers 136-134) will correspond to the values of y n+2 , y n+1 and y n (stored in, respectively, 122, 121, and 120) and to the values of y n+2 , x n+1 and x n (stored in registers 104, 103 and 102).
Alternatively, if the absolute value of x n+4 -x n+3 and the absolute value of y n+4 -y n+3 are both between 0.5 and 1.0 pixel units, then the comparators 94 and 112 instruct control circuit 92 to instruct all four AFDU circuits to perform a forward step operation as previously described.
It is important to note that all four AFDU circuits 10, 12, 14 and 16 of FIG. 1 are adjusted upwardly, downwardly, or forwardly in synchronicity by pixel filter 30.
Elimination of redundant pixels in a displayed image will now be described. Comparator 96 compares the value x n+2 which is stored in register 104, with the x n+1 in register 103. Comparator 114 compares the value y n+2 in register 122 with the value y n+1 in register 121. If x n+2 =x n+1 and y n+2 =y n+1 , comparators 96 and 114 assert signals at control circuit 92 which, in turn, output an invalid pixel bit to paint section 150, such that paint section 150 invalidates the modifications corresponding to the pixel having the coordinates corresponding to x n+1 and y n+1 .
Elimination of "elbows" in a displayed image will now be disclosed. Comparator 96 compares the integer part of the value x n+2 in register 104 with the integer part of the value x n in register 102 and the comparator 114 compares the integer part of the value y n+2 in register 122 with the integer part of the value y n in register 120. If the absolute value of x n+2 -x n is equal to 1 and the absolute value of y n+2 -y n is equal to 1 then comparators 96 and 114 assert signals at control circuit 92, which, in turn, outputs an invalid pixel bit to paint section 150, such that paint section 150 will not paint the pixel whose coordinates correspond to x n+1 and y n+1 .
Defining a clipping region in the displayed screen will now be described. Preloaded into registers 100, 118, 132 and 146 are, respectively, x minimum and x maximum values, y minimum and y maximum values, z minimum and z maximum values and t minimum and t maximum values. Comparator 98 is coupled to register 103 and compares the value x n+1 with x maximum and x minimum. If x n+1 is not within x minimum and x maximum value, comparator 98 asserts a control signal to control circuit 92, which, in turn, instructs paint section 150 to invalidate the modifications corresponding to the pixel defined by the coordinate x n+1 , y n+1 , z n+1 , t n+1 which pixel is outside of the window defined by x min and x max values stored in register 100. The same actions occur with respect to y minimum and maximum register 118, z minimum and z maximum register 132 and t minimum and maximum register 146. Accordingly, if y n+1 , which is stored in register 121, is less than the y minimum value or greater than the y maximum value stored in register 118, comparator 116 initiates a control signal to control circuit 92, which ultimately instructs the paint section 150 not to paint the pixel (x n+1 , y n+1 , z n+1 , t n+1 ). Similarly, if z n+1 , which is stored in register 135, is less than a z minimum value or greater than the z maximum value stored in register 132, a comparator 130 asserts a control signal at control circuit 92, which in turn instructs the paint section 150 not to paint the pixel (x n+1 , y n+1 , z n+1 , t n+1 ). Finally, if t n+1 , which is stored in register 150, is less than t minimum or greater than t maximum stored in register 146, comparator 144 asserts a signal at control circuit 92, which in turn instructs paint section 150 not to paint the pixel (x n+1 , y n+1 , z n+1 , t n+1 ). The minimum and maximum values stored in registers 100, 118, 132 and 146 are preloaded by CPU 9 in order to define a desired "window" or clipping region on the display screen.
A pre-computed value dt which corresponds to the a, b, c, and d parameters of the curve being rendered (which are stored in register 34, 50, 62 and 72) is calculated by the CPU 9 at initialization time and loaded into register 158. t is given a value equal to 0 at initialization time. Since dt represents the parameter step size, it must be adjusted upwardly or downwardly in order to coincide with the adjustments to the X, Y, Z and W AFDU circuits which were previously described with reference to FIGS. 1 and 3. Accordingly, dt is shifted one bit to the left to obtain 2dt at multiplexor 153 when an adjust up is required in order to correspond dt to an adjust up in the AFDU circuits. Similarly, dt is shifted one bit to the right in order to obtain dt/2 at multiplexor 153. 2dt or dt/2 are selected by appropriate control signals asserted by control circuit 92 at multiplexor 153 in order to correspond dt to the adjustments made to the X, Y, Z and W AFDU circuits. The value of dt is outputted to adder 156 which adds t thereto and stores the results thereof in register 154. The output register 154 is delayed several clock cycles in delay register 152 so that t n+1 and t n which are stored respectively, in registers 159 and 148 coincide in time with values x n+1 , and y n+1 , y n , z n+1 , and z n so that the value t n=1 will be an appropriate value for comparator 144 to compare against values t min and t max .
It will be appreciated that the above-described invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are, therefore, to be considered in all aspects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency are, therefore, intended to be embraced therein.
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An adaptive forward differencing apparatus wherein, when rendering curves, calculated x, y values are increased or decreased in order to create values which correspond to the next pixel of the display CRT, such that curves of substantially one pixel increments are continuously and uniformly generated. The apparatus also provides circuitry for generating coordinates of display elements which approximate an ideal vector and to define curves, vectors or objects within maximum and minimum coordinates of the CRT display. The present invention also provides efficient circuitry for computing the value of 1/w of the homogenous coordinate w.
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BACKGROUND OF THE INVENTION
A vibration damper assembly is conventionally utilized for a clutch assembly in the drive train between an automotive engine and a manual transmission to neutralize any torsional vibrations emanating from the engine. Although a torque converter for an automotive automatic transmission normally does not require a vibration damper as undesirable vibrations are hydraulically dampened in the converter, if a lock-up clutch is inserted in the torque converter to provide a direct drive between the impeller and turbine at higher speeds, vibrations again become a problem.
To overcome the problem of undesirable vibrations in the drive train, the present invention provides a vibration damper assembly having the capability of extended travel through the use of groups of springs arranged to operate in parallel.
SUMMARY OF THE INVENTION
The present invention relates to an improved vibration damper assembly for use in a torsional coupling between torque input and output members, such as in a vehicle clutch for a manual transmission or a lock-up clutch for a torque converter, wherein three groups of damper springs are arranged in parallel with three sets of springs in each group acting in series. The vibration damper provides for a relatively high amplitude damping at a low spring rate.
The present invention also relates to an improved vibration damper assembly comprising a hub adapted to be connected to torque output means and having a centrally positioned flange with three circumferentially spaced radial arms extending therefrom, a pair of equalizers journalled on the hub at opposite sides of the flange, each equalizer having three circumferentially spaced radial arms, and a housing substantially enclosing the hub and equalizers and attached to suitable torque input means. The arms of each equalizer are offset inwardly to lie in the same plane as the hub arms and arranged alternately between adjacent hub arms.
Further objects are to provide a construction of maximum simplicity, efficiency, economy and ease of assembly and operation, and such further objects, advantages and capabilities as will later more fully appear and are inherently possessed thereby.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a rear elevational view with portions broken away of a vibration damper assembly of the present invention.
FIG. 2 is a cross sectional view taken on the irregular line 2--2 of FIG. 1.
FIG. 3 is an exploded perspective view of the vibration damper hub and equalizers.
FIG. 4 is an enlarged partial front elevational view of an alternate version of vibration damper.
FIG. 5 is a partial cross sectional view taken on the line 5--5 of FIG. 4.
FIG. 6 is an enlarged perspective view of a portion of the housing for FIGS. 4 and 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring more particularly to the disclosure in the drawings wherein are shown illustrative embodiments of the present invention, FIGS. 1 through 3 disclose a vibration damper assembly 10 adapted to be connected to a suitable torque input means 11 and acting to drive a torque output means 12, such as a transmission input shaft of either the manual or automatic variety. The vibration damper assembly 10 includes a hub 13 having a barrel 14 with a central splined opening 15 to receive the splined end of shaft 12, a radial flange 16 centrally located on the barrel 14 to provide a pair of shoulders 17, and three circumferentially equally spaced radial arms 18 extending from the flange; each arm having outwardly diverging edges 19 terminating in a pair of circumferentially oppositely extending fingers 20.
Journalled on the shoulders 17 on opposite sides of the hub flange 16 are a pair of floating equalizers 21 and 22. The equalizer 21 has an annular flat body 23 closely adjacent the flange 16 with a central opening 24 and three circumferentially equally spaced arms 25 extending radially outwardly from the periphery of the body 23. Each arm is offset inwardly at 26 adjacent the body so that the outer portion of the arm will lie in the same plane as the hub arms 18. Each equalizer arm 25 has outwardly diverging edges 27 terminating in circumferentially oppositely extending fingers 28.
The equalizer 22 is a substantial mirror image of equalizer 21 having an annular flat body 29 with a central opening 31, three circumferentially equally spaced radial arms 32 offset at 33, so that the major portion of each arm 32 lies in the same plane as the hub arms 18 and the arms 25 of equalizer 21; each arm 32 having outwardly diverging edges 34 terminating in fingers 35.
A damper housing or cover 36 consists of a pair of cover plates 37 and 38, the rear plate 37 having a central opening 39 receiving a shoulder 17; the plate being closely adjacent the equalizer body 22. An outwardly bulged generally imperforate portion 41 on the plate 37 generally encompasses the damper springs and terminates in an inwardly offset radial flange 42. The front plate 38 has a central opening 43 receiving the opposite shoulder 17 and is provided with an outwardly bulged imperforate portion 44 terminating in an annular flange 45 abutting the input means 11; and the flanges 42 and 45 abut and are secured to the input means 11 by suitable means such as rivets 46.
Stamped out of each of the plates 37 and 38 are three circumferentially equally spaced and inwardly disposed drive arms or straps 47 having inward offsets 48 so that the straps 47 lie closely adjacent the hub arms 18. The straps 47 of the two plates are axially aligned and formed in the bulged portions 41 and 44. Adjacent the cutouts are formed oppositely extending inclined or re-entry ramps 49,49 acting to retain the damper springs in position and to prevent outward movement of the springs when the housing 36 moves relative to the hub arms 18.
Three groups of spring sets 51,52,53 act in parallel between the hub arms 18 and the equalizer arms 25 and 32. When the equalizers 21 and 22 are positioned on the shoulders 17,17 on opposite sides of the hub flange 16, the arms of the two equalizers alternate; thus in counterclockwise rotation, looking at FIG. 1, a hub arm 18 is followed by an equalizer arm 32, then an equalizer arm 25 followed by a second hub arm 18; all of the hub arms and equalizer arms lying in the same plane.
As disclosed in the prior patent applications Ser. Nos. 801,989 now U.S. Pat. No. 4,188,805; 801,990; 860,348 now U.S. Pat. No. 4,188,806 and 865,082 now U.S. Pat. No. 4,139,995; the springs for the damper are arranged in groups acting in parallel, with the springs in each group acting in series. In the present application, three groups of springs 51,52,53 act in parallel, with the three spring sets of each group acting in series. Thus, where the torque input means 11 is rotated due to the application of torque by a lock-up clutch in a torque converter, a friction clutch for a manual transmission, etc., rotation of the means 11 causes rotation of the housing 36 and drive straps 47. The drive straps engage the spring sets 51 to compress these springs and move them against arms 32 of equalizer 22 compressing spring sets 53, moving spring sets 53 against arms 25 of equalizer 21 to compress spring sets 52, which in turn move against the arms 18 of the hub to cause rotation of the output means 12.
Although, the spring sets in each group can have different rates or all the same rate, a preferred arrangement is to have the spring sets 51 and 52 of identical rates with the spring set 53 of a higher rate. Thus, the spring sets 51 and 52 would be compressed equally under the application of torque until they reached their solid heights, while the spring sets 53 would be compressed to a lesser extent than the spring sets 51 and 52. Obviously, the amount of compression of the spring sets depends on the resistance of the output means to rotation.
FIGS. 4 through 6 disclose an alternate embodiment of vibration damper wherein identical parts will have the same reference numeral with the addition of a script a. The damper assembly 10a includes a torque input means 11a, torque output means 12a, a hub 13a having a barrel 14a with a splined opening 15a, a radial flange 16a and three spaced hub arms 18a having diverging edges terminating in fingers 20a, and a pair of equalizers 21a, 22a. The equalizer 21a includes an annular body 23a journalled on a shoulder 17a of the hub and three radial arms 25a with circumferentially extending fingers 28a. Also, the equalizer 22a similarly has an annular body 29a journalled on the opposite shoulder 17a with three radial arms 32a terminating in fingers 35a. The arms 25a and 32a of the equalizers are offset in opposite directions so as to lie in the same plane as the hub arms 18a.
The damper cover 36a includes a rear plate 37a journalled on one shoulder 17a with a bulged portion 41a terminating in a radial flange 42a. However, the front plate 54 has a central opening 55 journalled on the opposite shoulder 17a and is provided with three circumferentially spaced radially extending arms 56 offset at 57 to lie closely adjacent and generally parallel to the hub arms 18a. The arms terminate in an annular flange 58 sandwiched between the input means 16a and the flange 42a, the flanges 42a and 58 being secured to the input means 11a by rivets 46a or other suitable means.
The arms 56 define three arcuate elongated openings or slots 59 in the plate, with the periphery of the plate 54 having upwardly and outwardly inclined arcuate lips 61, while outwardly and downwardly inclined arcuate lips 62 extend from the inner periphery of the annular flange 58. The arms 56 are axially aligned with the drive straps 47a in the plate 37a and act as drive straps for the assembly. Spring sets 51a,52a,53a are positioned between the hub arms 18a and the equalizer arms 25a and 32a and act in parallel as in the previous embodiments.
The slots 59 are provided in the front plate 54 where space is a problem as shown in FIG. 5; the adjacent structure preventing the use of a full bulged wall portion. Also, adjacent each arm 56, the outer lips 62 are provided with inclined ramps 63,63 which act in the same manner as the ramps 49a formed in the cover plate 37a. This assembly operates in the same manner as that of the first embodiment of FIGS. 1 through 3.
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A vibration damper assembly providing for extended travel in the damper operation, wherein the assembly includes a hub having an integral radial flange and three circumferentially equally spaced radially extending hub arms, a pair of equalizers journalled on the hub on opposite sides of the flange, and a housing substantially enclosing the hub and equalizers and adapted to be secured to a torque input member. Each equalizer has three circumferentially equally spaced radially extending arms, with the arms of the two equalizers alternating between the hub arms. This assembly provides for three groups of damper springs acting in parallel with three spring sets acting in series in each group.
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BACKGROUND OF THE INVENTION
The present invention relates to a method of analysis of signals, notably vibrational signals, generated by the rotation of a drill bit.
In the drilling technique, be it intended for oilfield development or for other purposes, a drill bit screwed on to tubes whose assembly is commonly called drill string is used. The drill string is the mechanical link between the bottom of the hole drilled and the ground surface. The drill rig is the surface installation which notably drives the drill bit into rotation, assembles and bears the weight of the drill string, injects a fluid into the drill string. In a variant, the bit can be driven into rotation by a downhole motor assembled in the drill string. A compression stress called weight on bit (WOB) has to be applied on the bit so that the bit can destroy the rock. To that effect, drill collars are assembled above the bit. Drillpipes complete the drill string.
The drill man who drives the drill rig knows some parameters which condition the action of the drill bit: the weight hanging on the pipe hook, the rotary speed and the torque applied by the rotary table, the flow rate and the pressure of the fluid injected. These parameters, measured at the surface, are used for running the drilling operation without knowing the real working conditions of the bit at the bottom of the well.
Downhole devices for performing recordings and transmissions of measurements provided by downhole sensors have been developped. These devices, commonly called MWD (Measurement While Drilling), are mainly intended for transmitting towards the ground surface the geographic position of the drill bit. However, they can also include load sensors that measure the stresses in the drill collars located above the bit.
Document EP-A-0,558,379 also describes a measurement system located in the drill string, close to the bit, the system being connected to the surface by at least one electric conductor.
There are thus well-known means allowing acquisition of data relative to the dynamic behaviour of the drill string during the drilling operation.
However, in order to run the drilling in an optimized manner, having signals representative of the behaviours of the drill bit is not sufficient, these signals also have to be interpreted in order to know the drilling process. In fact, the vibrational signals generated by the drill bit are complex signals which can provide a good representation of the evolution of the drilling operation, an operation which is not linear but which is a succession of different phases and behaviours.
A first problem encountered in the presence of such signals is the detection of one behaviour among the others. When these behaviours have been detected, the characterization of each behaviour can then be contemplated. Once characterization is completed, it will allow given behaviours to be recognized and predicted, and only characteristic coefficients to be processed or transmitted.
In certain signal instances, one may merely segment the signal into segments of a duration determined a priori, then each segment can be characterized according to the method of the invention. Once characterization is completed, analyses, processings or transmissions of the characterization coefficients can be performed. Furthermore, the means used can allow the original signal to be reconstructed from the characterization coefficients.
Optimization can consist in interpreting the vibration ranges of the drill string, notably at the level of the drill collars, in order to detect certain dysfunctionings of the drill bit. Certain dysfunctionings are well-known, such as stick-slip, where the rotation of the bit is very irregular until the bit jams, bit bouncing where the bit comes off the working face, or whirling where the bit moves in an uncoordinated precession motion. Analysis of the vibrations due to the reaction of the bit on the rock can also allow the changes of nature of the rocks to be detected, and maybe even the specific nature of a rock, the wear of the bit edges or the balling up of the bit (bad cleaning of the edges) to be identified.
To that effect, a method of analysis of the signals representative of the vibration ranges generated by the running of the bit is necessary.
One of the methods used is based on the use of the Fourier transform. The signal is decomposed into an infinite amount of sinusoids. However, when non stationary phenomena such as the behaviours of a bit during drilling are to be studied, the Fourier transform is inadequate. In fact, it appears that the most pertinent information is to be found in the non stationary parts of the signal.
SUMMARY OF THE INVENTION
The present invention describes a method for analyzing and for processing drilling signals. Drilling signals are understood to be signals provided by sensors located in the drill string. Preferably, these sensors will be placed close to the drill bit in order to avoid at best damping and noise. However, in some cases, certain sensors can be placed close to the ground surface, which facilitates signal transmission.
The processing of signals according to the present invention comprises the stage of splitting the signal into homogeneous segments.
What is understood to be a homogeneous segment is a sequence of a determined length of time having common characteristics or characteristics representative of the same event or behaviour.
In another stage, homogeneous segments are characterized by calculating coefficients related to the signal segment and the coefficients representative of the information contained in said segment are selected.
These representative coefficients may be transferred between the signal acquisition and characterization zone and a signal analysis zone, the latter zone being far from the first one.
The behaviour represented by the signal can be classified and identified by analyzing the characteristics of the segmented signal by comparison with a data base or according to classification criteria determined according to the conditions.
The present invention thus relates to a method of analysis of the drilling conditions and/or of the behaviour of an element of a drill string comprising a drill bit driven into rotation. The method comprises the stages as follows:
acquisition of a signal by at least one sensor located in said drill string,
calculation means are operated, which perform: splitting of the signal into segments of a determined length of time, determination of the wavelet coefficients of said segments by applying a Time-Frequency wavelet to at least two consecutive segments, merging of the segments so as to form at least one homogeneous segment by using an algorithm referred to as a merging algorithm,
means are operated for determining at least one magnitude associated with each homogeneous segment representative of drilling conditions and/or of the behaviour of a drill string element.
The Time-Frequency wavelet can be a Malvar wavelet.
The merging algorithm can minimize the entropy of the wavelet coefficients of said segments.
Two consecutive segments can be merged when the entropy of the merging of the two segments is less than the sum of the entropies of each of the segments.
Said homogeneous segments can be decomposed into Time-Scale wavelets by calculation means providing wavelet coefficients of each homogeneous segment.
The Time-Scale wavelet applied can be a Morlet wavelet, orthogonal, biorthogonal or dyadic.
Characteristic coefficients of each segment can be selected.
The characteristic coefficients can be the local maxima of said wavelet coefficients.
The characteristic coefficients can be the most energetic coefficients of each segment.
A stage of quantification of the coefficients to be transmitted can be performed.
The original signal can be reconstructed at least partly from said coefficients.
Transmission of the characteristic coefficients selected can be achieved through appropriate transmission means.
The acquisition, calculation and transmission means can be located in the same vicinity and transmission can be achieved between said means and the ground surface.
The invention further relates to a system of analysis of the drilling conditions and/or of the behaviour of an element of a drill string comprising a drill bit driven into rotation. The system comprises:
means of acquisition of a signal comprising at least one sensor located in said drill string,
calculation means which perform a splitting the signal into segments of a determined length of time, determination of the characteristic wavelet coefficients of said segments by applying a Time-Frequency wavelet to at least two consecutive segments, merging of the segments so as to form at least one homogeneous segment by using a merging algorithm,
means for determining at least one magnitude associated with each homogeneous segment representative of the drilling conditions and/or of the behaviour of a drill string element.
In the system, the acquisition, calculation and determination means can be located in the same vicinity, and the system can include means for coding and for transmitting towards the ground surface the characteristic coefficients of said segments.
The present invention is based on the application, to a drilling signal, of the wavelet transform referred to as "Morlet wavelets" and of the Local Cosine Transform or "Malvar wavelets".
The documents cited in the annex attached to the description, in which the wavelet theory used in the present invention is described, can be consulted.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the invention will be clear from reading the description hereafter given by way of non limitative examples, with reference to the accompanying drawings in which:
FIGS. 1A and 1B show means of acquisition of a drilling signal,
FIG. 2 shows an example of a drilling signal,
FIGS. 3A and 3B show the segmentation of the drilling signal and the materialization of the characteristic coefficients of each segment,
FIG. 4 shows a part of the reconstructed signal.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1A shows means of acquisition and of transmission of drilling signals. This means is described in document EP-0,558,379.
Reference number 2 refers to the drill bit lowered by means of the string in well 1. Conventional drill collars 3 are screwed above the bit. The first measuring means consists of a sub 4 generally placed above bit 2 where measurements next to the bit are of greater interest, notably for following the bit dynamics. It can however be located inside or at the top of the drill collars, or even at the level of the drillpipes.
The drill string is completed by conventional pipes 7 up to the suspension and connection sub 8. Above this sub, the drill string is lengthened by adding cabled pipes 9.
The cabled pipes 9 will not be described in this document since they are known in the prior art, notably through patents FR-2,530,876, U.S. Pat. No. 4,806,115 or application FR-2,656,747.
A second measuring means located in a sub 10 is screwed below kelly 11, the cabled pipes being then added below this sub 10. A rotary electric connection 12 located above kelly 11 is electrically connected to the surface installation 13 by a cable 14.
When the drill rig is fitted with a power swivel, there is no kelly and the measuring sub 10 is screwed directly below rotary connection 12, which is located below the power swivel.
The measuring sub 4 includes a male connector 6 whose contacts are linked to the measuring sensors and to the associated electronics included in sub 4.
A cable 5 equivalent to a wireline logging cable comprises, at its lower end, a female connector 15 adapted for co-operating with connector 6. The other, upper end of cable 5 is suspended from sub 8. Sub 8 is adapted for suspending the cable length 5 and for connecting electrically the conductor or conductors of cable 5 to the electric link or links of the cabled pipe located immediately above. The electric link provided by the cabled pipes bears reference number 16. This electric link passes through 17 in the second measuring sub 10. When a kelly 11 is used, it is also cabled and includes two electric cables 18 and 19. One cable, 18, connects the second sub 10 to the rotary contacts of rotary connection 12, and the other, 19, connects line 17 to other rotary contacts of connection 12.
The rotary electric connection 12 can comprise 12 tracks. It is designed to meet the antiblast standards required in the neighbourhood of a drill floor.
The surface cable 14 can include at least six conductors.
Sub 4 is generally connected by a single-conductor to the surface installation 13. The measurements and the power supply pass through the same line.
The measuring means of sub 4 preferably comprises sensors for measuring, alone or in combination:
the weight on bit,
the reactive torque about the drill bit,
the bending moments along two orthogonal planes,
the accelerations along three orthogonal axes, one of them merging in the longitudinal axis of the drill string,
the temperature and the pressure inside and outside the string,
the rotation acceleration,
the components of the magnetic field.
The first three measurements can be obtained through strain gages stock onto a test cylinder. They are protected from the pressure by an appropriate housing. The design and the build-up of this housing are adapted for preventing measuring errors due to efficiency.
Accelerations are measured by two accelerometers per axis in order to control errors induced by the rotation dynamics.
The last set of measurements is obtained by specific sensors mounted in a separate part of the sub.
The second measuring means of measuring sub 10 preferably includes, alone or in combination, sensors for measuring:
the tension,
the torsion,
the axial acceleration,
the internal pressure or pump pressure,
the rotation acceleration.
The design of this surface sub 10 is not basically different from that of the first sub, apart from the obligation to leave a free mud passage substantially coaxial to the inner space of the string so as to allow, if need be, transfer of a bit inside the string.
In a variant of the acquisition system, a high frequency of measurement transmission is obtained by electric links consisting of cable 5, line 16 and 17, and surface cable 14. Certain downhole sensors which require no high frequency sampling can transmit their measurements through other channels, by pressure wave or electromagnetic wave for example.
Sub 4 can include the necessary electronics to compact the information provided by at least one drilling signal. The characteristic coefficients of signal segments can then be transmitted either through the electric conductor of the device of FIG. 1, or by pressure wave or electromagnetic wave, or by any other suitable transmission means.
Sub 4 can also comprise the electronic means of automatic segmentation into homogeneous segments, and means for selecting the characteristic segments of a behaviour of the determined drilling, a behaviour which will be brought to the operator's attention after transmission of the characteristic coefficients to the surface.
FIG. 1B shows a conventional drill rig in which one has inserted in the drill collars a measuring sub 4 which records at least one drilling signal, an electronic installation 20 including the signal compaction means, an installation 21 for coding and transmitting to the surface the characteristic coefficients of the signal. Transmission can be achieved by pressure waves in the column of fluid inside the drill string. A pressure detector 22 located on the surface injection line 23 transmits the pressure waves to a surface processing installation which decodes the pressure waves to obtain the characteristic coefficients. The surface installation can identify the behaviour according to a data base or to particular instructions, or reconstruct the signal in order to give the operator for example analog measurements.
FIG. 2 shows an example of a drilling signal as a function of time t.
FIG. 3 A shows the signal segmentation obtained with a preferred method according to the invention.
The homogeneous segment 30 to which the wavelets have been applied provides, in FIG. 3B, the representation 31 of vertical lines which materialize the characteristic coefficients of the homogeneous segments.
FIG. 4 illustrates the reconstruction of segment 30 from certain coefficients materialized by lines 31.
ANNEX
The present invention is based on the application, to a drilling signal, of a time-scale wavelet transform and of a time-frequency wavelet transform.
The following documents provide additional information and further details about the concepts handled:
(1) R. Coifman, V. Wickerhauser, "Entropy-based Algorithms for Best Basis Selection", IEEE Transactions on Information Theory. Vol.38, No. 2, March 1992.
(2) M. Holschneider, R. Kronland-Martinet, J. Morlet, Ph. Tchamitchian, "A Real Time Algorithm for Signal Analysis with the Help of Wavelet Transform", in Wavelets, Time-Frequency Methods and Phase Space, J. M. Combes, A. Grossmann and Ph. Tchamitchian, Eds. Berlin: Springer, ITPI 1989, pp. 286-297.
(3) H. Malvar, "Lapped Transforms for Efficient Transform/Subband Coding", IEEE Transactions on Acoustics, Speech and Signal Processing, 38:969-978, 1990.
(4) J. Morlet, A. Grossmann, "Reading and Understanding Continuous Wavelet Transform".
(5) K. R. Rao, P. Yip, "Discrete Cosinus Transform", Academic Press, New York, 1990.
The use of the wavelet techniques can be considered as an alternative in relation to the methods based on the Fourier transform. In fact, these methods reach their limits when non stationary phenomena (beginning or end of events, ruptures, modulations, . . . ) are studied. A distinctive feature of the Fourier transform is that it delocalizes the information along the time variable, which may be very unfavourable for the study of a non stationary signal. In fact, the pertinent information is mainly to be found in the non stationay parts. These parts are generally limited in time, but they have a wide frequency spectrum. The wavelets will therefore allow a more localized study of the signal to be performed, with a time variable as well as with a Fourier variable.
A wavelet transform consists of the decomposition of a signal on functions which vibrate like sinusoids within a certain time range and which decay very strongly outside this range. Such an analysis is constructed from a function ψ(x) called mother wavelet or analyzing wavelet, meeting the definition as follows:
Definition No.1: A function ψ of value in R or in C is a wavelet if it has a compact support (or if it is of fast decay to infinity) and if it meets the essential condition as follows: ##EQU1##
In the transform calculation, there is no multiplication by sines or cosines (as in the methods derived from the Fourier transform). A family of wavelets is generated by translation and by dilatation from the mother wavelet: ##EQU2##
These wavelets are the base elements which will be used for the analysis construction. Parameter a gives the average width of the wavelet and parameter b its position. The wavelet coefficients of a function f(x) of the real variable x, or of a signal s(t) (t being a time variable) are the scalar products defined by the formula: ##EQU3##
The following remark can be made here: ##EQU4##
A wavelet transform thus consists of a filtering of f by band-pass filters of impulse response ψa. ##EQU5##
In the case where Kψ<+∞, the signal can be reconstructed from its decomposition by applying the formula as follows: ##EQU6##
Kψ plays the part of a normalizing coefficient.
The wavelet analysis thus provides a tool for measuring the local fluctuations of a function f about a point b, at a scale a, as well as a method of reconstruction from these fluctuation coefficients.
The wavelet transform, by definition, is rather a time-scale representation than a time-frequency representation. However, since it can be identified with a band-pass filtering, the wavelet transform can generally admit a time-frequency interpretation by considering that the variation of the scale parameter a allows the frequency axis to be explored. This is notably the case for wavelets "reasonably" localized in frequency about a value v 0 . It is then possible to perform a time-frequency interpretation by means of the formal identification v=v 0 /a.
0.1 Use
The formula of the continuous version of the wavelet transform given by Equation (2) cannot be used directly to achieve an implementation. Analysis of a signal is generally performed with a number of scales ranging between 8 and 12 octaves. The process thus requires the use of a fast algorithm in order to reduce the complexity of the operations and to allow calculations to be envisaged. Such algorithms are achieved from discrete versions of the wavelet transform. However, there are differents ways to consider this discretization, which mainly depend on the way the time and scale variables are processed.
The "gapped algorithm" described in this document uses for example the discrete version: ##EQU7## δ being the inverse of the sampling frequency of the signal. This algorithm, by reducing the complexity of the convolutions (measured by the size of the filter used for convolving) by means of factorizations, allows the discretization (4) to be efficiently used.
By studying the plane paving structure associated with the wavelet transform, one observes that the latter is all the more narrow in time since the evaluation point is at a higher frequency, and the use of a non-uniform grid:
{(t,a)=(nt.sub.o a.sub.o.sup.m,a.sub.o.sup.m);t.sub.o >0,a.sub.o >0;n,m.di-elect cons.Z}
allows the discrete wavelet transform to be defined by: ##EQU8##
The choice a o =2 corresponds to a dyadic scale decomposition (one coefficient series per octave).
To sum up, the analysis of a signal will be performed according to the following pattern:
acquisition of the drilling signal,
application of the decomposition algorithm,
fixing the percentage of the highest coefficients to be taken into account during reconstruction,
finding the original signal again with the inverse transform formula from the coefficients selected.
0.2 Gapped algorithm
One of the algorithms implementing a continuous transform is briefly described hereunder. This algorithm, referred to as "gapped algorithm", is based on the principle as follows: in the coefficient calculation, the analyzing wavelet g is replaced by another wavelet constructed from the previous one by interpolation (by means of filtering) between points forming the initial sampling of g. This method can be carried out in practice only with a simplification of the convolution products to be calculated.
Let D and I be the dilatation and inversion operators. The wavelet transform of a signal s with respect to a wavelet g(t) can be written in the form of the convolution product as follows:
S.sub.a =S(.,a)=Kg.sub.a s with g.sub.a =D.sub.a Ig (5).
Consider the sampling operator P which associates with the sequence s(t) t.di-elect cons.R the sequence s(n) n.di-elect cons.Z. It is then possible to write, from equation (5):
S.sub.a =Kg.sub.a s with this time g.sub.a =PD.sub.a Ig (6).
The calculation iterations are such that a sampling of the dilated original wavelet must be available. In order to reduce the complexity of the convolutions with the dilated wavelets, they are factorized in convolutions with smaller filters. This operation is performed as follows:
Construction of an operator O such that ##EQU9## Take O=D 2 , therefore (D 2 g)(n)=0 for any odd n.
An interpolation procedure will rather be performed (refer to the bibliography for further details) with the operator O=D 2 +TD 2 K F , which gives non systematically zero values for the odd positions.
Simplification of the convolutions
The convolution by (O n .g) is factorized in more simple convolutions
K.sub.o n.sub.g =α.sup.n K.sub.g.sbsb.n K.sub.F.sbsb.1 . . . K.sub.F.sbsb.n with α=2.sup.-1/2
and
g.sub.n =(α.sup.-1 D.sub.2).sup.n g
F.sub.i+1 =(α.sup.-1 D.sub.2)F.sub.i
From the previous result, the transform on N octaves is then calculated according to the pattern as follows: ##EQU10## Transform on several voices
In this case, a restriction of S(b,a) to a set of discrete values of the scale parameter a will be considered. Such a restriction S(b,a i ) is called a voice. Two consecutive voices form a constant ratio a i /a i+1 . The most common situation is that where a j =a o 2 j/nv =2 no+k/nv , the integer nv defining the number of voices per octave, j the number of the voice in the analysis, no the number of the octave and k the number of the voice in the octave. These are thus intermediate values taken for passing from a=2 j to a=2 j+1 . A division in 12 voices per octave appears to be satisfactory to approach continuity on the scales axis (by analogy with the temperate distributions).
Since nv voices are to be considered in each octave, implementation is achieved by superposing nv versions of the algorithm corresponding to nv different wavelets (dilated versions of the original wavelet). In fact, the ratios between the values a i being constant, the ratio between the kth voice of the octave O i and the kth voice of the octave O j will be the same as the ratio between the nth voice of the octave O i and the nth voice of the octave O j . The wavelet will therefore be calculated for the first nv dilatations (corresponding to the nv voices of the octave O), and the previous pattern will be applied with, at each time, a different original wavelet g v defined by: ##EQU11##
Let [Inf-Wave, Sup-Wave] be the base sampling of the wavelet, i.e. the interval in which t varies when g(t) is calculated.
The sampling intervals [Maxi v , Mini v ] will then be calculated as follows for the dilated versions:
a. Calculation of Maxi v : 2 v-1/nv ×Inf-Wave
b. Calculation of Mini v : 2 v-1/nv ×Inf-Wave
c. Definition of the wavelet calculation points:
Let ƒe be the sampling frequency of the signal to be analyzed, put Freq=ƒe/2 (which is the maximum frequency analyzed). The wavelet will then be calculated at the points t=jaδ/ƒe with a=2 v-1/nv , j being a point of the sampling interval (i.e. j varies from Mini to Maxi), and δ=2ω o /Freq.
By carrying out a wavelet transform, one passes from a one-dimensional signal s(t) to a two-dimensional signal S(n,m), i.e. a sequence of one-dimensional signals (a sequence of coefficients for each value of the dilatation parameter). Reading of these signals may prove very difficult if no appropriate representation mode is available.
In order to facilitate the interpretation of the results obtained, the coefficients will not be used directly as they are. One will choose, for example, to consider them as the pixels of an image indexed by the parameters n (time parameter) and m (scale parameter). The small scales, representing the high frequencies, are at the top of the image and the large scales, for the lower frequencies, are at the bottom of the image (article [4] gives further information concerning the interpretation of these images). The passage of a coefficient of the transform to a grey level occurs by projecting the interval [Coeƒƒ-Min, Coeƒƒ-Max] in [0.255]. The introduction of a saturation coefficient is sometimes necessary to be able to perfectly exploit the images obtained.
This image thus has as many columns as there are points in the initial signal, which facilitates interpretation. In fact, the image and the signal just have to be juxtaposed to get an idea of the behaviours involved.
For each signal, one gets an image representing the analyses at the various scales. Interpretation is much more simple since the whole information is directly available in the image. Furthermore, this image allows to get a first notion of the signal to be processed and to give a first assessment concerning its characterization.
1 Time-frequency wavelets
The time-scale analysis (also called multiresolution algorithm) is based on the use of a wide range of scales for analyzing the signal. Although it is interpretable as regards frequency, it does not offer a high precision in this domain.
To overcome this drawback, we present hereafter a second method of analysis leading directly to a segmentation algorithm and based on the use of time-frequency wavelets referred to as Malvar wavelets. The analysis through Malvar wavelets lies within the general framework of the window Fourier transform. The Malvar wavelets allow a local frequency analysis of the signal to be performed, while minimizing the artifacts which generally go with such algorithms.
1.1 Description of the algorithm
This method rests on the local cosine transform of a signal or "Malvar wavelets". It provides an invertible spectral representation enabling a perfect reconstruction, as well as a very efficient data compression tool. ##EQU12##
With I j =[a j , a j+1 [an interval of length greater than or equal to ε (ε>0 fixed).
Let b j be the window as follows: ##EQU13##
The family of functions as follows: ##EQU14## with j.di-elect cons.Z, k.di-elect cons.N is then an orthonormal base of L 2 (R). This means that any signal S(t).di-elect cons.L 2 (R) can be written: ##EQU15##
This decomposition offers a complete and non-redundant spectral representation. The sequence of coefficients c k j =<S(t), ψ k j (t)> for k.di-elect cons.N being the local spectrum of S on the interval I j .
Several local transforms can be calculated at the same time by dividing the intervals by two recursively. The base functions for each interval are the direct sum of the bases of the two subintervals. The convolution product (8) can be calculated by using a fast cosine transform. This calculation is preceded by a stage called "folding stage".
Let ##EQU16##
The following operator: ##EQU17## is called folding operator. Applying this operator to a signal S(t) amounts to associating therewith a set of signals S j (t).di-elect cons.L 2 (I j ), j.di-elect cons.Z such that: ##EQU18##
The coefficients c k j =<S j (t),.O slashed. k j (t)> thus form a local spectrum in I j .
Furthermore, this local spectrum in I j can be represented in the base of {ω k j (t)}k.di-elect cons.N, we have the equality as follows:
c.sub.k.sup.j =<S.sub.j (t),.O slashed..sub.k.sup.j (t)>=<S(t),ω.sub.k.sup.j (t)>.
Applying the cosine transform to the S j (t) therefore amounts to calculating all the convolution products with the functions ω k j .
The folding operation allows the edges to be taken into account while avoiding the overlap biases in the transform calculation, or the appearance in the analysis of discontinuities which would not be due to the signal but to the sudden breaks imposed by insufficiently soft windows. The unfolding operation which comes into play for the reconstruction can be defined reciprocally.
Let S(t) be a given signal, a folding is started at the edges (S o (t) is thus obtained), then in a recursive manner at the center of the signal obtained (the signal is in a way folded up on itself).
At each level, a set of functions {S j 1 (t)} is associated with S(t), knowing that: {S j 1 (t)}.di-elect cons.L 2 (I j 1 ) gives at the next level: S 2j 1+1 (t).di-elect cons.L 2 (I 2j 1+1 ) and S 2j+1 1+1 (t).di-elect cons.L 2 (I 2j+1 1+1 ), (1 being the level in the decomposition).
It is then possible to calculate the transform (through the conventional algorithm DCT-IV) for each S j 1 , which gives the corresponding local spectrums d j 1 .
The following result is important: ##EQU19## which means energy conservation. 1.2 Adaptive segmentation
The Malvar algorithm performs no segmentation, it decomposes the signal in a window of a given size. It may be interesting to adapt the window to the local characteristics of the signal (wide windows for stationary zones and short ones for transitions) by using a window growth algorithm by merging.
This modification is performed by acting upon the values (a j ) which are used for defining the segments I j . The elementary modification consists in merging two intervals [a j-1 ,a j ] and [a j ,a j+1 ] while removing a j , the others remaining unchanged.
The use of this merging procedure requires introduction of a decision criterion allowing the cost of the operation and therefore the interest to do it to be assessed.
Let {x k } be a sequence of 1 2 , the spectral entropy of {x k } is denoted by: ##EQU20## is the theoretical dimension of the sequence {x k }.
The entropy allows the number of significant terms in the decomposition to be measured. This value constitutes an interesting criterion for assessing the cost of a merging. Of course, this does not rule out the use of other criteria which may lead to the same results.
The segmentation algorithm uses a procedure of "best base search" among a family of orthonormal bases of L 2 (R). These bases are obtained from an arbitrary segmentation of the time axis into dyadic intervals. These intervals are constructed in a "free to coarse" dynamics. One starts from an arbitrary base (associated with a segmentation of the signal) comprising 2 1 segments. The local spectrum is calculated in each interval. The dynamics consists in removing certain points used in the segmentation and in replacing two contiguous dyadic intervals I 1 and I 2 by the dyadic interval I=I 1 ∪I 2 . And the operation is continued recursively.
For example, suppose that the finest (arbitrary) segmentation of the interval I is I 1 =[a 1 1 ,a 2 1 ]∪ . . . ∪[a n-1 1 ,a n 1 ]. The local spectrum will thus be calculated in the intervals I j 1 =[a j 1 ,a j+1 1 ]. The same will be done with I 1-1 =∪ j=1 [a 2j-1 1 ,a 2j+1 1 ] until I o =I.
Once this operation is completed, the best base search algorithm can be applied.
⊕ Search of the adapted local spectrum by entropy minimization
What is available is: ##EQU21## a local spectrum for each interval I j 1 at the level l:
c.sub.j.sup.1 ={c.sub.j,k.sup.1 :0≧k>2.sup.N-1 }
The recursive procedure of division of the intervals by two implies that |I j 1 |=2×|I j 1+1 |.
The adapted local spectrum is obtained by means of the entropy minimization algorithm presented hereunder:
initializing with the local spectrum at the lowest level (maxl):
a.sub.j.sup.o =c.sub.j.sup.o (Rq:m=01=max1)
calculating a j m as follows:
a.sub.j.sup.m =c.sub.j.sup.m if H(c.sub.j.sup.m)<H(a.sub.2j.sup.m-1)+H(a.sub.2j+1.sup.m-1),
or else a 2j m-1 ∪a 2j+1 m-1 for m=1, . . . , maxl.
The division of the time interval corresponding to this adapted spectrum is called: adapted temporal partition.
1.3 Use
According to the invention, the signal S(t) is a "drilling signal", sampled within a time interval [0,T].
From the previous results, we know that each S j (t).di-elect cons.L 2 (I j ) can be decomposed on an orthonormal base of elementary waves: ##EQU22## n j being the number of samples of the interval I j considered, and c k j the coefficients obtained by DCT-IV. The algorithm (analysis and reconstruction) can be summarized as follows: ##EQU23##
Each coefficient c k j gives the amplitude of the elementary wave associated therewith. The period of this wave being ##EQU24## its frequency thus is: ##EQU25##
The sampling frequency being ##EQU26## we have ##EQU27##
For a signal sampled in a uniform manner in [0,T], each interval I j can theoretically contain the same maximum frequency.
In a given segment, the spectrum of the frequencies is then studied more precisely. The index of the most significant spectral component is determined first: ##EQU28##
The frequency F ko associated with k o is called fundamental frequency.
When this value has been determined, all the coefficients located in its frequency neighbourhood (i.e. all the c k such that |k o -k|<ν)are removed (by zeroing them). And the operation is reiterated.
The search for the fundamental frequencies associated with a given interval is thus performed as follows:
1. Seeking in the sequence {c k } the value k i by means of relation (9)
2. Putting c k =0 if |k i -k|<ν, if ν is fixed
3. Going back to (1) as long as there are non zero coefficients or as long as x% of the highest coefficients have not been used up (in the second case, the lowest "peaks" are thus eliminated).
It should be noted that the coefficients c k such that |k-k i |<ν carry information that can be summed up in a parameter. This parameter will be the center of mass μ i associated with a fundamental frequency F ki . ##EQU29##
For each interval, one can thus have a list {μ i ,E i } for the most energetic frequencies. This data then comes into the intervals characterization.
1.4 Summary
1.4.1 Signal analysis
The segmentation method can thus include the following stages:
Defining the minimum size of an interval in the decomposition or the maximum number of levels (maxl) (knowing that |I j 0 |=2 N=max1 ).
Preprocessing of the signal at each level (l=0, . . . ,maxl) ##EQU30## by the folding operator. Calculating the local spectrum at each level: ##EQU31## by using the DCT-IV. Selection of the adapted local spectrum by entropy minimization, and "calculation" of the corresponding adapted temporal partition.
Realization of a definitive partition by comparing the intervals of the adapted temporal partition according to the criteria as follows:
the fundamental frequency (and the main frequencies),
the centers of mass (or centers of frequency),
the theoretical dimensions of the segments,
autocorrelation, covariance . . .
A given behaviour can be characterized by particular values for these different parameters. Any segment can thus be known with precision.
This process thus allows segmentation of the signal into parts as homogeneous as possible, and each segment can be associated with an easily manipulable parameter vector.
1.4.2 Synthesis
The segmentation can be followed by the following stages:
Reconstruction of the preprocessed signal from the adapted temporal partition by using the DCT-IV
Reconstruction of the original signal by means of the unfolding operator.
1.4.3 Compression
Reconstruction of the signal can be performed, for example, from 5% of the most energetic coefficients of each interval of the adapted temporal partition (see the fundamental frequencies search method for selecting the most energetic frequencies). ##EQU32##
|
The present invention relates to a method and to a system for analyzing drilling conditions and/or the behaviour of a drill string element. It comprises the stages as follows:
acquisition of a signal,
calculation means are operated, which determine the wavelet coefficients of segments of the signal, the segments are merged to form a homogeneous segment,
a magnitude associated with each homogeneous segment is determined.
The invention further relates to a system for implementing the method.
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BACKGROUND OF THE INVENTION
1. Technical Field
The invention relates to decorative, imitation candles and, more particularly, to an imitation candle simulating a lighted wick.
2. Description of the Problem
Numerous manufacturers have attempted to meet a demand for a flameless, candle like luminary using electrical illumination. There are many imitation candles available that use incandescent lamps or LEDs as a light source. These devices address people's concern with having an open flame indoors. Most of these devices try to implement the appearance of a realistic flame using a specially shaped bulb or lens that is exposed to view. Typically, the bulb or lens sits on top of a thin cylindrical sleeve, which is shaped and colored to resemble a candle. The results are typically disappointing, especially when these devices are not illuminated. The visible, flame shaped artificial light source draws attention to the fact that the device is an imitation candle. The result can look more like a caricature of a candle than a real candle. The color of incandescent light can leave something to be desired in many candles as well.
In addition, there are also imitation candles available that utilize one or more very small incandescent lamps or LEDs as the light source which do not place the light source inside a flame shaped structure. Examples exist of imitation candles which have a deep well on the top to simulate a candle that has been burning for some time. As these light sources are relatively small they can be concealed within the deep well of the artificial candle. From most viewing angles, the wall of the artificial candle would be between the light source and the viewers eye. At these viewing angles there is no artificial flame structure visible that would detract from the candle's realism. However, when viewed from above, the small light source (or sources) are readily visible and reveal that the candle is an imitation. It would be desirable to provide an imitation candle that is viewable from the side or above without revealing an obvious artificial light source.
A key visual element of a real flame is a rather intense area of light. When the flame is viewed directly, in a darkened environment, the flame can become a source of glare for an eye accommodated to scotopic vision. Eyes adjusted to darkness cannot tolerate the large contrast in brightness and as a result, the physical outline of the flame is often lost to the eyes in the glare. In the case of artificial flame structures, the outer surface is often frosted so that the flame structure is itself lit up. By spreading the light from the artificial light source across a larger surface area, the intensity of light across the surface is much less than that from an illumination source. Because of this lack of point source intensity, the brain does not interpret the flame structure as a real flame, but still comprehends the structure. Incandescent lamps that have clear glass flame structures reveal an intense filament, but the filaments are generally linear, detracting from their appearance. The glass, though clear, may still be visible as well.
U.S. Pat. No. 6,616,308, which is incorporated herein by reference, teaches an imitation candle configured to diminish any expectation on the part of an observer of seeing an open flame. Many of the typical deficiencies found in imitation candles are addressed in the '308 patent. The flame structure is eliminated and so does not detract from the candle's realism when not illuminated. In addition, the candle's structure is such that from most viewing angles the observer would not expect to have a direct view of the flame and so the lack of a flame when illuminated does not detract from the candle's realism. When the candle is off and viewed from above, there is no visible bulb or other structure to reveal that the candle is artificial. An imitation wick, visible when the candle is viewed from above, can be used to complete the illusion that the candle is real. However, when the imitation candle of the '308 patent is on and viewed from above, there is no bright source of light at the end of the wick as would be expected in a real candle. It would be desirable to provide an artificial candle with an artificial wick that when viewed from the side or above, does not reveal an obvious light source or other structure that would reveal that the candle is artificial, while at the same time providing a bright source of light at the tip of the wick when the candle is on.
One approach to creating a realistic illusion of a flame is disclosed in U.S. patent application Ser. No. 10/844,075, filed 12 May 2004 (now U.S. Pat. No. 7,093,961 and assigned to the assignee of the present application), which is incorporated herein by reference. This application discloses an LED hidden within a fixture above an imitation candle body. Light emitted by the LED is directed to illuminate the candle body and wick from above. The LED is driven by a variable current to produce flickering light. The imitation wick has a reflective tip which reflects the incident light to create a small bright spot. The bright spot at the tip of the wick is sufficiently bright that even though the light source may be flickering, the intensity remains strong enough that the eye sees the resultant glare but cannot see the change in intensity of the spot. At the same time, light shines past the wick and onto the candle body where it is diffused throughout a relatively large volume. The light intensities within the candle body are much lower resulting in a dramatic, flickering effect.
For standalone imitation candles that are not housed in a permanent fixture, the approach of the '075 application is more difficult to effect since there is no convenient place to hide the LED but within the candle body itself. An approach to creating a realistic illusion of a flame that does not require a permanent fixture is disclosed in U.S. patent application Ser. No. 11/053,397, filed 31 Mar. 2005 (now U.S. Pat. No. 7,360,935 and assigned to the assignee of the present application), which is incorporated herein by reference. This application discloses an LED hidden within an imitation candle body as in the '308 patent. One end of a fiber optic wick is positioned in close proximity to the LED and captures part of the emitted light. The captured light is directed to the upper, exposed end of the fiber optic wick which then glows brightly in response. The majority of the length of the artificial wick is covered by a dark material, so the overall visual effect is that of a real wick, the tip of which is glowing brightly. The candle can be viewed from the side or above without revealing any light sources or artificial structures that detract from the candles realism.
While the approach described in the '397 application is effective, it may be desirable to produce a light intensity at the tip of the wick that is even brighter than that which can be achieved using a fiber optic wick to transmit a portion of the light emitted by the LED. It would be desirable to place the light source at the tip of the wick for maximum brightness while at the same time incorporating the light source and its support structure into an artificial wick that does not detract from the candle's realism when the candle is viewed from the side or from above.
The present inventors are familiar as well with a decorative, miniature Christmas tree, which is constructed from wires which terminate in surface mount technology light emitting diodes. The wires are soldered to the SMT LEDs, which are scattered about the tree producing the effect of a fully lighted tree.
SUMMARY OF THE INVENTION
According to the invention there is provided an imitation candle having a body and an imitation wick. The imitation wick extends outwardly from the body and supports a light emitting diode on its exposed portion at a location spaced from the body of the imitation candle. An energization circuit for the light emitting diode is housed within the body and electrical leads extend from the energization circuit along the imitation wick for connection to the light emitting diode.
Additional effects, features and advantages will be apparent in the written description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself however, as well as a preferred mode of use, further objects and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a perspective view of an imitation candle.
FIG. 2 is a cross sectional view of a possible internal configuration for the imitation candle of FIG. 1 .
FIG. 3 is a close up view of the lighting element of the internal configuration shown in FIG. 2 .
FIG. 4 is a cross sectional view of an alternative internal configuration for a lighting element in accordance with a second embodiment of the imitation candle of FIG. 1 .
FIG. 5 is a cross sectional view of still another alternative internal configuration for a lighting element in accordance with a third embodiment of the imitation candle of FIG. 1 .
FIG. 6 is a cross sectional view of yet another alternative internal configuration for a lighting element in accordance with a fourth embodiment of the imitation candle of FIG. 1 .
FIG. 7 is a cross sectional view of still another alternative internal configuration in accordance with a fifth embodiment of the imitation candle of FIG. 1 .
FIG. 8 is a cross sectional view of still another alternative internal configuration in accordance with a sixth embodiment of the imitation candle of FIG. 1 .
FIG. 9 is a close up view of a downward facing LED mounted to the artificial wick.
FIG. 10 is a circuit schematic for a representative drive circuit for the LEDs.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 an exterior configuration for several possible embodiments of the imitation candle 100 of the invention is illustrated in perspective view. Imitation candle body 1 is preferably squat, configured to resemble a self supporting candle which has burned down by the center. Imitation candle body 1 , which can be fabricated in wax or translucent plastic, may contain an internal light source positioned within the imitation candle body so as to illuminate the candle body with a diffuse, flickering glow that simulates the appearance of a lit candle. An artificial wick 2 extends from the upper surface of candle body 1 and both supports, and provides electrical connections to, an external light source 3 , typically a super bright surface mount light emitting diode (LED). A depression 4 in the upper surface 52 of the candle body 1 may be incorporated to simulate a candle that has been partially burned. The part of artificial wick 2 below the external light source 3 may be painted black or enclosed within a thin black sleeve (not shown) to better simulate the appearance of a burnt wick.
FIGS. 2 and 3 show cross-sectional views of the imitation candle of FIG. 1 illustrating a possible internal configuration thereof. A cavity 5 within the imitation candle body 1 allows space for the installation of an electronics module and a power source 6 . The power source 6 would typically include one or more batteries 7 , but could also be a connection and conversion assembly to an external source of power. A main circuit board 8 would contain the electronics module 29 needed to supply current to an internal light source 9 and the external light source 3 . The external light source 3 is a surface mount light emitting diode which is located mounted face up and flat on a narrow end edge 23 of the imitation wick 2 . The surface mount light emitting diode, when illuminated, emits light at the tip of the wick that is undiminished in intensity to an observer. The position of the light source 3 is such that emitted light thus may be directly observed to the sides and from above and a light emitting diode is preferred. The light source 3 and its support structure are incorporated into the imitation wick 2 in a way intended to not detract from the imitation candle's realism when the imitation candle is viewed from the side or from above.
While a cordless model is preferred, it is possible to provide external energization to the device. An internal light source 9 is provided, preferably using a super bright light emitting diode (LED) as described in U.S. Pat. No. 6,616,308, but it could be an incandescent source. External light source 3 is preferably a surface mount technology (SMT), super bright, light emitting diode (LED). In addition to supplying current to the light sources 3 and 9 , electronics module 29 may include on/off timers, daylight sensors and a flicker energization circuit to cause either the light source 3 , 9 or both, to flicker as would an unstable candle flame.
The size and position of main circuit board 8 is chosen to control the illumination levels from top to bottom of the imitation candle body 1 , reducing light emission from the lower portion of the body. A secondary circuit board 10 is mounted along one of its edges to the upper surface of main circuit board 8 . Secondary circuit board 10 provides conductive traces 11 to supply current to the external light source 3 along a narrowed section of the secondary board which serves an imitation wick 2 . The artificial wick 2 is a narrowed section of the secondary circuit board 10 and passes through a hole 12 in the upper surface of the candle body 1 . Hole 12 would typically be filled with a small, insulating plug (not shown) to provide mechanical support for the artificial wick 2 . A dark colored, opaque sleeve (described below) would typically surround the exposed portion of artificial wick 2 serving to disguise the artificial wick 2 and give it the appearance of a real wick which has burned down. Alternatives to the sleeve could be used to disguise artificial wick 2 as a wick, but care must be taken not to interfere with light emission from the external light source 3 .
FIG. 3 is a close up view illustrating the mounting of a single SMT LED 3 to the artificial wick 2 of the secondary circuit board 10 . The secondary circuit board 10 is double sided and has conductive traces 11 on both sides. The LED is mounted to the narrow end edge 23 of the circuit board and soldered 13 on each of two sides to the conduction traces 11 to hold the LED in place and to make electrical connection with the conductive traces 11 . Soldering may be used to provide electrical connection between the main circuit board 8 and the traces 11 .
FIG. 4 shows an alternate embodiment supporting a single SMT LED 3 . The secondary circuit board 10 is reduced in size and is connected to the main circuit board 8 with two wires 15 which are soldered 14 to the conductive traces 11 on the secondary circuit board 10 . The LED 3 is attached as before. By eliminating most of the secondary circuit board 10 the potential for shadowing a portion of candle body 1 from light emitted by LED 9 is reduced, though in practice, this has proven a minor advantage. In all of the embodiments of the invention provision of a candle body 1 outer wall of sufficient thickness operates to distribute light around the circumference of the body.
FIG. 5 shows an alternate construction that eliminates the need for the main circuit board. The electronics module 29 and the internal light source 9 are all mounted to the secondary circuit board 10 . LED 9 is supported on wires 21 extending from Board 10 . Conductive traces 22 supply power to LED 3 .
FIG. 6 shows an alternate embodiment that significantly reduces the size of the secondary circuit board 24 . The internal light source 9 is slightly offset on the main circuit board 10 , but not so much as to cause any significant irregularity in illumination of the surrounding candle body. LED 9 is positioned within a cylindrical section 47 made of the same translucent material as the walls of candle body 1 , which serves to distribute light evenly outwardly from the LED.
FIG. 7 shows an alternate embodiment that eliminates the secondary circuit board. Two wires 15 are attached to a plastic rod 16 and to the main circuit board 8 . The plastic rod 16 serves to separate the wires 15 and provides mechanical support for the LED 3 . The opposite ends of the wires 15 are soldered 13 to the LED 3 . A thin sleeve (not shown) helps hold the wires to the plastic rod and provides the appearance of a burnt wick. A plug would fill hole 12 and provide support for the artificial wick 2 . The wires 15 could be enameled. The enamel would provide insulation and allow the wires to touch without shorting. The plastic rod 16 would no longer be necessary to keep the wires 15 separated. Twisting enameled wires 15 together to form a twisted pair would provide enough mechanical support for the LED 3 , and eliminate the need for the plastic rod 16 . A dark sleeve could be used as described before to make the wires look like a real wick, or a dark enamel on the wires 15 could be used to disguise them as a wick.
FIG. 8 shows yet another alternate embodiment that eliminates the secondary circuit board and the internal light source. The LED 3 is mounted inverted with respect to candle body 1 to direct light downward toward a beveled, mirrored tip 18 of rod 38 and toward the upper surface of the candle body 1 . The beveled tip 18 reflects light to create the hot spot as required for the desired lighting effect. Spillage from LED 3 illuminates the candle body 1 where light is diffused and appears to cause the candle body 1 to glow from within. A sleeve 19 encloses a portion of rod 38 below beveled tip 18 .
FIG. 9 illustrates an LED mounting scheme using a printed circuit board (PCB) 42 that is cut or formed in a hook shape to allow the SMT LED 3 to be mounted facing downward. Printed circuit board carries conductive traces 11 which are electrically connected by solder 44 to wires 15 extending from a main circuit board as shown in FIG. 7 .
FIG. 10 illustrates representative energization electronics 29 for driving a pair of LEDs 3 , 9 . A power source 50 is provided by four size D batteries. Different power sources can be used depending upon desired battery life or the desired brightness to be obtained from the LED. As mentioned above, alternatives include combinations of solar cells and rechargeable batteries or an outside line source of power. LED 9 is preferably provided in a Global Opto G-L202YTT-T amber light emitting diode package. LED 3 is preferably a G-S160YTT type LED. Energization electronics may be switched on and off using a switch 52 which is attached at one pole to the positive terminal of battery 50 . Switch 52 may be a photosensitive device, such a photosensitive transistor. Battery 50 also supplies V cc within energization electronics 29 .
LEDs have a constant voltage drop when conducting current and the intensity of light emission from an LED is controlled by varying the current sourced to the LED. Accordingly, the LED energization circuit 29 sources a varying amount of current to LEDs 3 , 9 . The first major element of energization circuit 46 is a base current source provided by zener diode 54 , resistors 56 and 62 , and a PNP transistor 60 , which sources current to the load, here light emitting diodes 3 , 9 . The voltage source provided by battery 50 is connected to the transistor 60 emitter by resistor 56 and to the base of the transistor by reverse oriented zener diode 54 . The transistor is assured of being constantly biased on by the voltage drop set by the reverse breakdown voltage of zener diode 54 as long as battery voltage remains above the minimum required for zener breakdown operation. Thus transistor 60 sources current to the load through which the current returns to ground. As a result LEDs 3 , 9 always produce a minimum level of light output when the device is on.
Variation in light output is effected by variably increasing the current supplied to LEDs 3 , 9 . A hex inverter, such as a SN74HC14N hex inverter, available from Texas Instruments of Dallas, Tex., is used to implement several parallel oscillators or clocks. All of the oscillators are identically constructed though external component values may be altered. In the preferred embodiment 4 of 6 available inverters ( 91 - 94 ) are used with resistors ( 105 - 108 ) providing feedback from the outputs of the inverters to the inputs. Capacitors 101 - 104 are connected from the inputs of inverters 91 - 94 to set the operating frequency of the oscillators. The connection of V cc to the inverters is represented for inverter 90 (U 1 E) only but is identical for each of inverters 91 - 94 .
The supply of power to the internal LED 9 is described first. Oscillators 68 and 70 are designed to be low frequency oscillators running at approximately 2 Hz. Oscillators 68 and 70 , formed using inverters 94 and 93 , can use similar timing components to run at approximately a 10% difference in frequency. The 10% difference in frequency prevents oscillators 68 and 70 from synchronizing with each other or drifting past one another too slowly. Low frequency oscillators 68 and 70 provide current to LED 9 through series connected resistors and forward biased diodes 76 and 78 , and 72 and 74 , respectively, to a summing junction. As a result, current flow through LED 9 is increased from the minimum set by the current source formed by PNP transistor 60 pseudo-randomly. When either of oscillators 68 or 70 is high, it supplies extra current to LED 9 and the LED becomes slightly brighter. When both of oscillators 68 and 70 are high, a third, higher level of current is supplied to the LED 9 . The three current levels (both high, only one high, or both low) provide three brightness levels that can be selected by the choice of values for resistors 76 and 72 and the current from the current source. As long as the two oscillators are not synchronized, the three brightness levels will vary in a pseudo-random manner as the oscillators drift. Loose component tolerances are acceptable as contributing to the degree of randomness in current sourced to LED 9 . In some applications oscillators 68 and 70 may be set to have as great as a 2:1 variation in frequency. The rate at which the oscillators drift past one another is consequential to the appearance of the luminary.
In the preferred embodiment oscillator 66 , formed using inverter 92 , operates at about 8 Hz. and provides two more current levels. Three parallel current sources allow for a total of six brightness levels. Again the output from the inverter is fed through a series connected resistor 84 and forward biased diode 86 to a summing junction and then by resistor 126 to LED 9 . The value chosen for resistor 84 is higher than for resistors 78 and 74 with the result that oscillator 66 makes a smaller current contribution to LED 9 than oscillators 68 and 70 . This contributes still more to the impression of randomness in the light output of LED 9 by providing that changes in light output occur in differing sized steps. Oscillator 64 , formed using inverter 91 , is also set to run at about 8 Hz. The resistance of resistor 80 is comparable to that of resistor 84 so that oscillator 64 contributes a current comparable to the current supplied by oscillator 66 . The current from inverter 91 is routed to LED 9 by resistor 80 and diode 82 to the summing junction and than by resistor 126 . A capacitor 125 may be connected between V cc and ground to short circuit noise to ground preventing circuit noise from causing the oscillators to synchronize with one another.
As shown, two of the gates of the hex inverter are not used, but these gates could be used to create two more oscillators with outputs driving additional candles using multiple LEDs or supplying additional current levels to a single LED.
The externally mounted LED 3 is intended to be driven less hard than an internal LED 9 and is connected to the output of the summing junction fed by resistor 126 and PNP transistor 60 . Luminosity of LED 3 may be determined by varying the resistance of a resistor 136 , if desired, which operates as a voltage divider assuring that LED 3 luminesces at a lower level than does LED 9 . Swapping the positions of the LEDs changes which gives off more light.
While the invention is shown in only a few of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit and scope of the invention.
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A decorative, imitation candle effectively simulates a lighted wick in a darkened environment by location of a light source at the tip of an imitation wick. The light source is provided by an LED located at the tip of the wick for direct viewing in order to obtain maximum brightness and high contrast to an observer in a darkened environment. The light source and its support structure are incorporated into the imitation wick so that they do not detract from the imitation candle's realism when the imitation candle is viewed from the side or from above under higher ambient lighting.
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This is a continuation of application Ser. No. 07/993,906 filed Dec. 18, 1992, abandoned, which is a continuation of application Ser. No. 07/735,299, filed Jul. 24, 1991, now abandoned, which is a continuation of application Ser. No. 07/346,448, filed May 1, 1989 (now U.S. Pat. No. 5,069,658), which is a continuation of application Ser. No. 07/158,031 filed Feb. 12, 1988, now U.S. Pat. No. 4,826,004 which is a continuation of application Ser. No. 06/329,335, filed on Dec. 10, 1981, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to the production of display boxes for a variety of products. A large variety of boxes of this kind is known in which the actual display of the contents of the box is provided by means of a window formed by an aperture in the wall of the box covered by a transparent sheet of plastics material as a rule, which is applied to the interior of the box.
No problem of any kind arose if the window did not extend beyond one surface of the box and was limited in surface in such manner as not to overlap the edge folds.
On the other hand, for example in the case of a rectangular box, if it was wished to produce a window overlapping at least one edge fold, it was necessary in view of the presence of fold projections or the like on the cardboard panel, to make use of a thin and pliable sheet of plastics material. The result was that if the window had a considerable area, the box lacked stiffness and this raised problems for example whilst filling or handling the same.
Boxes of this kind which comprise windows extending across one or more edges of the box are known and, for example, described in the U.S. Pat. Specifications Nos. 3,292,513 and 3,273,702. In accordance with these two prior patents however, the windows are covered with sheets of a flexible or semi-rigid transparent plastics material.
In the U.S. Pat. No. 3,273,702, the box comprises a panel 2 of opaque cardboard which in known manner has incipient or preparatory fold lines 6a, 6b, 6c, 6d and 6e (FIG. 3) delimiting the different sides 10, 12, 14, 16 and 18 of the box. The cardboard panel 2 has an opening 32 covered by a transparent sheet 4 which comprises fold lines 34 and excisions 36 situated in alignment with the extension parts or projections 38 of the cardboard panel. The sheet 4 of plastics material should be a semi-rigid sheet which is sufficiently flexible to be capable of being folded at a comparatively acute angle without a preparatory fold line or crease. The plastics material utilized in accordance with this patent are poly styrene, or hi-axially oriented PVC (column 3, lines 35 to 50). Furthermore, FIG. 2 clearly shows that the sheet 4 is actually a pliable sheet, allowing for the very founded off folding angles illustrated in particular in the upper part of the sheet 4.
The U.S. Pat. No. 3,292,513 discloses a box of a similar kind, in which the opening cut-out of a cardboard panel is covered with a plastics material sheet 28. In this case however, the form of excision of the opening which is comparatively complex and comprises reinforcing strips for the plastics material sheet, clearly demonstrates that the plastics material sheet should be a flexible sheet.
The boxes in accordance with these prior patents consequently lack stiffness which entails considerable trouble when it is required to store and handle them. Furthermore, they are unusable for packaging heavy elements such as bottles filled with a liquid. Finally, their production is complex and expensive as demonstrated in particular by the U.S. Pat. No. 3,292,513.
SUMMARY OF THE INVENTION
It is a primary object of the invention to make a box of the kind comprising a part of opaque material such as cardboard, and an opening overlapping at least one edge of the box and closed off by a sheet of plastics material, but which is of such nature as to eliminate or minimize the disadvantages hereinbefore described.
In accordance with the invention, the plastics material sheet forming the window is of rigid transparent material.
The rigid sheet consequently does not weaken the box and maintains its mechanical strength. To eliminate the problems raised by the fold projections of the cardboard panel, use is made of a rigid sheet of PVC for example, the rigid sheet being weakened along two lines corresponding to the edges to be formed. This weakening may be performed directly by pre scoring.
In accordance with a preferred embodiment, the sheet consists of a single sheet and has two preparatory or incipient fold lines produced by pre-scoring along the lines corresponding to the edges which are to be formed, the edges of the sheet having notches at the extremities of each such preparatory or incipient fold.
In a modification the plastics material sheet comprises a composite sheet formed from a pliable sheet and rigid elements, the rigid elements being clear of the edges of the box.
The invention also consists in a method of and apparatus for manufacturing a box according to the invention.
The method of manufacture in accordance with the invention consists in applying a single or double sheet cut after continuous withdrawal from a reel on to a cardboard panel cut to shape and coated with adhesive.
In a modification, a sheet drawn singly from a magazine in which a plurality of sheets is held in readiness for laying, may be associated with a panel cut to shape and coated with glue or other suitable adhesive, but hereinafter generally referred to as glue.
For carrying out the manufacturing method the invention consists in apparatus which comprises, in this order, a panel supply means, a feeder, a gluing station, means of supplying sheet material from a reel and discharge or delivery means and a station for cutting and laying the plastics material sheet comprising a suction cylinder.
If the plastics material sheets are available in the form of precut individual sheets, the apparatus includes suction or negative pressure supply means, a glue-coating station, a hot-melt station, a sheet magazine, a pressing station and a pressing mat or the like at the outlet. In this case, the supply of plastics material sheets is provided by means of suction operating via the opening of the cardboard panel whilst the sheet magazine is positioned at the other side of the panel opposite the suction device.
The method and apparatus of the invention render it possible to secure satisfactory results, but the pre-scored plastics material sheet must be positioned with high precision on the cardboard panel so that its scored lines are properly aligned to or in register with those of the cardboard. The least error in alignment becomes manifest afterwards by trouble in the folding of the box. A high-precision positioning or setting operation cannot be performed on automatic machines except at lowered production speeds, which entails a substantial increase in cost.
Accordingly the invention also relates to a manufacturing method which renders it possible to eliminate or minimize this disadvantage.
This method consists in putting the said opening from a cardboard panel larger than the panel forming the box, placing the said plastics material sheet, which is larger than the said opening, on the opening, securing the said sheet along the edges of the said opening on the cardboard panel, scoring the said sheet to form preparatory or incipient fold lines abreast of the edge or edges of the box, scoring the cardboard sections of the box and cutting from the panel the cardboard sections intended to form the box with the said sheet. This avoids the necessity of positioning the plastics material sheet with a high degree of precision, which thus enables high production speeds to be obtained corresponding to those achieved during the production of boxes wholly formed from cardboard.
According to a particularly advantageous embodiment of this method, the scoring of the said sheet of plastics material and of the cardboard sections of the box is performed by mechanical means, and it is advantageous in this case to perform simultaneous scoring of the said sheet of plastics material and of the cardboard sections of the box.
The plastics material sheet may be affixed on the cardboard panel by bonding and preferably by hot-melting or fusion, for example by HF welding.
In this latter case, the scoring action on the said plastics material sheet may be performed in accordance with the invention by means of heating means which heat-weaken the parts of the sheet corresponding to the scored lines which are to be formed. In this manner, it is possible to perform the fastening of the plastics material sheet on to the cardboard panel and the scoring of this sheet in a single stage and with a single tool.
If the plastics material sheet has notches at the ends of its scored lines, the scored lines and the notches of the said plastics material sheet may be made simultaneously and by the same means, according to this method. Several operations performed with an identical tool are thus combined within the same stage of an automatic production process, which represents a great saving on facilities, reducing the production cost of the boxes.
According to another embodiment, the scoring action on the said plastics material sheet and the scoring and excising action on the cardboard sections of the box, may be performed at the same time and by the same means. This allows for an even greater reduction of the number of operations and handling actions needed for production of the box.
According to another and particularly economical version of the manufacturing method, the excision of the said opening, the scoring of the cardboard sections and a partial cutting out of the cardboard sections intended to leave behind bridges between these sections and the remainder of the cardboard panel, said bridges being intended to be broken at the time of completing production after affixing the said plastics material sheet, may be performed at the same time and by the same means. This is highly advantageous if several boxes are produced from one and the same cardboard panel.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more clearly understood, reference will now be made to the accompanying drawings which, by way of example, show several embodiments of the box in accordance with the invention and of the method of and apparatus for manufacturing it, and in which:
FIG. 1 is a view of a first embodiment of the box in flat form,
FIG. 2 is a view of a second embodiment of the box in flat form,
FIG. 2a is an enlarged-scale view of a detail portion A of FIG. 2,
FIG. 3 and 3a are views in elevation of apparatus for carrying out a first embodiment of the method in accordance with the invention,
FIG. 4 is a diagramatical elevational side view of a modified form of the apparatus illustrated in FIG. 3,
FIGS. 5 to 11 show the successive stages of a second method for the manufacture of a box in accordance with the invention and in these figures:
FIG. 5 shows a cardboard panel utilized for production of the box,
FIG. 6 shows the excision of a window in the cardboard panel,
FIG. 7 shows the positioning in alignment with the window of a sheet of a rigid transparent plastics material,
FIG. 8 shows the method of securing the plastics material sheet on the cardboard panel,
FIG. 9 demonstrates the simultaneous scoring or grooving of the cardboard panel and of the plastics material sheet by mechanical means,
FIG. 10 demonstrates the final cutting out of the cardboard panel, and
FIG. 11 is a view from below of a tool which renders it possible to perform simultaneous scoring or grooving and cutting out of the cardboard sections and the scoring or grooving of the plastics material sheet of the box in accordance with the invention.
FIG. 12 is a schematic view of a groove forming means between rolls 24 and 25.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings, the box shown in flat form in FIG. 1 comprises a cardboard panel 1 having a series of flaps enabling, for example, a rectangular box to be formed. A rectangular display or sight opening 3 which extends over three of the surfaces 4, 5 and 6 of the lateral surface of the box, is formed in the panel 1. To form the shape of the box, the different sections of the cardboard panel 1 are prefolded and projections are formed abreast of the fold lines as illustrated at 7 in FIG. 2a.
The opening 3 is closed off by a sheet of transparent plastics material 8. This sheet is preferably produced from PVC (polyvinylchloride). In the case of FIG. 1, it comprises a single rigid sheet. Abreast of the edge folds 9 and 10 it has weakening lines formed by scoring or grooving. The sheet 8 is glued to a peripheral strip 11. The adhesive utilized will preferably be of the hot-melt type.
Difficulties in respect of bending, adhesion and corrugation are encountered at the level of the fold projections 7, since the sheet 8 is rigid.
To eliminate these difficulties, the edge of the sheet 8 has notches or excisions 13 at the level of these projections, for example at 12. The bottom of these notches 13 is situated at the level of the edge of the opening 3 of the panel and does not reach the extremity of the projections 12 in any event.
Upon forming the box shape, the weakening lines 9 and 10 for the edges at the level of the box window. The folding projection 7, 12 no longer impede this folding action due to the presence of the notches 13.
The box illustrated in FIG. 2 is identical to that of FIG. 1 in respect of the cardboard panel 1, the opening 3 and the fold projections 7. Only the transparent plastics material sheet 8 is different. In this case, it comprises a one-piece flexible sheet 14 lined with three rigid sheet elements 15. Thus, abreast of the fold projections 7, the flexible sheet 14 acts as a hinge, and straddles or overlaps and perfectly matches the outline of the projection 7. Notches such as those illustrated in FIG. 1 may be omitted in this case.
In the two embodiments illustrated in FIGS. 1 and 2, the single or lined sheet 8 is rigid and enables a perfectly rigid box to be obtained after assembling said box into its shape. This stiffness enables the same to withstand stacking and the various handling operations occurring for example upon filling, carrying and storing the same.
Apparatus for manufacturing the box is illustrated in FIGS. 3 and 3a. This apparatus comprises an endless chain 16 provided with catches 17 and driven by two rollers 18 and 19. The cardboard panels 1 are laid on the top run of the chain 16 and come from a supply system 20 of any desired kind known in the art and therefore not illustrated in detail herein. The panels 1 are fed in by means of a roller 21, then coated at 22 with an adhesive of the hot-melt type coming from a trough 23. The transparent sheet 8 is unwound from a reel 24, cut at 25 and then laid on a suction cylinder 26 for conveying on to a panel 1 supplied by means of the chain 16. After pressing the sheet 8 on to the adhesive-coated panel 1, the box is withdrawn by means of a delivery chain 27.
The reel or roll 24 illustrated in perspective in FIG. 3a comprises a flexible sheet 14 of transparent plastics material and three rigid strips 15, and thus forms the complex illustrated in FIG. 2a for production of the box according to FIG. 2.
It is also possible for a box according to FIG. 1, that is to say comprising a single rigid transparent plastics material sheet 8 only, to be produced by means of the apparatus of
FIG. 3. In this case, the axis of the roll or reel supplying this sheet should be arranged at right angles to the delivery chain 27. Furthermore, a device for forming the notches 13 by excision and the required weakening lines should be positioned before the point at which the sheet 8 is combined with the panel 1.
The apparatus of FIG. 3 operates in a wholly continuous manner.
The apparatus of FIG. 4 operates in an intermittent manner, meaning that it is supplied with sheets 8 which are already cut out and ready to be placed on the panels 1. These panels 1 are fed to a coating station 28 by means of a suction-operated pick-up device 29. The panels 1 are then received on a chain 30 similar to chain 16 shown in FIG. 3 and travel successively to a known kind of hot-melt station 31 not illustrated in detail, below the magazine 32 distributing the sheets 8 and a pressing station 33 not illustrated therein. The withdrawal of the sheets 8 from the magazine 32 is performed by means of a suction device 34 situated below the chain 30 and fitted in such manner that it may be displaced in vertical direction, the sheets 8 being drawn by suction via the opening 3 of the panels 1. The panel 1--sheet 8 pair then leaves the chain 30 and is received on another delivery chain 35 which discharges the same to a reception station 36 after having exerted a pressure thereon by means of a mat 37 applied under thrust on the pair 1,8.
The devices illustrated in FIGS. 3 and 4 render it possible to obtain very satisfactory results, but the positioning of the sheet 8 of transparent plastics material with respect to the cardboard panel 1, that is to say its precise alignment with respect to the opening 3, proves to be difficult and restricts production speeds in the case of both these devices. It is possible to make use of highly developed positioning or setting devices. In this case however, the production cost of the box rises to a high level and thereby becomes irreconcilable with particular practical applications.
To minimize or even eliminate this drawback, the invention also provides another method for the production of the box, which will be described in the following with reference to FIGS. 5 to 11.
In FIG. 5 is shown a rectangular cardboard panel 38 from which one or more packaging or display boxes are produced. In accordance with the invention, the box again comprises an opening overlapping or straddling at least one of its edges and this opening is shut off by a sheet of rigid transparent plastics material. In FIG. 10, the cardboard sections of the box bear the references 39, 40, 41 and 42 whereas the reference 43 denotes the window intended to be covered by a rigid transparent plastics material sheet 48. Preparatory or incipient fold lines or scored lines of the plastics material sheet are illustrated by dotted lines at 44, and the scored lines of the cardboard sections 39 to 42 are shown at 45.
In accordance with this particular embodiment of the method according to the invention, the cutting out of the window 43 in the cardboard panel 38 is undertaken initially as illustrated diagrammatically in FIG. 6. A tool (not illustrated) is utilized for this purpose, which comprises a framework arranged to be displaceable in vertical direction and which carries a series of cutting blades arranged to correspond to the outline of the window 43 which is to be cut out.
After excising the window 43, the same has laid on it a sheet 48 of a rigid transparent plastics material (FIG. 7) whose dimensions are a little larger than those of the window 43. The sheet 48 is cut out beforehand and simply positioned on the window in such manner as to cover the latter and overlap on to the cardboard sections. This operation requires moderate precision, since the sheet 48 is not as yet scored or grooved, which condition would have required an alignment to very great precision with respect to the future scored or grooved lines of the cardboard. This latter operation for positioning with very great position has proved to be difficult if it was intended to operate at high production speeds.
The plastics material sheet 48 correctly placed on the cardboard panel 38 is secured thereupon. This fastening action may be performed by gluing, but the sheet 48 and the cardboard panel 98 are preferably Joined together by thermic welding and in particular by means of a high-frequency welding device as illustrated in FIG. 8. To this end, it is possible to utilize a tool comprising a framework 49 arranged to be displaceable in vertical direction and which bears welding electrodes 50 connected to a generator of high-frequency electric current not illustrated therein.
The simultaneous mechanical scoring or grooving of the cardboard panel 38 and of the plastics material sheet 48 are carried out during the next stage. Use is again made to this end of a tool comprising a framework 51 arranged to be displaceable in a vertical direction and which bears blades 52 for grooving or scoring the cardboard panel 38 and blades 53 having an appropriate structure for scoring or grooving the rigid plastics material sheet. The mutual alignment of the incipient folds this formed on the cardboard panel 38 and the plastics material sheet 48 is assured by utilizing a single tool without requiring positioning with high precision which would be impossible in a machine operating at high working speeds.
The cutting out of all of the cardboard sections 39 to 42 of the box is now shown by solid lines in FIG. 10. It would easily be appreciated that a box of this kind cannot be produced mechanically at high output rates except by applying this embodiment of the method of the invention, according to which the cutting out of the cardboard panel occurs only after the cutting out of the window 43 (FIG. 6) and after the placing in position (FIG. 7) and the fastening (FIG. 8) of the rigid plastics material sheet 48 on the cardboard panel. As a matter of fact, the cardboard sections 39 to 42 are interconnected only by the plastics material sheet 48. Their preliminary cutting out and subsequent individual fastening would represent a protracted and costly operation preventing any profitable mechanization in practice.
In another modification of the method according to the invention, the grooving or scoring action on the plastics material sheet 48 may equally be performed by heat-welding.
In this case, the grooving action will be performed at the same time as the heat-welding (FIG. 8) of the sheet 48, and the framework 49 will carry appropriate grooving electrodes (not illustrated) apart from the electrodes 50.
Similarly, if there is a need to provide notches at the extremities of the grooves or scores of the plastics material sheet 48 as described in particular in the foregoing with reference to FIGS. 1 to 4 and as illustrated again in very sketchy manner at 46 and 47 in FIG. 7, these notches are produced by heat-weakening of the sheet 48 during the heat-welding stage (FIG. 8) and the framework 49 will carry the tools needed for this action. The notches 46 and 47 may however alternatively be produced beforehand by mechanical means before the plastics material sheet is placed in position (FIG. 7).
In accordance with a particularly economical embodiment, the grooving or scoring of the plastics material sheet 48 and the grooving and cutting out of the cardboard sections 39 to 42 of the box are performed during one and the same stage and with a single tool. This operation is performed after the plastics material sheet 48 has been placed in position and affixed in alignment with the opening 43.
FIG. 11 diagrammatically shows a tool which renders it possible to perform these three operations at the same time. The tool comprises a bearer 54 arranged to be displaceable in a vertical direction above a work table. The bearer 54 is provide with a series of rules 55 for grooving the plastics material sheet 48, a series of rules 56 for grooving the cardboard sections 39 to 42 and a series of cutting rules 57 for cutting out the cardboard panel. The marking and satisfactory alignment or registration of the scored or grooved lines with respect to each other are thus assured by the positioning of the rules 55, 56 and 57 on the bearer 54.
According to yet another version, the cutting out of the said opening 43, and the grooving and cutting out of the cardboard sections 39 to 42 may be performed at the same time before the plastics material sheet 48 is placed in position, and this with one tool only. In this case however, it is necessary to retain a series of narrow bridges between the sections 39 to 42 and the remainder of the panel: these bridges are broken at the end of production, after the placing in position, affixing and grooving of the plastics material sheet.
It will be apparent that the invention is not limited to the embodiments described and illustrated herein, and numerous changes may be made thereto without departing from the scope of the invention as defined by the appended claims.
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The present invention relates to a method and apparatus for making display boxes having windows made of substantially rigid plastic material. The boxes comprise substantially rigid opaque material, such as paperboard, in combination with substantially rigid plastic material. The substantially rigid plastic material includes at least one fold line or groove which cooperates with a fold line in the opaque material when the box is set up. The present invention provides a method and means for making such boxes in a single machine from a supply of blanks of the opaque material and a roll of ungrooved plastic material. The machine comprises means for feeding of the opaque blanks, feeding of a length of the plastic material, means for forming at least one groove in the length of plastic material, means for cutting the grooved plastic material into sheets, and means for juxtaposing and joining the blanks of opaque material and the cut plastic sheets of material.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of copending U.S. patent application Ser. No. 10/125,171, filed Apr. 18, 2002, the entire disclosure of which is incorporated herein by reference.
BACKGROUND
The present embodiment relates generally to the recovery of hydrocarbons from a subterranean formation penetrated by a well bore and more particularly to non-radioactive compositions and methods of utilizing the non-radioactive compositions for determining the source of treatment fluids being produced from a production formation having multiple zones. For example, the compositions and methods can be utilized for tracking the transport of particulate solids during the production of hydrocarbons from a subterranean formation penetrated by a well bore.
Transport of particulate solids during the production of hydrocarbons from a subterranean formation penetrated by a well bore is a continuing problem. The transported solids can erode or cause significant wear in the hydrocarbon production equipment used in the recovery process. The solids also can clog or plug the well bore thereby limiting or completely stopping fluid production. Further, the transported particulates must be separated from the recovered hydrocarbons adding further expense to the processing. The particulates which are available for transport may be present due to an unconsolidated nature of a subterranean formation and/or as a result of well treatments placing particulates in a well bore or formation, such as, by gravel packing or propped fracturing.
In the treatment of subterranean formations, it is common to place particulate materials as a filter medium and/or a proppant in the near well bore area and in fractures extending outwardly from the well bore. In fracturing operations, proppant is carried into fractures created when hydraulic pressure is applied to these subterranean rock formations to a point where fractures are developed. Proppant suspended in a viscosified fracturing fluid is carried outwardly away from the well bore within the fractures as they are created and extended with continued pumping. Upon release of pumping pressure, the proppant materials remain in the fractures holding the separated rock faces in an open position forming a channel for flow of formation fluids back to the well bore.
Proppant flowback is the transport of proppants back into the well bore with the production of formation fluids following fracturing. This undesirable result causes undue wear on production equipment, the need for separation of solids from the produced hydrocarbons and occasionally also decreases the efficiency of the fracturing operation since the proppant does not remain within the fracture and may limit the width or conductivity of the created flow channel.
Current techniques for controlling the flowback of proppants include coating the proppants with curable resin, or blending the proppants with fibrous materials, tackifying agents or deformable particulates (See e.g. U.S. Pat. No. 6,328,105 to Betzold, U.S. Pat. No. 6,172,011 to Card et al. and U.S. Pat. No. 6,047,772 to Weaver et al.) For a multi-zone well that has been fractured with proppant and is plagued with proppant flowback problems, it is quite difficult to identify the zone from which the proppant is emanating unless the proppant is tagged with a tracer. Radioactive materials have been commonly used in the logging or tagging of sand or proppant placement, however, such radioactive materials are hazardous to the environment and the techniques for utilizing such radioactive materials are complex, expensive and time consuming. Therefore, there is a need for simple compositions and methods for tracking the flowback of proppant in subterranean wells to avoid the above problems.
DETAILED DESCRIPTION
According to one embodiment, to determine from which zone(s) a fluid is being produced, a water soluble inorganic or organic salt is dissolved in the base treatment fluid as the fluid is being pumped downhole during the treatment. Such treatment fluids include but are not limited to fracturing fluids, drilling fluids, disposal fluids and injection fluids used as displacement fluids in hydrocarbon recovery processes. Acting as a fluid tracer agent, a salt is tagged into the fluid that is unique for each treatment job such as a fracturing job treatment. Suitable water soluble salts for this purpose are metal salts in which the metal is selected from Groups Ito VIII of the Periodic Table of the Elements as well as the lanthanide series of rare earth metals so long as the metal salts do not constitute a component of fluids naturally present in the formation and are compatible with the fluids injected into the formation. Preferred metals include barium, beryllium, cadmium, chromium, cesium, sodium, potassium, manganese and zinc. Particularly preferred water soluble salts include barium bromide, barium iodide, beryllium fluoride, beryllium bromide, beryllium chloride, cadmium bromide, cadmium chloride, cadmium iodide, cadmium nitrate, chromium bromide, chromium chloride, chromium iodide, cesium bromide, cesium chloride, sodium bromide, sodium iodide, sodium nitrate, sodium nitrite, potassium iodide, potassium nitrate, manganese bromide, manganese chloride, zinc bromide, zinc chloride, zinc iodide, sodium monofluoroacetate, sodium trifluoroacetate, sodium 3-fluoropropionate, potassium monofluoroacetate, potassium trifluoroacetate, potassium 3-fluoropropionate.
The fluid tracer agents used in the method of this embodiment must meet a number of requirements. They should be relatively inexpensive, must be compatible with fluids naturally present in the reservoir and within the rock itself, as well as be compatible with the fluids injected into the reservoir as part of the formation treatment. The fluid tracer agents must be susceptible to being readily detected qualitatively and analyzed quantitatively in the presence of the materials naturally occurring in the formation fluids. For example, an aqueous sodium chloride solution could be utilized as a fluid tracer agent but for the fact that most field brines contain sodium chloride in substantial quantities, and so detection and analysis to differentiate the presence of sodium chloride used as tracer in the presence of naturally-occurring sodium chloride would be difficult.
In field application, a known amount of a selected water soluble salt based on a known concentration (i.e. 100 parts per million) is dissolved in a volume of water which is 1/1,000 of the total actual volume of base fluid required for the treatment. The mixed solution is then metered to the base fluid line at a rate of one gallon per 1,000 gallons of the base fluid. To handle multiple zones, various salts can be used provided that the interest cations or anions of selected compounds are unique to prevent any interference between zones.
According to another embodiment, metals are tagged onto proppant material or materials to be blended with proppant material to provide for the ready identification of flowback proppant from different stages or zones of the well. Suitable metals for this purpose may be selected from Groups Ito VIII of the Periodic Table of the elements as well as the lanthanide series of rare earth metals so long as the metals do not constitute a component of the proppant, the fracturing fluid or the reservoir fluid and so long as the metals are compatible with the fracturing fluid. Preferred metals include gold, silver, copper, aluminum, barium, beryllium, cadmium, cobalt, chromium, iron, lithium, magnesium, manganese, molybdenum, nickel, phosphorus, lead, titanium, vanadium and zinc as well as derivatives thereof including oxides, phosphates, sulfates, carbonates and salts thereof so long as such derivatives are only slightly soluble in water so that they remain intact during transport with the proppant from the surface into the fractures. Particularly preferred metals include copper, nickel, zinc, cadmium, magnesium and barium. The metal acts as a tracer material and a different metal is tagged onto the proppant, or onto the materials to be blended with the proppant, so that each proppant stage or each fracturing job treatment can be identified by a unique tracer material. Suitable metals for use as the tracer material are generally commercially available from Sigma-Aldrich, Inc. as well as from Mallinckrodt Baker, Inc. It is understood, however, that field grade materials may also be used as suitable tracer materials for tagging onto proppant material or materials to be blended with proppant material.
Samples of flowback proppant collected from the field may be analyzed according to a process known as the inductively-coupled plasma (ICP) discharge method to determine from which proppant stage and which production zone the proppant has been produced. According to the ICP discharge method, an aqueous sample is nebulized within an ICP spectrometer and the resulting aerosol is transported to an argon plasma torch located within the ICP spectrometer. The ICP spectrometer measures the intensities of element-specific atomic emissions produced when the solution components enter the high-temperature plasma. An on-board computer within the ICP spectrometer accesses a standard calibration curve to translate the measured intensities into elemental concentrations. ICP spectrometers for use according to the ICP discharge method are generally commercially available from the Thermo ARL business unit of Thermo Electron Corporation, Agilent Technologies and several other companies. Depending upon the model and the manufacturer, the degree of sensitivity of currently commercially available ICP spectrometers can generally detect levels as low as 1 to 5 parts per million for most of the metals listed above.
It is understood that depending on the materials used as tagging agents, other spectroscopic techniques well known to those skilled in the art, including atomic absorption spectroscopy, X-ray fluorescence spectroscopy, or neutron activation analysis, can be utilized to identify these materials.
According to yet another embodiment, an oil-soluble or oil-dispersible tracer comprising a metal salt, metal oxide, metal sulfate, metal phosphate or a metal salt of an organic acid can be used to tag the proppant by intimately mixing the metal with a curable resin prior to coating the curable resin onto the proppant. Preferably, the metal is selected from the Group VIB metals, the Group VIIB metals, and the lanthanide series of rare earth metals. Specifically, the metal according to this embodiment may be chromium, molybdenum, tungsten, manganese, technetium, rhenium, lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium and lutetium. It is preferred that the metals according to this embodiment, do not constitute a component of the proppant, the fracturing fluid or the reservoir fluid, and that the metals are compatible with the fracturing fluid.
Preferably, the organic acid is a substituted or unsubstituted carboxylic acid. More preferably, the organic acid may be selected from alkanoic and alkenoic carboxylic acids, polyunsaturated aliphatic monocarboxylic acids and aromatic carboxylic acids. Most preferably, the alkanoic carboxylic acids have from 5 to 35 carbon atoms, the alkenoic carboxylic acids have from 5 to 30 carbon atoms, the polyunsaturated aliphatic monocarboxylic acids may be selected from the group of sorbic, linoleic, linolenic, and eleostearic acids and the aromatic acids may be selected from the group of benzoic, salicylic, cinnamic and gallic acids. Suitable organic acids are generally commercially available from Sigma-Aldrich, Inc. as well as from Mallinckrodt Baker, Inc.
For proppant to be coated with a curable resin, the tracer agent is blended homogeneously with the resin mixture and the resin is then coated onto the proppant. The proppant can be pre-coated as in the case of curable resin-coated proppants, for example, such as those commercially available from Santrol or Acme Borden, or it can be coated on-the-fly during the fracturing job treatment. The nature of the resin materials and the processes for performing the coating process is well know to those skilled in the art, as represented by U.S. Pat. No. 5,609,207 to Dewprashad et al., the entire disclosure of which is hereby incorporated herein by reference. Also, it is understood that materials to be blended with proppant such as the fibrous materials, tackifying agents or deformable beads disclosed in U.S. Pat. No. 6,328,105 to Betzold, U.S. Pat. No. 6,172,011 to Card et al. and U.S. Pat. No. 6,047,772 to Weaver et al., the entire disclosures of which are hereby incorporated by reference, can be similarly treated with a tracer agent.
According to still another embodiment, the metal elements or their derivative compounds can be tagged as part of the manufacturing process of proppant. As a result, the proppant is tagged with a permanent tracer.
According to yet another embodiment, the proppant can be coated with phosphorescent, fluorescent, or photoluminescent pigments, such as those disclosed in U.S. Pat. No. 6,123,871 to Carroll, U.S. Pat. No. 5,498,280 to Fistner et al. and U.S. Pat. No. 6,074,739 to Katagiri, the entire disclosures of which are hereby incorporated herein by reference. According to this embodiment, the phosphorescent, fluorescent, or photoluminescent pigments may be prepared from materials well known to those skilled in the art including but not limited to alkaline earth aluminates activated by rare earth ions, zinc sulfide phosphors, aluminate phosphors, zinc silicate phosphors, zinc sulfide cadmium phosphors, strontium sulfide phosphors, calcium tungstate phosphors and calcium sulfide phosphors. Suitable phosphorescent, fluorescent and photoluminescent materials are commercially available from Keystone Aniline Corporation (TB Series) and Capricorn Chemicals (H Series and S Series Glowbug Specialty Pigments). The particular structure of the materials has a strong capacity to absorb and store visible light such as sunlight or light from artificial lighting. After absorbing a variety of such common visible light the phosphorescent, fluorescent, or photoluminescent materials will glow in the dark. Various pigment colors can be combined with the luminescent capability of the materials to enhance the differentiation of the stages or zones. According to this embodiment, micron sized particles of the phosphorescent, fluorescent, or photoluminescent materials are intimately mixed with a resin to be coated onto a proppant to be used in a fracturing treatment.
According to still another embodiment, proppant materials having a naturally dark color can be dyed or coated with a marker material having a bright, vivid and intense color which marker material may be selected from oil soluble dyes, oil dispersible dyes or oil dispersible pigments. Suitable oil soluble dyes, oil dispersible dyes and oil dispersible pigments are well known to those skilled in the art and are generally commercially available from Keystone Aniline Corporation and Abbey Color. According to this embodiment, proppant materials having a dark color, such as bauxite proppant which is naturally black in color, are dyed or coated with such marker materials. In this regard, reference is made to the dyes disclosed in U.S. Pat. No. 6,210,471 to Craig, the entire disclosure of which is hereby incorporated herein by reference.
According to all of the above-described embodiments, the proppant material may comprise substantially any substrate material that does not undesirably chemically interact with other components used in treating the subterranean formation. It is understood that the proppant material may comprise sand, ceramics, glass, sintered bauxite, resin coated sand, resin beads, metal beads and the like.
The following examples are illustrative of the methods and compositions discussed above.
EXAMPLE 1
ZnCl 2 was selected to tag 50,000 gallons of a base fracturing fluid. For a 100-ppm concentration of ZnCl 2 in the fracturing fluid, it requires 0.2084 gram per liter of fluid, or 39.44 kg for the total fluid volume. This amount of ZnCl 2 is dissolved in 50 gallons of fluid, and the mixed solution is metered into the base fluid line at a rate of 1 gallon for every 1,000 gallons of the base fluid.
A number of methods well known to those of ordinary skill in the art such as wet chemistry titration, colorimetry, atomic absorption spectroscopy, inductively coupled plasma (ICP) discharge, ion chromatography (IC), gas chromatography (GC), liquid chromatography (LC) and nuclear magnetic resonance (NMR), can be used to analyze the fluid samples produced from the well and to determine from which zones the fluid has been produced, and the theoretical production level of each zone in the well.
EXAMPLE 2
A total of three separate hydraulic fracturing treatments were performed in a subterranean formation penetrated by a well bore. For each fracturing treatment, sufficient metal tracer was added to the liquid hardenable resin to provide an initial concentration of 1000 ppm of the metal tracer in the resin treated proppant. Cuprous oxide, manganese oxide, and zinc oxide were used as tagging agents in fracturing treatments 1, 2, and 3, respectively. Samples of flowback proppant were collected during the flow back of the well. Each proppant sample was weighted and digested in concentrated nitric acid before being measured against known, calibrated metal concentrations according to the inductively coupled plasma (ICP) discharge method for the ARL Model 3410 ICP which is commercially available from the Thermo ARL business unit of Thermo Electron Corporation. Table 1 shows the concentrations of each metal obtained in each proppant flowback sample. The data indicated that the highest concentration of flowback proppant was produced from the interval of the well that was fractured in the second fracturing treatment.
TABLE 1
Sample
Frac Treatment 1
Frac Treatment 2
Frac Treatment 3
Number
Cu (ppm)
Mn (ppm)
Zn (ppm)
1
1.9
217.3
11.5
2
2
219.2
11.8
3
2.8
120.5
9.1
4
3.1
204.1
12
5
670.6
382
24.1
6
51.6
214.1
15.3
7
7.3
234.5
13.3
8
2.7
437.7
17.1
9
2.3
183.8
11.9
10
2.7
220.2
12.8
11
2.9
465
19.3
12
2.1
408.1
17.4
13
2.7
577.2
19.3
14
3.1
410.2
18.2
15
2.3
342.9
40.2
16
2.1
299.8
14.9
17
6.5
296.8
12.5
18
2.1
494.8
18
19
51
385.8
16.5
20
2.7
443.8
17
21
2.8
564.8
44.6
22
35.5
551.8
16.1
23
2.4
545.8
23.3
24
2
538.8
14.7
25
181
342.8
16.6
26
1.5
119.8
10.3
27
1.4
34.8
11.9
28
1.9
204.8
43.2
29
2
240.8
13.7
30
2.4
175.8
11.3
31
7.5
171.8
10.9
32
2.3
57.8
7.7
33
5.8
192.8
17
34
1.7
188.8
12.1
35
1.9
115.8
9.6
36
2.1
168.9
11.1
37
1.6
245.3
13
38
1.7
173.9
11.6
39
1.9
219.4
12.9
40
1.9
224.6
12.6
41
2
383.3
17.1
42
1.7
284.7
12.5
43
1.9
270.6
13.4
44
2.4
311
12.7
45
1.9
177.1
10.3
46
1.8
304.2
12.9
47
2.4
343.2
13.3
48
2
308.2
12.6
49
5.4
241.6
11.2
50
3.4
209.1
11.4
51
3.3
217.1
11.1
52
1.9
299.7
12.7
53
2.3
228.6
11.4
54
1.5
162.8
10.1
EXAMPLE 3
A total of five separate hydraulic fracturing treatments were performed in a subterranean formation by a well bore. For each fracturing treatment, sufficient metal tracer was added to the liquid hardenable resin to provide an initial concentration of 1000 ppm of the metal tracer in the resin treated proppant. Manganese oxide, cuprous oxide, zinc oxide, magnesium oxide, and barium oxide were used as tagging agents in fracturing treatments 1 through 5, respectively. Samples of flowback proppant were collected during the flow back of the well. Each proppant sample was weighted and digested in concentrated nitric acid before being measured against known, calibrated metal concentrations according to the inductively coupled plasma (ICP) discharge method for the ARL Model 3410 ICP which is commercially available from the Thermo ARL business unit of the Thermo Electron Corporation. Table 2 shows the concentrations of each metal obtained in each proppant flowback sample. The data indicated that the highest concentration of flowback proppant was produced from the intervals of the well that were fractured in fracturing treatments 1 and 5.
TABLE 2
Frac
Frac
Frac
Frac
Frac
Treatment
Treatment
Treatment
Treatment
Treatment
Sample
1
2
3
4
5
Number
Mn (ppm)
Cu (ppm)
Zn (ppm)
Mg (ppm)
Ba (ppm)
1
256.9
7.3
18.2
26.8
106.2
2
210.3
14.5
23.1
24
110.6
3
164.5
12.4
20.2
22.5
94.8
4
236.5
9.1
19.9
23.3
100.4
5
97.8
10.5
14.7
19
105.7
6
288.9
2.8
15.8
25.4
110.4
7
202.8
172.8
12.1
21.3
99.7
8
221.3
3
12.8
22.3
115.9
9
167.9
2.9
12.5
21.8
115.7
10
236.1
2.2
12.5
22.8
90.7
11
162.6
1.6
10.8
19.5
85.9
12
111.8
1.6
8.9
18.8
74.9
13
231.8
1.7
11.5
21.7
86.7
14
246.9
2.5
13.1
24.4
98.3
15
348.2
2
13.5
26.8
112.8
16
273.5
2.4
12.4
24.4
101
17
221.5
2
11.4
29.3
83.8
18
268
1.4
11.9
25.8
88.4
19
177.8
1.8
10.4
22.3
77.8
20
247.5
2.4
11.3
28
92.2
21
132.8
1.8
10
22.2
72.4
22
165.8
2.3
9.4
20.9
75.3
23
306.9
66.4
11.9
28.7
103.8
24
205.7
1.6
9.4
23
87.1
25
241.2
2.6
10.6
23.4
90.4
26
197.6
2.2
10.1
24.1
88
27
242
2.3
10.7
26.2
98.9
28
202.8
3
10.8
24.6
94.6
29
165.7
2
9
20.7
85.5
30
138.3
1.4
8.7
21.3
76.1
31
227.4
1.5
10.3
24
92.8
32
192.1
1.7
9.8
23.5
86.6
33
201.9
1.2
9.6
22.3
86.4
34
138.4
1.7
8.6
19.8
73.9
Variations and Equivalents
Although only a few exemplary embodiments have been described in detail above, those skilled in the art will readily appreciate that many other modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages described herein. Accordingly, all such modifications are intended to be included within the scope of the following claims.
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Compositions and methods for determining the source of treatment fluids being produced from a production formation having multiple zones by introducing a treatment composition having a tracking material into a zone in the subterranean formation, and detecting the tracking material in treatment composition that flows back from the subterranean formation.
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FIELD OF THE INVENTION
The present invention pertains to a process and an apparatus for making a seam which is uninterrupted on a side facing the needle of a sewing machine in which, during the preparation of the seam, the operation of the sewing machine is interrupted in the case of a shuttle thread disturbance and a new shuttle thread is fed in.
BACKGROUND OF THE INVENTION
West German Patent Specification No. DE-PS 2,028,027 discloses a sewing machine on whose housing a guide groove is provided in close proximity to the shuttle, and a cutting device is arranged at the end of the guide groove facing away from the shuttle. The guide groove serves to receive the end of the old shuttle thread coming from the fabric being sewn and, after changing the bobbin, to receive the beginning of the new shuttle thread. After the shuttle threads extending in the guide groove have been shortened by the cutting device, the sewing process is continued, and the new shuttle thread is knotted with the needle thread during the first stitching and pulled to the stitch formation site, while the old shuttle thread is gradually pulled out of the guide groove by the feed motion of the fabric being sewn.
Since the needle thread in the sewing machine is not cut when the shuttle thread has come to its end, a seam whose top side is made without interruption is obtained. However, since the needle thread is connected only to the old shuttle thread at the time of the last stitch prior to the change of the bobbin and only to the new shuttle thread at the time of the first stitch after bobbin change, the lower side of the seam has an interruption, which is a weak point under stress.
SUMMARY AND OBJECTS OF THE INVENTION
It is an object of the present invention to provide a process and a sewing machine for making a seam, in which the needle thread extends uninterrupted and both the knotting with the old shuttle thread and the knotting with the new shuttle thread are to be accomplished in a reliable manner, so that the strength of the seam is not reduced.
According to the invention, a process and sewing machine arrangement are provided for making a seam which is uninterrupted on a side facing the needle of the sewing machine. The arrangement provides that in the case of a disturbance of the shuttle thread during the preparation of the seam, the operation of the sewing machine is interrupted and a new shuttle thread is fed in. The process includes stopping the sewing machine in the position in which the needle is in its bottom most position after the appearance of a shuttle thread disturbance and after the completion of a stitch formation cycle which has already begun. A stitch length regulating mechanism is set for reversing stitching. The sewing machine is then brought into a position in which the needle is in its top position. A stitch length regulating mechanism is then set to zero. After the elimination of the disturbance, at least one stitch is formed to knot the new shuttle thread with the needle thread in the insertion hole in which the needle was located prior to the appearance of the shuttle thread disturbance. Subsequently, stitch formation is continued with the original stitch length.
The apparatus according to the invention provides a sewing machine including means for detecting the appearance of a shuttle thread disturbance and means for stopping the sewing machine in a position in which the needle is in its bottom most position upon the appearance of the shuttle thread disturbance after the stitch formation cycle which has been begun is completed. A control arrangement is provided for setting the stitch length regulating mechanism for reverse stitching subsequent to machine stoppage and the control mechanism brings the sewing machine into a position which the needle is in its top position at which point a stitch length regulating mechanism is set to zero. After the elimination of the thread disturbance, at least one stitch is formed to knot the new shuttle thread with the needle thread in the insertion hole in which the needle was located prior to the appearance of the disturbance and stitch formation is then continued with the original stitch length.
Reversal of the stitch length regulating mechanism to reverse stitching after a disturbance in the shuttle thread causes the fabric being sewn to be moved back relative to the needle to the insertion hole formed prior to the thread disturbance, at which the last regular knotting with the old shuttle thread took place. After feeding in new shuttle thread by pulling thread from the bobbin in the case of double lockstitch sewing machines or from an endless thread reserve in the case of the multiple-thread chain 10 stitch sewing machines following a thread break or after a bobbin change in the case of double lockstitch sewing machines at the thread end, the stitch length regulating mechanism is set to zero, so that the needle thread is knotted one or several times in the same insertion hole with the new shuttle thread, depending on the number of stitches subsequently made. Multiple knotting ensures greater safety against loosening of the knot. Since the old shuttle thread and the new shuttle thread are knotted with the uninterrupted needle thread next to each other in a nearly punctiform area in the insertion hole, this connection point is just as load-bearing as the rest of the seam.
After elimination of the thread disturbances, seam formation is continued by changing over the stitch length regulating mechanism to forward sewing.
The measure according to the invention including knotting the new shuttle thread with a needle thread and subsequently cutting the free ends of the old and new shuttle thread off causes the free ends of the old and new shuttle threads hanging down from the fabric being sewn to be shortened to the extent that they will certainly not be grasped by the shuttle when the seam is continued and will not be bound into the seam.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a schematic representation of an adjusting and driving parts for the feed dog of a sewing machine according to the invention;
FIG. 2 is a schematic representation of a bobbin case according to the invention;
FIG. 3 is a schematic representation similar to FIG. 2, showing the guiding of the thread according to the invention;
FIG. 4 is a schematic representation of a cutting device according to the invention;
FIG. 5 is a schematic representation of a control device according to the invention;
FIG. 6a-6e are schematic representations of the process steps after a thread disturbance wherein,
FIG. 6a shows a needle in its lower reversal point in the last insertion hole,
FIG. 6b shows a needle in its upper reversal point above the penultimate insertion hole,
FIG. 6c shows a needle during its movement toward the upper reversal point after a repeated insertion into the penultimate insertion hole,
FIG. 6d shows a needle in its upper reversal point above the penultimate insertion hole after the repeated insertion,
FIG. 6e shows a needle as seam formation is continued.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings and in particular to FIG. 1, a sewing machine 1 with a housing part 2 is provided with an arm shaft 3 mounted carrying an impulse disk 4 of an impulse generator 5. A broader marking 6 and a narrower marking 7, arranged offset from each other, are provided on the impulse disk 4. The markings 6 and 7 can be monitored by a sensor device 8 of the impulse generator 5.
One end of a crank 10 is hinged eccentrically to a disk 9 which is formed in one piece with the arm shaft 3. The opposite end of the crank acts on a needle bar 12 carrying the needle 13 via a clamp 11.
To feed a fabric to be sewn, which is arranged on a base plate 14 (FIG. 4), the sewing machine 1 has a feed dog 15, which extends through slots of a needle plate 16 held by the base plate 14 (FIG. 4). The feed dog 15 is held by a feed dog holder 17 (FIG. 1), whose fork-shaped end surrounds a cam 19 fastened on a shaft 18, and the shaft 18 imparts one lifting movement to the feed dog 15 per stitch formation cycle. The still free end of the feed dog holder 17 acts pivotally on a pin of an oscillating crank 20. The oscillating crank 20 has a fork-shaped design with arms and is arranged on a shaft 21, with which it is forced to rotate, and which imparts one feed motion to the feed dog 15 per stitch formation cycle.
A double lockstitch shuttle 24 is fastened, just under the feed dog 15, on a shuttle drive shaft 22, which is driven in a ratio of 2:1 relative to the arm shaft 3 or a stitch length adjusting mechanism drive shaft 23. A thread monitor 25 and a cutting device 26 are associated with the shuttle 24.
The elements necessary for the operation of the thread monitor 25 are shown enlarged in FIGS. 2 and 3. The bobbin case 27 of the shuttle 24 is provided with an annular wall, in which an exit opening 28 for the shuttle thread of a bobbin 29 is provided. The ends of a groove 30, which forms a guide surface and is provided over at least part of the circumference of the bobbin case 27, adjoin the exit opening 28. A deflecting surface 31 for light beams is arranged recessed in the wall of the bobbin case 27. The deflecting surface 31 is provided behind the exit opening 28 in the direction of thread pull and is monitored by a photodiode 32 and by a photodetector 33 of the thread monitor 25, which photodetector is designed as a phototransistor. The deflecting surface 31 is received in the wall of the bobbin case 27 inclined relative to the photodetector 33, and a spring 34 for tensioning the shuttle thread is fastened to the outside of the bobbin case.
The cutting device 26 of the sewing machine is shown enlarged in FIG. 4. The thread catcher 35 of the cutting device 26, provided to grasp the shuttle thread, is arranged coaxially to the shuttle 24 and cooperates with a cutting blade 36 indicated by dash-dotted line, which is arranged on the lower side of the base plate 14. The thread catcher 35 is fastened to a bracket 37 that is connected to a ring 38 loosely surrounding the shuttle drive shaft 22. This ring 38 is mounted, secured in the axial direction and rotatably, in a ring member 39 that is mounted under the base plate 14. A connecting rod 40, which is connected to an arm of an angle lever 41 held by a bearing block 42 attached rigidly to the housing, is hinged to the bracket 37. The other end of the angle lever 41 is connected to the piston rod of a pneumatic cylinder 44 via a connecting rod 43.
Two cams 45 and 46 are arranged nonrotatably on the stitch length regulating mechanism drive shaft 23 (FIG. 1). A cam rod 47 surrounding the cam 45 is hinged at its opposite end to an oscillating crank 48 fastened to the shaft 18. A second cam rod 49 surrounding the cam 46 is hinged to a pin 50, on which a connecting rod 51, which is connected to a crank 53 fastened to the shaft 21 by means of a pin 52, is hinged on a pin 50. Next to the cam rod 49, a connecting rod 54, which surrounds a pin 56 carried by a crank 55, acts on the pin 50. The effective length of the connecting rod 51 is equal to the effective length of the connecting rod 54, so that when the two pins 52 and 56 are aligned, the shaft 21 remains immobile despite the moving cam rod 49.
To vary the movement of the cam rod 49 acting on the shaft 21, the crank 55 is clamped on an adjusting shaft 57. The adjusting shaft 57 carries a two-armed crank 58, on one of the arms of which a tension spring 59 fastened to the housing of the sewing machine 1 acts. The other arm of the crank 58 is in contact with a two-position pneumatic cylinder 60 which has two piston rods 61 and 62 and a cylinder jacket 63 subdivided into two chambers for receiving the piston rods 61 and 62. The piston rod 61 is fastened to a housing part 2, while the piston rod 62 is in contact with the lower side of the arm of the crank 58.
Via a tie rod 64, the crank 58 is connected to one end of an oscillating lever 65, which is fastened to a shaft 66, which is mounted in the housing and carries a switching lever 67. The still free end of the oscillating lever 65 has a spherical projection 68 which extends between side walls of an adjusting groove 69 of an adjusting wheel 70, which is arranged rotatably on an axis that is a rigid part of the housing. The elements 50 through 70 form a stitch length regulating mechanism 71, and the stitch length is adjusted by rotating the adjusting wheel 70 in the known manner.
The sewing machine 1 is provided with a control device 72, which is represented in a simplified form in FIG. 5.
The thread monitor 25 has a stabilized power source, from the positive pole of which current flows via the photodiode 32 and a resistor 73 to the ground. Current also flows from the positive pole of the power source via the phototransistor 33 and a resistor 74 to ground. The emitter of the phototransistor 33 is connected to the input (E 1) of a microcomputer 76 via a NOT element 75.
The sensor device 8 of the impulse generator 5 is connected to the input ZE 1 of a counter 77. This counter 77 has two outputs ZA 1 and ZA 2, of which the output ZA 1 is connected to an input E 2 and the output ZA 2 is connected to an input E 3 of the microprocessor 76. One input ZE 2 of the counter 77 can be reset to zero via a line connected to an output A 1 of the microprocessor 76.
The microprocessor 76 has an input E 4, which can be controlled via a foot pedal (not shown) of the sewing machine 1.
Four more outputs A2 through A5 of the microprocessor 76 are connected to the pressure-switch magnets of two 4/2-way valves via four amplifiers (not shown) and four lines. The directional control valves 78 and 79 serve to admit pressure into the two-position cylinder 60 in a controlled manner and are supplied from a compressed air source 80. One output A6 of the microprocessor 76 is connected via an amplifier (not shown) and a line to the pressure-switch magnet of a 3/2-way valve 81, which is connected to the compressed air source 80 via a throttle 82. One output of the cylinder 44 controlled by the 3/2-way valve 81 is connected to an adjustable throttle 83.
The outputs A7 through All of the microprocessor 76 are connected via lines to a known control circuit (not shown) of a positioning motor 84, which is in driving connection with the arm shaft 3 via a belt drive 85.
The device operates as follows:
After exiting from the bobbin case 27, the shuttle thread is led, in at least one turn on its circumference, in the groove 30. The shuttle thread covers part of the deflecting surface 31.
The light beams of the photodiode 32 fall on the shuttle thread and, in the case of a larger deflecting surface 31, on its exposed parts on both sides of the shuttle thread. Due to the inclination of the deflecting surface 31 relative to the photodetector 33, the light beams falling on the deflecting surface 31 are reflected in a direction in which they cannot be received by the photodetector 33. However, part of the scattered light beams reflected by the shuttle thread reaches the photodetector 33.
Due to the scattered light beams, the photodetector 33 is conductive, and current flows to the ground through the resistor 74. The voltage thus occurring on the emitter is transmitted to the NOT member 75, whose output carries no voltage as long as the photodetector 33 is conductive. However, when the shuttle thread is broken or has been consumed to the extent that the deflecting surface 31 is exposed, light beams will no longer reach the photodetector 33. While a signal is no longer present at the input of the NOT member 75 as a result of this, a signal is available at its output and is sent to the input E1 of the microprocessor 76.
The signal of the thread monitor 25 causes the microprocessor 76 to send a signal from its output A7, by which the working speed of the positioning motor 84 is reduced to a markedly lower speed. At the same time, the inputs E2 and E3 of the microprocessor 76 receive the signals sent from the counter 77 of the impulse generator 5.
The counter 77 is put into operation by the entry of one of the markings 6 and 7 into the monitoring zone of the sensor device 8, and its input ZE1 receives a signal until the marking 6, 7 leaves the monitoring zone. As long as the signal is present at input ZE1, the counter 77 counts up beginning from zero, and a higher value is associated with the marking 6, which indicates the lower reversal point of the needle bar 12, than with the marking 7, which indicates the upper reversal point of the needle bar 12. The counter 77 sends a signal to the microprocessor 76 from its output ZA 1 when the higher value is reached and from its output ZA 2 when the lower value is reached. After each signal received by the microprocessor 76 at its inputs E2 or E3, the microprocessor sends a signal from its output Al, as a result of which the counter 77 is reset to zero.
When the signal of the counter 77 first arrives at the input E2 of the microprocessor 76, it sends a signal from its output A8, as a result of which the needle 13 is stopped in its lower reversal point in the last insertion hole in the fabric being sewn (FIG. 6a). When the needle 13 stops, the microprocessor 76 sends signals to the outputs A2 and A4, which cause the 4/2-way valves 78 and 79 to be switched over and the cylinder jacket 63 to be raised relative to the piston rod 61 and the piston rod 62 to extend. As a result, the free end of the piston rod 62 is moved from the position (a) shown in FIG. 5 to the position (c). As a result, the two-position cylinder 60 pivots the crank 58 according to FIG. 1, as a consequence of which the projection 68 of the oscillating lever 65, which is in contact with the outer side wall of the adjusting groove 69, is pulled to its inner side wall, and the stitch length adjusting mechanism 71 is thus set for reverse stitching.
After a fed motion in the reverse direction, a signal is sent from the output ZA 2 of the counter 77 to the input E3 of the microprocessor 76. The needle 13 is then located in its upper reversal point above the penultimate insertion hole of the fabric being sewn (FIG. 6b). To stop the needle 13 in this position, the microprocessor 76 sends a signal from its output A9 to the positioning motor 84.
In this position of the needle 13, new shuttle thread is pulled from the bobbin 29 in the case of thread break, and the empty bobbin 29 is replaced with a full one in the case of thread end. After actuating the foot pedal of the sewing machine 1, a signal is sent to the input E4 of the microprocessor 76, after which it sends a signal for reversing the 4/2-way valve 78 from its output A3, so that the cylinder jacket 63 will be extracted. The free end of the piston rod 62 will then assume the position (b) shown in FIG. 5, in which the stitch length regulating mechanism 71 is reset to zero. In position (b), the projection 68 of the oscillating lever 65 is in a position between the inner and outer side walls of the adjusting groove 69.
As soon as the stitch length regulating mechanism 71 is reset to zero, a stitch is formed after the microprocessor 76 sends a signal from the output A10. After the needle 13 returns into its upper reversal point, this process can be repeated several times to achieve particularly firm knotting. FIG. 6c shows the needle 13 on its way to the upper reversal point.
On completion of this knotting, the 3/2-way valve 81 is reversed at the upper reversal point of the needle 13 by a signal sent from the output A6 of the microprocessor 76, so that the piston rod of the cylinder 44 extends and drives the cutting blade 36 to cut the two free ends of the shuttle thread (FIG. 6d). The throttle 82 acts to delay the time of reversal of the 3/2-way valve 81, and the throttle 83 acts to reduce the speed of the piston rod during the retraction of the piston.
After the thread has been cut, the microprocessor 76 sends a signal from its output A5 to the 4/2-way valve 79, as a result of which the piston rod 62 is retracted and its free end assumes the position (a) (FIG. 5). The stitch length regulating mechanism 71 is thus again set for forward stitching. By sending a signal from the output All of the microprocessor 76, the positioning motor 84 is again accelerated to the working speed, and stitch formation is continued.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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A processing and sewing machine arrangement for preparing a seam which is uninterrupted on a seam side facing the needle of the sewing machine. The arrangement includes a shuttle thread disturbance detection arrangement and a control arrangement activating a stopping arrangement for stopping the sewing machine after the shuttle thread disturbance has been detected and after a stitch formation cycle which has been begun is completed. A regulating mechanism for setting stitch length is set into a reverse stitching mode by the control arrangement while the fabric being sewn is moved backward by one stitch length. After the shuttle thread has been fed in, thread is knotted by at least one stitch with the needle thread in the same insertion hole in which the old shuttle thread is located such that the old shuttle thread is correctly knotted with the needle thread.
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The application is a 35 USC 371 of PCT/CH2006/000170 filed Mar. 21, 2006 which claims the benefit of Switzerland application 633/05 filed Apr. 7, 2005.
FIELD OF THE INVENTION
The invention relates to a method and a device for the suppression of vibrations in a system having an actuating drive for actuating a flap or a valve for the dosing of a gas or liquid volume flow, in particular in the field of HVAC, fire or smoke protection.
BACKGROUND OF THE INVENTION
In practice, regulating circuits having actuating drives for flaps and valves in the field of HVAC continually begin to vibrate. A vibration of said type can be of short duration, for example during start-up, but also occurs because regulating circuits can never be set to be stable. This leads to an early failure of actuating drives, and the latter must be repaired or replaced before the expected service life has expired. It is therefore in the interests of suppliers and customers that early failures of said type are prevented.
In order that vibrations can occur, two conditions in particular must be met:
amplitude condition: the gain of the entire system must be at least equal to 1. phase condition: there must be a time lag in the system which is sufficiently large.
A vibration remains in the steady state if, in the case of a total gain of at least 1, the phase shift of the entire system is 360°.
The undesired vibrations can therefore differ not only in frequency but also in amplitude. If intense non-linearities are involved, as is the case for example with unfavorably-designed valves, a vibration can thus generally occur only in certain operating ranges of a system. Depending on this, the amplitude of a steady-state vibration can also be different. If a regulator is set in a grossly incorrect manner, a vibration can encompass the full range of an actuating signal until it is limited by the restricted output range of the regulator. In said limit case, the vibration can also be rectangular or approximately rectangular.
In U.S. Pat. No. 6,264,111 A, the gain of a regulator, the so-called P component, is adjusted. If the gain of the entire system, for example regulator, actuating member, air conditioning system, room and sensor, is small enough, then the vibration disappears. The means for suppressing the vibration are integrated directly in the regulator, and the input and output variables of the regulator are always known. It is possible using different means, also adaptive means, to suppress or eliminate vibrations, though it is in part necessary to accept significantly poorer regulating performance. Said degradation can be expressed for example in persistent temperature deviations or a very lethargic matching of the temperature.
BRIEF SUMMARY OF THE INVENTION
The inventors have set the object of creating a method and a device of the type specified in the introduction, by means of which vibrations in the system can be suppressed or eliminated without the regulating performance being noticeably degraded.
With regard to the method, the object is achieved according to the invention in that vibrations, which are generated by means of an unfavorable or incorrect setting or configuration of the regulation arrangement and/or by means of disturbing influences, of the flap or of the valve are detected, and damped or suppressed, by means of an algorithm stored in a microprocessor.
Special and refining embodiments of the method are the subject matter of dependent patent claims.
The algorithm according to the invention is based on three components:
vibration detection adaptive filtering step detection
For vibration detection, that is to say in order to determine the frequency of a vibration, the minima and maxima of the signal are sought and the time interval in between these is measured (extreme value analysis). This however often leads to imprecise or even incorrect results if the signal simultaneously contains a plurality of frequencies. In order to avoid such false results, a new method called wavelet analysis is introduced. Said method is described in detail by the co-inventor M. Thuillard in the publication “Wavelets in Soft Computing”, World Scientific Press, 2002. In very broad terms, said wavelet analysis involves a greatly simplified Fourier analysis which, with basic mathematical operations by means of a simple microprocessor, leads to the goal. Here, a small number of frequency ranges are defined, thereby fixing a coarse raster. A wavelet analysis highlights the region of said raster in which most of the energy of the signal is situated. This makes it possible to check whether the extreme value analysis which was originally carried out was correct. In the case of an excessively large deviation, on the basis of the wavelet analysis, an assumption for the vibration frequency is generated, and it is decided whether or not the vibration suppression should be activated at all.
Within the context of adaptive filtering, a phase-reducing element, a so-called lag element, is selected in order to reduce the gain or the amplitude of the vibration of the system. The lag element selected for the approach has the following properties:
in the event of very slow, low-frequency changes in the control signal, the gain of the system is not influenced. in the event of faster, high-frequency changes in the control signal, the gain is reduced, and the signal is damped. From a certain frequency of the control signal, the amplitude remains approximately constant at a minimum value, and the damping therefore remains at a maximum value.
A Bode diagram which is known to a person skilled in the art is expediently used for a graphic description of the adaptive filtering, in which Bode diagram the amplitude and the angle of a signal, or the gain and the damping, are illustrated in each case as a function of the frequency. A lag element is the core of the vibration suppression. Said lag element must be correctly parameterized; this involves defining the cut-off frequencies of the lag element, for which purpose the frequencies of the vibration which is to be damped must be known.
The lag element is parameterized and activated with cut-off frequencies determined from the Bode diagram. In general, the filter now already operates in approximately the correct frequency band. Should this not yet be optimal, it is checked by means of the continuing vibration detection as to whether the vibration now decays as predefined. If not, the two cut-off frequencies are periodically moved in the direction of lower frequencies, thereby increasing the damping action for the vibration frequency. The movement of the filter frequency is associated with a change in the phase shift, so that both conditions for the occurrence of vibrations, the amplitude condition and the phase condition, are varied until one of the conditions is no longer met and the vibration decays. The algorithm therefore operates in a self-adaptive manner.
The lag element damps fast changes in the actuating signal, as a result of which the drive no longer reacts quickly enough in all cases to desired steps in the actuating signal. For example, if someone turns an adjustment knob for the room temperature, such steps must be detected and passed on to the drive. In other words, the step detection arrangement must, in the event of a desired step, deactivate the lag element again so that a step can be made immediately in an accompanying fashion. After the step, the entire algorithm starts from the beginning.
Alternatively, the cut-off frequencies of the lag element are temporarily moved in the direction of higher frequencies, and then successively reduced again.
The preferred functions of the algorithm according to the invention can be summarized as follows:
The vibrations in the system are adaptively, preferably self-adaptively, filtered, with a lag element, which is parameterized by means of cut-off frequencies, expediently being used as a filter. In the case of vibrations which do not decay as predefined, the two cut-off frequencies of the lag element are periodically moved in the direction of lower filter frequencies, and the damping for the vibration frequency is thereby increased. If a load step is detected, the lag element is immediately deactivated or re-parameterized, and the step is made in an accompanying fashion. The flap and/or valve characteristic is dynamically linearized. Vibrations in the range from 1 to 1800 seconds' duration, preferably from 30 to 300 seconds' duration, are detected, and damped or suppressed. Vibrations of a flap up to an angle Δφ and/or of a valve up to a lift Δh, of the maximum actuating range, are detected, and damped or suppressed.
The algorithm used according to the invention is preferably software-programmed and operates without configuration requirements. It additionally provides information regarding the vibration characteristic, in particular mean values, amplitudes and/or frequencies, for analysis.
With regard to the device for carrying out the method, the object is achieved according to the invention in that a microprocessor with algorithms for vibration suppression and linearization is arranged in the actuating drive.
The arrangement of the vibration suppression arrangement in the actuating drive ensures reliable functioning of the system with all commercially available regulators. The disadvantage specified in the introduction, that vibration suppression arrangements accommodated in a regulator lead to a significantly degraded regulating performance, is therefore eliminated.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in more detail on the basis of exemplary embodiments which are illustrated in the drawing and are also the subject matter of dependent patent claims. In the drawing, in each case schematically:
FIG. 1 shows a pivotable flap in a ventilation pipe,
FIG. 2 shows uninfluenced vibrations of the flap as per FIG. 1 ,
FIG. 3 shows the flap as per FIG. 1 with vibration suppression,
FIG. 4 shows damped vibrations of the flap as per FIG. 3 ,
FIG. 5 shows a typical regulating circuit,
FIG. 6 shows a vibration suppression arrangement in the rest state,
FIG. 7 shows a vibration suppression arrangement with the algorithm activated,
FIG. 8 shows a heating system, and
FIG. 9 shows vibrations generated by means of the boiler regulator of FIG. 8 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a detail of a ventilation pipe 10 with an installed flap 12 which is pivotable under the action of an electromotive actuating device 14 . A gas volume flow 16 , in the present case an air flow, which is illustrated with an arrow is blown through the ventilation pipe 10 . The flap which is embodied according to the prior art vibrates about an angle Δφ of approximately ±15°, and a vibration period is approximately two minutes.
In FIG. 2 , the vibrations 18 are plotted with regard to their amplitude proportional to the angle Δφ as a function of the time t, with the amplitude Δφ corresponding to the deviation from the central normal position N. The vibrations 18 lie substantially on a horizontal band with parallel edges.
FIG. 3 corresponds substantially to FIG. 1 , but a vibration suppression arrangement 20 is connected upstream of the actuating drive 14 . Said vibration suppression arrangement 20 passes a control signal 38 , also referred to as an actuating variable, to the actuating drive 14 . The profile is illustrated in FIG. 4 ; the vibrations initially run as in FIG. 2 . After the time t x , the actuating drive 14 receives control signals which immediately and effective dampen the vibrations 18 , and the maximum amplitude deflections decay until a normal position N is reached. This significantly lengthens the service life of the drives.
A regulating circuit 22 illustrated in FIG. 5 has a vibration suppression arrangement 20 which simultaneously serves to provide linearization and which is arranged in the actuating drive 14 .
A nominal value transducer 24 feeds predefined control signals into a comparing element 26 of a regulator 34 , and at the same time receives the actual value of a feedback variable 35 which corresponds to the regulating variable 32 which is output from a regulating path 28 and is passed via a signal inverter 30 . The regulator 34 calculates a regulator output variable 36 and feeds the latter into an adaptive filtering arrangement ( 48 in FIGS. 6 , 7 ) with the algorithm of the vibration suppression arrangement 20 .
If the vibration detection arrangement 46 (in FIGS. 6 , 7 ) of the vibration suppression arrangement 20 detects vibrations, it generates a control signal 38 or an actuating variable for the actuating drive 14 with the integrated vibration suppression arrangement 20 , as a result of which the vibrations 18 are immediately damped ( FIG. 4 ). According to a variant which is not illustrated, the vibration suppression arrangement 20 can also be arranged separately outside the actuating drive 14 .
A vibration suppression arrangement 20 illustrated in FIG. 6 , substantially a microprocessor 49 , is illustrated in the rest position. Two logic switches 40 , 42 are set such that a signal, the regulator output variable 36 , is supplied via a direct signal path 44 as an actuating variable 38 to the actuating drive 14 . A vibration detection arrangement 46 having a load step detection arrangement 50 in the same block constantly monitors the regulator output signal 36 for any vibrations 18 ( FIG. 2 ). An adaptive filtering arrangement 48 is deactivated. There is a logic connection 45 , illustrated by dashed lines, between the vibration detection arrangement 46 and the switches 40 , 42 .
In the illustration of the vibration suppression arrangement 20 as per FIG. 7 , the vibration detection arrangement 46 has detected vibrations of the system which lie above the tolerance. The two logic switches 40 , 42 switch, and the regulator output variable 36 is now supplied to the adaptive filtering arrangement 48 with the algorithm. The adaptive filtering arrangement 48 is supplied by means of a logic connection 52 with the filter parameters obtained by means of the vibration detection arrangement 46 . The algorithm of the adaptive filtering arrangement 48 contains, in the present case, a lag element. In this way, vibration damping is initiated which continues until the disturbance is eliminated and the vibration detection arrangement switches back to the arrangement as per FIG. 6 .
According to an embodiment which is not illustrated, the switch 40 can be replaced by a conventional branch.
A heating system 54 illustrated in FIG. 8 , as is used for example for a double-bedroom detached house, comprises a heating boiler 56 having a burner 58 and two heating circuits 60 , 62 with a common feed line 64 and return line 66 which lead to the heating boiler. The two heating circuits 60 , 62 are fed by in each case one circulation pump 68 ; a part of the returning water can be admixed into the feed line 65 of the relevant heating circuit 62 by means of a mixing valve 70 . The mixing valves 70 have an electric actuating drive 14 which receives actuating signals 38 from the relevant heating circuit regulator 72 , 74 . The heating circuit regulators 72 , 74 receive signals from a temperature sensor 78 in the heating circuits 60 , 62 , a room temperature gauge 80 and an outdoor temperature gauge 82 .
An on-off boiler regulator 84 regulates the water temperature of the heating boiler 56 by virtue of a temperature sensor 86 activating and deactivating the burner 58 . Here, vibrations can be generated which are unavoidable. The heating circuit regulators 72 , 74 attempt to compensate the fluctuating boiler temperature by means of corresponding actuating signals 38 to the actuating drives 14 of the mixing valves 70 .
The profiles of the boiler temperature 88 and of the actuating signal 38 for the actuating drives 14 of the mixing valves 70 are illustrated in FIG. 9 as a function of the time t. The period T of a vibration 18 fluctuates greatly within a system as a function of the meteorological conditions, and typically lies in a range from approximately ten minutes to two hours. The actuating signal 38 for the actuating drives 14 of the mixing valve 70 oscillates about a central value N ( FIGS. 2 , 4 ), with no extreme steps being expected.
In the case of floor heating systems, the actuating drive 14 may remain in the central position without any loss of comfort. In the case of radiator heating systems, it is at the most possible to notice a slight variation in the radiator temperature. In the case of air heaters, in contrast, the actuating drive 14 for the mixing valve 70 must perform a correcting movement, since unpleasant, noticeable temperature fluctuations otherwise occur. Further fluctuations 18 in the heating system 54 as per FIG. 8 can have various causes:
As a result of inadequate assembly, the outdoor temperature gauge 82 can be exposed to direct sunlight. In the event of changeable weather, this can lead to intense fluctuations in the measured outdoor temperature, and therefore to vibrations. The heating circuit regulators 72 , 74 attempt to compensate this. Disturbing influences in the indoor temperature measured by means of the room temperature gauge 80 can also occur as a result of fluctuating exposure to direct sunlight. The heating circuit regulators 72 , 74 also attempt to compensate said disturbance. As a result of defective hydraulic decoupling of the two heating circuits 60 , 62 , the one heating circuit can be influenced by the other. The two heating circuits can incite vibrations in one another. In the case of an incorrectly configured regulator, it is possible for vibrations to be generated on account of the incorrect settings for the P-band or the reset time. The periods of the vibrations are system-specific, and are generally approximately three to five minutes.
According to a variant of FIG. 8 which is not illustrated but is preferred, a vibration suppression arrangement 20 is integrated into the actuating drive 14 for the mixing valves 70 of the two heating circuits 60 , 62 , which vibration suppression arrangement 20 detects and eliminates undesired steady-state vibrations.
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Disclosed are a method and a device for suppressing vibrations ( 18 ) in an installation comprising an actuator ( 14 ) for actuating a flap ( 12 ) or a valve ( 70 ) used for metering a gas or liquid volume flow ( 16 ), especially in the area of HVAC, fire protection, or smoke protection. Vibrations ( 18 ) of the flap ( 12 ) or valve ( 70 ) caused by an unfavorable or wrong adjustment or configuration of the controller and/or by disruptive influences are detected and dampened or suppressed by means of an algorithm ( 1 ) that is stored in a microprocessor ( 49 ). Said algorithm is preferably based on the components recognition of vibrations ( 46 ), adaptive filtering ( 48 ), and recognition of sudden load variations ( 50 ).
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a beam recorder which records an image on a record medium by a beam.
2. Related Background Art
In a conventional laser beam printer of this type, a rotating polygon mirror for scanning a laser beam is constructed such that all planes thereof scan the beam for forming an image. Accordingly, for each of the planes of the rotating polygon mirror, it is necessary to attain high precision in planarity and parallelism of the planes. However, in actual, use since it is not possible to completely eliminate a difference between parallelisms of the planes, an optical system for compensating resulting ununiformity in the scan in a sub-scan direction (a correcting cylindrical lens) is required. As a result, the apparatus is complex and expensive in view of pat precision, number of parts, and assembly work of the parts. In a low speed and low grade apparatus, the number of planes of the rotating polygon mirror is reduced as much as possible to reduce a cost. Nevertheless, the complex and expensive construction has not yet been resolved.
In the conventional laser beam printer of this type, various restrictions are imposed when an intensity of the laser beam is to be controlled. A semiconductor laser is usually used as a laser light source for the laser beam printer of this type. The semiconductor laser has a disadvantage of variation of intensity with a temperature and reduction of intensity by deterioration. As a result, an intensity control system is adopted in which an output of a photo-sensor mounted in the semiconductor laser is detected to keep the laser light intensity constant.
FIG. 4 shows a laser light intensity control circuit. A microprocessor (MPU) 21 produces a laser on (LON) signal to turn on a transistor 27 and supplies a digital value to a D/A converter 22 to gradually increase the output of the D/A converter 22. As a result, a current I OP flowing through a laser diode 29 of a laser unit 28 gradually increases by a constant current circuit (CC) 24 so that a light intensity of the laser diode 29 increases. A laser beam from the laser diode 29 is emitted externally and also to an internal photo-diode 30. As a result, a photo-diode current I M which is proportional to the light intensity emitted externally flows. It is converted to a voltage V M by a resistor 31 and supplied to an amplifier (AMP) 25. The output of the amplifier 25 is supplied to an A/D converter 23 where it is converted to a digital signal, which is read by a microprocessor 21. The microprocessor 21 increases the output of the D/A converter 22 until the output read by the microprocessor 21 reaches a predetermined value, when the output of the D/A converter 22 is fixed. The digital value currently applied to the D/A converter 22 is stored and the signal LON is turned off. In this manner, the laser light intensity is controlled.
In a print mode, the microprocessor 21 applies the stored digital value to the D/A converter 22. A video (VDO) signal turns on and off a transistor 27 so that the laser diode 29 is turned on and off by a constant current pulse.
In the laser light intensity control system described above, it is necessary to continuously emit the laser beam when the light intensity of the laser is detected. Where the conventional rotating polygon mirror is used, the emitted laser beam is necessarily directed to a photosensitive member. Accordingly, if toner deposits to the photo-sensitive member, the toner is wasted. Accordingly, it is necessary to control the process such that the toner is not developed. In a one-sheet print operation, the process may be controlled prior to the actual print operation such that the toner is not developed and then the light intensity of the laser may be detected. In continuous print operation, because of the change of laser intensity by temperature, it is necessary to detect the laser light intensity between n-th printing and (n+1)th printing. Accordingly, in order to control the process such that the toner is not developed during that period, a complex process control is required, and fast response of the development process is required.
In the conventional laser beam printer of this type, the photo-sensitive member is deteriorated by the wasteful laser beam irradiation to the photo-sensitive member.
In order to attain stable light intensity and provide an inexpensive recorder, the assignee of the present invention proposed the apparatus disclosed in U.S. Pat. No. 4,201,994, U.S. Pat. No. 4,443,695, U.S. Pat. No. 4,695,714, and U.S. Ser. No. 149,526 (filed on Jan. 28, 1988). However, further improvement has been desired.
SUMMARY OF THE INVENTION
It is an object of the present invention to overcome the disadvantages described above.
It is another object of the present invention to improve a beam recorder.
It is other object of the present invention to provide a beam recorder which can reproduce a high quality image.
It is other object of the present invention to provide an inexpensive beam recorder.
It is other object of the present invention to provide a long-life or durable beam recorder.
It is other object of the present invention to provide a beam recorder of a simple construction which attains a stable light intensity.
It is other object of the present invention to provide a recorder which prevents degradation of a record medium.
It is other object of the present invention to provide a beam recorder which prevents complex construction or complex program.
It is other object of the present invention to provide an image recorder which eliminates restriction on sequence control when the laser light beam is controlled, saves degradation factor and waste for process elements such as photo-sensitive member and developing unit, and improves performance such as fine control of the laser light beam so that higher quality of image is attained.
Other objects of the present invention will be apparent from the following description which refers the accompanying drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1C show a schematic view of one embodiment of a laser beam printer of the present invention and timing charts of laser light intensity control which uses a polygon mirror of the embodiment.
FIG. 2 shows an internal construction of the laser beam printer of the embodiment.
FIG. 3 shows laser beam scan by a polygon mirror of the embodiment and a BD signal detection method.
FIG. 4 shows a circuit diagram of laser light intensity control of the embodiment.
FIGS. 5A-5C show a conventional polygon mirror and the polygon mirror of the embodiment.
FIGS. 6A-6C show a BD signal in the conventional method and a BD signal in the embodiment, and a period of laser light intensity control.
FIGS. 7A and 7B show a circuit diagram for detecting the laser light beam control period of the embodiment and a time chart of the operation.
FIG. 8 shows a sequence of laser light intensity control of the embodiment and signal levels in the circuit.
FIGS. 9A, 9B, 10A and 10B show polygon mirrors in other embodiments.
FIG. 11 shows a time chart for the laser light intensity control in a print mode, and
FIG. 12 shows another time chart for the laser light intensity control in the print mode.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A recorder of one embodiment of the present invention is an electrostatic recording type image recorder having an optical system for forming and scanning an image by a rotating polygon mirror and a laser beam emitted from a laser light source at least one of reflection planes of the rotating polygon mirror is a non-scan plane which does not form or scan the image and a laser light intensity is controlled while the laser beam is directed to the non-scan plane.
The present embodiment is now explained with reference to the drawings.
FIG. 2 shows a construction of the laser beam printer of the present embodiment. After power-on, a printer 1 checks if the temperature of a fixing unit 12 is proper, if sheets 13 are in a sheet cassette 14 and other internal status, and inform an external host controller (not shown) whether a print operation is ready or not. When the print operation is ready, the host controller sends a start of print command to the printer 1 as required so that the printer 1 starts the print operation. In the laser beam printer of the present embodiment, in order to initialize a surface potential of a photo-sensitive drum 2, a pre-exposure lamp 8, a primary charger 3 and a transfer unit 6 are activated and a polygon mirror 4 is rotated. As the photo-sensitive drum 2 is initialized and the rotation of the polygon mirror 4 is stabilized, a sheet 13 is fed from a sheet cassette 14 by a feed roller 9. When a leading edge of the sheet reaches a registration roller 10 and forms a loop, the feed of the sheet by the feed roller 9 is stopped and it stands by. The printer 1 then requests to the host controller to send a sub-scan direction synchronization signal (VSYNC signal). In response thereto, the host controller sends the VSYNC signal and sends an image signal (VDO signal) in synchronism with a main scan direction synchronization signal (BD signal) from the printer 1.
FIGS. 1A and 3 show laser beam scan by the polygon mirror and a method for detecting a BD (beam detector) signal. A laser beam emitted from the laser 18 is scanned by the polygon mirror 4 to form a light image on the photo-sensivive drum 2 in the main scan direction (arrow). The laser beam is directed to the photo-sensor 20 by the mirror 19 so that a synchronization signal (BD signal) indicating the beam scan position is produced. The mirror 19 is arranged outside of an area in which the laser beam form the light image on the photo-sensitive drum 2. The photo-sensor 20 is arranged at an equal distance to that from the polygon mirror 4 to the photo-sensitive drum 2. The laser beam reflected by the polygon mirror 4 is focused onto the photo-sensitive drum 2 by the fθ lens 17 and the mirror 16 of FIG. 2 to form the light image. The light image is then developed by the developing unit 5 into a toner image. The leading edge resigtration of the toner image and the sheet is effected by rotating the registration roller 10 in synchronism with the VSYNC signal. The toner image is transferred to the registered sheet by the transfer unit 6, and the sheet is fed to the fixing unit 12 by the feeder 11 where the toner image is fixed to the sheet. The sheet is then fed to the eject tray 15. The toner image which was not transferred to the sheet by the transfer unit 6 is scraped off the photo-sensitive drum 2 by the cleaner 7.
In a one-sheet print mode, the laser 18 is deactivated at the end of formation of the light image on the photo-sensitive drum 2 and the rotation of the polygon mirror 4 is stopped. At the end of transfer of the toner image to the sheet by the toner unit 6, the photo-sensitive drum 2 is initialized, and after the sheet has been ejected, the rotation of the photo-sensitive drum 2 is stopped to terminate the print operation. In a continuous print mode, after the image signal has been sent for the sheet on which the print operation is being effected, a start of print command for the next sheet is requested to the host controller. In response to the start of print command, the sheet 13 is fed from the sheet cassette 14 so that the print operation is continued.
FIGS. 5A and 5B show conventional polygon mirror, and FIG. 5C shows the polygon mirror of the embodiment. FIG. 1A also shows the polygon mirror 4 which is similar to that shown in FIG. 5C. As shown in FIGS. 5A and 5B, the conventional polygon mirrors have six or eight reflection planes, all of which are micro-finished to reflect the laser beam at a high reflection factor. On the other hand, the polygon mirror of the embodiment has four planes as shown in FIG. 5C, and the planes A and C are not mirror-finished and are blank-coated (non-reflection coating) to reduce the reflection of laser beam as much as possible. Accordingly, it is the planes B and D that scan the beam for forming the image. As a result, the number of planes is 1/3 to 1/4 of that of the conventional polygon mirror and hence the polygon mirror of the embodiment must be rotated at a speed which is as 3-4 times high level that of the conventional polygon mirror. However, in the laser beam printer of the embodiment, the print speed is 1/2-1/3 of that of the conventional printer. Accordingly, the rotation speed of the polygon mirror may be as 1-2 times high as that of the conventional mirror and this does not cause a practical problem. In the laser beam printer of the embodiment, an image exposure system is used so that the toner is developed only at the area on the photo-sensitive drum to which the laser beam was irradiated. Accordingly, the planes A and C are black-coated in order to minimize the reflection of the laser beam.
FIG. 6A shows the BD signal produced when the planes A and C of the polygon mirror of FIG. 5C are not non-reflection planes. The BD signal produced by the polygon mirror of the embodiment shown in FIGS. 1B and 6B, which has non-reflection planes A and C does not appear in periods τ A and τ C . The image is scanned on the photo-sensitive drum in periods T B and T D , as shown in FIGS. 1C and 6C. Since the planes A and C are non-reflection planes, the photo-sensitive drum is not affected even if the laser is left activated at least during the periods τ A and τ C . Accordingly, the laser beam intensity may be controlled during the periods τ A and τ C . Thus, the waste of the toner by the prior art laser light intensity control, the complexity of process control to prevent the waste of the toner, and the degradation of the photo-sensitive member are prevented.
A method for detecting the laser light intensity control period is explained. In the present embodiment, the laser light intensity is controlled in the periods τ A and τ C of FIG. 6C. Since the laser beam is not reflected by the planes A and C, the BD signal cannot be directly obtained. Accordingly, it is necessary to separately produce a signal indicating the periods τ A and τ C or the starts of those periods.
FIG. 7A shows a circuit diagram to produce the signal indicating the periods τ A and τ C , and FIG. 7B shows an operational timing chart. A microprocessor 21 sets a count to a counter 32. The microprocessor 21 control the light intensity as shown in FIG. 4 and controls the sequential operation of the printer. The count may be set to the counter 32 by other circuit than the microprocessor 21. The counter 32 is reset by the BD signal and then counts the above count by a clock signal CLK. The clock signal CLK may be one which is in synchronism with a record clock used to transfer the image signal. The count is selected such that an RC signal is produced after T 1 time as shown in FIG. 7B. In the present embodiment, T 1 ≧τ A (or T 1 ≧τ A =τ b =τ C =τ D ). The counter 32 counts up to produce the RC signal, and a latch 33 latches it to produce an H-level Q-output, which is cleared by the next BD signal to assume an L-level. Accordingly, the period T 2 in which the Q-output of the latch 33 is H-level is not shorter than τ A (T 2 ≦τ A , or T 2 ≦τ A =τ B =τ C =τ D ), and the microprocessor 21 controls the laser light intensity in the period of the H-level Q-output.
FIG. 8 shows a timing chart for a sequence of laser light intensity control of the embodiment. The circuit shown in FIG. 4 is used as the laser light intensity control circuit, although other circuit may be used. The microprocessor 21 renders a LON signal to H-level to turn on a transistor 27, and supplies a digital value to a D/A converter 22, which produces a signal D/A as shown in FIG. 8. As a result, the output of the D/A converter 22 is gradually increased. Accordingly, a current I OP flowing through a laser diode 29 of a laser unit 28 gradually increases as shown in FIG. 8 by a constant current circuit 24 so that the light intensity of the laser diode 29 increases. The output beam of the laser diode 29 is also directed to a photo-diode 30 in the laser unit 28 and a photo-current I M which is proportional to the externally emitted laser beam intensity flows, and it is converted to a voltage V M by a resistor 31 and it is supplied to an amplifier 25. The output of the amplifier 25 is supplied to an A/D converter 23 where it is converted to a digital signal, which is read by the microprocessor 21. The microprocessor 21 increases the output of the D/A converter 22 until the digital signal reaches a predetermined value (V M =V MS ), when it stops to increase the output. The microprocessor 21 stores the digital value applied to the D/A converter 22 when V M reaches V MS , and renders the LON signal to L-level and renders the output of the D/A converter 22 to zero to terminate the laser light intensity control.
In the print mode, the microprocessor 21 renders the LON signal to the L-level and supplies to the D/A converter 22 the stored digital value for the predetermined light intensity. Under this condition, the VDO signal is driven by the constant current pulse. The laser light intensity control, that is, the detection of the level of the signal V MS of FIG. 8 is effected in the periods τ A and τ C of FIG. 6C. However, when the apparatus is powered on, the microprocessor 21 does not have the digital value to be supplied to the D/A converter 22 to produce the signal V MS , because the laser current I OPS necessary to produce the predetermined light intensity differs from laser unit 28 to laser unit 28. Accordingly, before the image scan for the first print operation after the power-on, the microprocessor 21 must detects the V MS level. In order to detect the V MS level, the laser current I OP is supplied to some extent so that the laser diode 29 emits light. Otherwise, the output of the photo-sensor 20 for detecting the BD signal cannot be produced and the periods τ A and τ C of FIGS. 6B and 6C cannot be detected. Thus, when the V MS level is to be detected in the first laser light intensity control after the power-on, the laser current which is large enough to produce the BD signal may be supplied instead of gradually increasing the laser current I OP from zero. However, as described above, a relation between the laser current of the laser unit 28 and the light intensity differs from unit to unit, and in a conventional semiconductor laser, the laser device may be deteriorated or broken if it is operated over a specified maximum light intensity. For example, a laser A may emit a light below a maximum light intensity Pmax with the laser current I OP1 but a laser B may emit a light above the maximum light intensity Pmax with the laser current I OP1 . A laser C may emit a light which is too weak to produce the BD signal with the laser current I OP1 . Accordingly, it is difficult to determine the initial value of the laser current I OP in the first laser light beam control, and the initial value may be set to zero or I OP min which assures that the light intensity does not exceed the maximum light intensity for all lasers to be used. When those methods are used, the BD signal is not produced until the predetermined light intensity is reached in the laser light intensity control. In the present embodiment, the first laser light intensity control after the power-on is effected after the start of the print operation and the start of the rotation of the polygon mirror 4, and the initial laser current I OP is set to zero. Accordingly, until the first BD signal is produced as the laser current I OP increases, the laser beam is directed to all planes A, B, C and D of the polygon mirror of FIG. 5C. Thus, in the periods in which the laser beam is directed to the planes B and D, the laser beam is irradiated to the photo-sensitive drum 2. In the present embodiment, the process condition is controlled such that the toner is not developed in spite of the irradiation of the laser beam to the photo-sensitive drum 2 until the BD signal has a normal period as the laser current I OP is increased, that is, until the polygon mirror 4 is rotated at a normal rotation speed. In order to implement it, all outputs of the primary charger 3, the developing unit 5 and the transfer unit are turned off. Where the photo-sensitive drum 2 is initialized at the start of the rotation of the polygon mirror 4 and the laser light intensity control after the start of print operation in order to save wasteful time, only the primary charger 3 may be turned on. In this manner, the first laser light intensity control after the power-on is effected. If the detection of the predetermined laser light intensity is completed before the BD signal having the normal period is produced, the laser is activated at the predetermined light intensity until the BD signal of the normal period is produced. If the predetermined laser light intensity is not attained when the BD signal having the normal period is produced, the laser light intensity control is continued in the periods τ A and τ C of FIGS. 6B and 6C. In any case, when the laser light intensity control is completed and the BD signal having the normal period is produced, the laser is activated at the predetermined light intensity only at the timing to produce the BD signal until the actual print operation is started.
As described above, the laser light intensity control in the print mode is effected in the periods τ A and τ C of FIGS. 6B and 6C. The laser light intensity control may be effected between the n-th printing and the (n+1)th printing, that is, during the absence of the image scan, as well as during the image scan by utilizing the periods τ A and τ C of FIGS. 6B and 6C. In this manner, the image quality is improved by compensating for the variation of the laser light intensity for each line scan. The digital value to be supplied to the D/A converter 22 to supply the predetermined laser current I OPS in the first laser light intensity control after the power-on may be stored in a RAM of the microprocessor 21. Thus, in the subsequent laser light intensity control, the laser light intensity control may start from I OP =I OPS or I OP =I OPS -α instead of I OP =0 so that the light intensity control is finished in a shorter time. This is illustrated in FIG. 11. The start laser current I OPn at the n-th laser light intensity control may be I OPS (n-1) or I OPS (n-1)-α, where I OPS (n-1) is the laser current produced in the (n-1)th control. This is illustrated in FIG. 12.
FIG. 9A shows a polygon mirror in another embodiment. In the present embodiment, the planes A and C are round so that the laser beams directed to the planes A and C are reflected to areas other than the photo-sensitive drum and the BD sensor.
FIG. 9B shows a polygon mirror in other embodiment. In the present embodiment, the planes A and C are inclined relative to the planes B and D so that the laser beam is not reflected to the photo-sensitive drum or the BD sensor.
FIGS. 10A and 10B are polygon mirrors having more than four planes. In the present embodiment, the reflection plane and the non-reflection plane alternatively appear.
In the above embodiments, the laser light intensity control may be effected in either scan period or non-scan period of the image, or it may be continuously effected to improve the lifetimes of the apparatus and laser. Alternatively, it may be effected at any time such as periodically, at every predetermined number of printed sheets, or when a change in a temperature in a vicinity of the laser is detected.
In the above embodiment, the laser light intensity control is effected by continuously activating the laser until the BD signal has the normal period at the start of rotation of the polygon mirror. Alternatively, if the BD signal is produced and the periods τ A and τ C are longer than the period required to control the laser light intensity even if τ B >τ D (or τ C >τ A ), the laser light intensity control in the periods τ A and τ C may be started at this moment.
A circuit for generating a signal for assuring the periods τ A and τ C to be one half of the BD period may be provided to control the laser light intensity in the signal period.
The present invention is not limited to the above embodiments but various modifications thereof may be made without departing from the scope of the appended claims.
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A beam recorder comprises a beam generator, a deflector for deflecting the beam to scan the beam, and a light intensity control unit for controlling a light intensity of the beam. The deflection has a plurality of deflection planes to which the beam is directed, and at least one of the deflection planes in a non-scan plane. The light intensity control is effected by utilizing a period in which the beam is directed to the non-scan plane.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present invention claims priority from U.S. Provisional Patent Application No. 60/825,931 filed Sep. 18, 2006, the content of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention refers in general to Time Division Multiple Access (TDMA) communications and in particular to Ranging used in TDMA communications
Acronyms
AFE—Analog Front End. The AFE consists of a transceiver, a trans-impedance amplifier, a limiter amplifier and Clock Data Recovery (CDR) component.
OLT—Optical Line Termination
ONU—Optical Network Unit
MAC−Medium Access Control
TDMA—Time Division Multiple Access
CDR—Clock and Data Recovery
TO—Time Out
AGC—Automatic Gain Control
BACKGROUND OF THE INVENTION
Modern TDMA communication systems are known in a variety of configurations. FIG. 1A shows a typical point to multi-point communication system in which a receiver 102 (see also FIG. 3 ) communicates bi-directionally with a plurality of users 104 - 1 to 104 -N. FIG. 1B shows data packets (in order of users 1 , 2 , 3 . . . N) arriving in order at the receiver. FIG. 2 shows schematically a particular, passive optical network (PON) communication system, in which the receiver is represented by an OLT 202 and the users are represented by ONUs 204 - 1 to 204 -N. The PON may be of any known type, for example a Gigabit-capable Passive Optical Network (GPON) or Ethernet-capable Passive Optical Network (EPON)
A typical receiver 300 is shown in FIG. 3 . The receiver can both transmit and receive. It includes an AFE (receiving analog front end) component 302 , a CDR (receiving clock and data recovery) component 304 a logic unit (MAC) 306 and a transmitter TX 308 , interconnected as shown. AFE 302 amplifies the low power data in the receive side. A first control signal (Reset AFE) 310 is supplied by the logic unit to assist the AFE in its functions, This Reset AFE signal assists the AFE to tune to the incoming data. The CDR locks to the input data. It acquires the frequency and the phase of an input data 312 signal and outputs a digital Received Data signal 314 , synchronized with a Received Clock signal 315 , to the logic unit. A second control signal (Reset CDR) 316 is supplied by the logic unit to assist the CDR in its functions. This Reset CDR signal assists the CDR to fast lock (frequency and phase) to the input data. The logic unit performs all the processing and controls the Ranging processes (explained below).
Ranging is performed in multi-user networks, in which the packet arrival time should be accurate and much smaller than the propagation delay. In general, in such networks, the Ranging targets include detection of a new user, synchronization of the receiver with the incoming bit stream of the new user; and estimation of the propagation delay (or round trip delay) of the new user. After the Ranging process is successfully finished, the arrival time of the new user's packet is known to the receiving system, and receiving from the new user can be accurately initiated by the receiver.
FIG. 4 shows a typical situation when a ranging window is allocated for a new user to join the network. A ranging window is a period of time in which all the new users can try and join to the network (in order not to collide with other users during Steady State operation, defined as the operation mode after successful completion of Ranging. The packets of different users may have different propagation delays (or round trip delays). In order to prevent contentions, the receiver must synchronize the different users. Before Ranging, the start of packet arrival time from the new user is unknown to the receiver. Although it is performed only when a new user joins the network, Ranging is a difficult task and needs to be carefully addressed. Various Ranging methods (or “processes”) are exemplarily described in U.S. Pat. Nos. 6,980,561, 6,948,184, 6,768,730, 6,215,792, 5,802,061, 7,251,240, 7,016,355, 6,853,624, 5,850,525, 5,379,299, 5,043,982 and 4,845,735, all incorporated herein by reference in their entirety.
FIG. 5 shows a common packet structure, as known in the art. A packet includes, in order, a Guard Time section 502 , a Preamble section 504 , a Delimiter section 506 and a Payload section 508 . The Guard Time, Preamble and Delimiter sections are sometimes named “Header”. The Guard Time is a time period in which no energy is transmitted. The Preamble (or synchronization sequence) is a sequence of zeros and ones. The sequence should consist of a lot of transitions to help the CDR to lock. The Delimiter is a sequence of bits which must be different from the Preamble. Its main use is to assist in detecting the beginning of the Payload. The structure of the Header is defined to enable the clock recovery to lock on the right timing.
FIG. 6 shows a straightforward, prior art Ranging method, typical of those indicated in the abovementioned references. At the beginning of a ranging window, the receiver activates the AFE and starts looking for a Preamble and Delimiter of a Ranging Packet until it finds both. In the Ranging process, since the arrival time is not known, the Header is larger than in Steady State, in which the Header should be as small as possible. This is possible since the arrival time is known to the receiver. The straightforward Ranging process has no periodicity in it—it occurs once. The process is finalized (ends) when the Delimiter is found and the receiver starts receiving the data correctly. This straightforward method assumes that the AFE does not require special control signals synchronized with the incoming data, which is usually the case.
To summarize, this kind of Ranging is limited to only few cases and it can be used only:
1. when the AFE and the CDR can detect data without external control signals (usually with special timing requirements (the AFE and the Burst Mode CDR sometimes require that the control signals should be activated during the preamble reception) 2. when the AFE blocks the data when the signal is low (squelch). Otherwise, false alarm reception can mislead the Logic Unit. This requirement requires special hardware in the AFE, the CDR or both components.
The main drawback of this method appears when there is a chance of false alarms or when one of the above conditions is not fulfilled. If there is a false alarm, there is no second chance, the burst is not received and the Ranging needs to start again. Moreover, some types of receivers must be activated during the reception of data, so the above Ranging method can not work at all.
Usually, to enable the Ranging process, special hardware building blocks such as a Fast Power Detection flag, a Fast AGC (Automatic Gain Control), etc., are built in the front end of the system. These building blocks are expensive and suffer from limited performance in terms of probability of detection versus false alarms. They also require expensive calibration. Moreover, most communication receivers, for example Burst Mode optical receivers (optical receivers that are intended for burst operation) or Burst Mode CDRs require a reset signal to start a proper receiving operation. This reset is possible only after the Ranging process since the packet arrival time must be known to the receiver. Furthermore, in a noisy environment, the false alarm rate increases, which sometimes makes Ranging (using such hardware block) impossible.
Accordingly, there is a need for, and it would be advantageous to have a robust Ranging method, which requires no additional hardware for its implementation (except for the ability to receive data), and which can always guarantee successful Ranging.
SUMMARY OF THE INVENTION
The present invention discloses a “periodic” Ranging method that enables use of simple and inexpensive AFE and CDR components. Its special inventive aspect of “periodicity” is explained in detail below. In particular, a receiver periodically supplies control signals to both the AFE and the CDR, although the arrival time of a new packet is not known to the receiver. The logic unit (MAC) receives a sequence of bits from the CDR (which can be meaningless if the control signals are not in the right place) and compares it with an expected (i.e. known) Preamble. In case such a Preamble is not detected within the first timeout, the search process repeats (AFE and CDR activation, looking for the Preamble). If the Preamble is detected, the receiver searches for a delimiter. If the Delimiter is detected within the second timeout, the Ranging process is done. If not, the receiver starts looking for the Preamble again, etc. This periodic or “cyclic” process continues until both the Preamble and the Delimiter are detected or until a global timeout (preferably different than the first two) is exceeded. After the Delimiter is detected, the arrival time of the packet is known and propagation delay estimation can be performed.
According to the present invention there is provided a ranging method comprising the steps of: after start of a ranging window, periodically comparing received data with expected data to find a match therebetween; in case of a match failure, restarting the comparison within the same ranging window until a match is found; and if a match is found, moving to a steady state operation regime.
In some embodiments, the step of periodically comparing received data with expected data includes searching an incoming data stream for a known packet preamble until the preamble is found or until a first timeout is exceeded, whereby the exceeding of the first timeout represents a first match failure.
In some embodiments, the step of periodically comparing received data with expected data includes searching an incoming data stream for a known packet delimiter until the delimiter is found or until a second timeout is exceeded, whereby the exceeding of the second timeout represents a second match failure.
In some embodiments, if the preamble is found, the step of periodically comparing received data with expected data further includes searching the incoming data stream for a known packet delimiter until the delimiter is found or until a second timeout is exceeded, whereby the exceeding of the second timeout represents a second match failure.
In some embodiments, the step of periodically comparing ends in a match failure and the step of restarting includes restarting the comparing until a global timeout is exceeded.
In some embodiments, the step of restarting includes activating an analog front end unit of the receiver.
In some embodiments, the global timeout equals a ranging window.
According to the present invention there is provided a ranging method comprising the steps of: after start of a ranging window, searching for a ranging packet section until the ranging packet section is found or until a respective timeout is exceeded; if the packet section is not found or if the respective timeout is exceeded, checking if a global timeout TO 3 is exceeded and if not; repeating the steps of searching and checking within the same ranging window until global timeout TO 3 is exceeded.
In some embodiments, the method further comprises the step of: if the packet section is found in the step of searching, moving to a steady state operation regime.
According to the present invention there is provided a ranging method comprising the steps of: starting a ranging window, and, within the same ranging window, performing an iterative search and comparison process on incoming packet data, the iterative process involving a ranging packet, until at least one ranging packet section is matched with at least one received packet data section or until a global timeout TO 3 is exceeded.
In some embodiments, the step of performing an iterative search and comparison process includes using a respective timeout at an intermediate stage of the ranging window if a match is not found between the at least one ranging packet section and at least one received packet data section in that intermediate stage.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:
FIG. 1A shows schematically a typical, known, point to multi-point communication system;
FIG. 1B shows data packets arriving in order at the receiver of FIG. 1A ;
FIG. 2 shows schematically a typical, known, passive optical network (PON) communication system;
FIG. 3 shows a typical receiver unit used in a system as that of FIG. 1 ;
FIG. 4 shows a typical situation when a Ranging window is allocated for a new user to join the network;
FIG. 5 shows a commonly known packet structure;
FIG. 6 shows a typical existing Ranging method;
FIG. 7 shows a flow chart of a preferred embodiment of the Ranging method of the present invention;
FIG. 8 shows an exemplary propagation delay determination process following the method of FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
The present invention discloses a robust, periodic Ranging method, which requires no additional hardware for its implementation (except for the ability to receive data), and which can always guarantee successful Ranging. A preferred embodiment of the Ranging method of the present invention is described with reference to the flow chart shown. Each new user who wants to join the network transmits a Ranging packet (in the ranging window), which consists of a Header and a Payload (described in FIG. 5 ). After the start of a ranging window in step 702 , the MAC optionally activates the AFE (i.e. sends the required control signals Reset AFE 310 and Reset CDR 316 to) in step 704 , and optionally searches for a Preamble (step 706 ) of the Ranging packet. The “optional” term means that AFE activation may not be needed for some types of AFEs, or that the search for a Preamble is skipped. If no Preamble is found in a check step 708 or if a first timeout period TO 1 is exceeded, the AFE checks if a “global” timeout TO 3 is exceeded in step 709 , and if NO, the process returns to step 704 . If YES in step 709 , the Ranging process is stopped (being unsuccessful). If a Preamble sequence is found in step 708 , the AFE starts looking for a Delimiter of the Ranging packet in step 710 . Ranging packet data (such as the abovementioned Preamble and Delimiter) is also referred to herein as “expected data”. If no Delimiter is found in a check step 712 or if a second timeout period TO 2 is exceeded, the AFE checks if TO 3 is exceeded in step 713 , and if NO, the process returns to step 704 . If YES in step 713 , the Ranging process is also stopped (being unsuccessful). If a Delimiter is detected in step 712 , the MAC receives the data, registers the user and estimates the user's propagation delay (to the receiver). In both cases of failure (YES) in steps 709 and 713 , the ranging process needs to be restarted from step 702 in the next ranging window.
In an exemplary case, the Ranging packet is set as follows.
Guard time: 32 bits.
Preamble: 600 bits.
Delimiter: 20 bits.
TO 1 : 200 bits
TO 2 : 250 bits
TO 3 : Equal to the size of the ranging window.
FIG. 8 shows schematically an exemplary Ranging process. Since the arrival time of the Ranging packet is not known to the receiver, the receiver starts operating according to the Ranging method disclosed herein. First, it activates its AFE and start searching for a Preamble. In the figure, the Ranging packet of the single new user is shown as not having been found (not arrived) in a period up to TO 1 . Therefore, after TO 1 , the process is repeated for a second time, in which the Ranging packet is still not found. Therefore, after another TO 1 , the process is repeated for a third time. In this third “round” (still in the same ranging window) a Preamble of the ranging packet is found, so the receiver looks for a Delimiter. The Delimiter which follows the Preamble is found, so the ranging process ends successfully: the receiver can correctly receive the data, the user can register to the network and the propagation delay can be estimated.
The process described above and clearly illustrated in FIGS. 7 and 8 is “iterative”, in a cyclical or “repetitive” sense. In contrast with prior art processes, which start once per ranging window, the process here repeats itself in a ranging window if a match between expected data and received data is not found. The iterative (repetitive) process in a ranging window ends only if the match is found or if predetermined timeouts are exceeded.
After the process described in FIG. 8 is done, the propagation delay determination can follow (i.e. the receiver or the user can calculate the difference between the sending time at the user and the arrival time). After this point, the Ranging process is done and both the receiver and the user are now in a Steady State mode or regime of operation. In steady state operation (after the propagation delay is known to the system), the arrival time of each packet is known to the system. For this reason the logic unit can supply control signals (i.e. Reset AFE 310 and Reset CDR 316 ) to both the AFE and to the CDR exactly when required (usually at the beginning of data packet). Note that these control signals can not be supplied with exact timing when in Ranging mode, because of the unknown propagation delay.
In summary, the method described herein enables to range and find the propagation delay with almost any existing system and AFE. No dedicated expensive hardware is required for the Ranging. The main idea is periodic trial and error. The receiver activates its AFE and CDR and searches for a special sequence (a Preamble and Delimiter). If it does not find such a sequence, the process (AFE activation and search) periodically start from the beginning. This process ends when finding the delimiter or after TO 3 (unsuccessful). The method, by tuning certain parameters, can meet the requirement of almost any known AFE. It also proved itself as a very robust method in a noisy environment.
The disclosed ranging method requires cheaper and easier to implement AFE and CDR components. It is also more robust in case of noisy channels, when a high BER (Bit Error Rate) is expected.
All patents mentioned in this specification are incorporated herein in their entirety by reference into the specification, to the same extent as if each individual patent was specifically and individually indicated to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention.
While the invention has been described with respect to a limited number of embodiments, it will be appreciated that many variations, modifications and other applications of the invention may be made. In particular, the Ranging process disclosed herein may work without step 704 (activate AFE) in cases where the AFE does not require activation (as there are different kinds of AFE). It may also work without step 706 , directly searching for a Delimiter.
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In a communication system in which data is transferred by packets, a ranging method in which a receiver, in a given ranging window, periodically compares received data with expected data to find a match. The periodic comparison includes searching for known preamble and/or delimiter sequences of ranging packets and involves timeouts for each search period. In case a match between the known sequences and received sequences is not found and the respective timeout is exceeded, the search and comparison process is restarted and continues until a global timeout is exceeded.
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CROSS-REFERENCES TO RELATED APPLICATIONS
The present application claims the benefit under 35 USC 119(e) of U.S. Provisional Application No. 60/983,811, filed Oct. 30, 2007 and entitled “Contact Probe for the Delivery of Laser Energy”, the full disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention is directed generally to medical devices, systems, and methods, particularly for treatment of an eye. In particular, embodiments of the present invention are directed toward contact probes for the delivery of laser energy, and more particularly to contact probes that are used for lowering the intraocular pressure (IOP) in human eyes afflicted with glaucoma. Even more specifically, the present invention is directed toward laser therapy for lowering IOP in glaucomatous eyes via transconjunctival/transcleral ab-externo treatment with infrared laser energy directed to pigmented intraocular cells of the pars plana and/or the posterior portion of the pars plicata.
Glaucoma is a leading cause of blindness. Glaucoma involves the loss of retinal ganglion cells in a characteristic pattern of optic neuropathy. Untreated glaucoma can lead to permanent damage of the optic nerve and resultant visual field loss, which can progress to blindness. The loss of visual field due to glaucoma often occurs gradually over a long time and may only be recognized when the loss is already quite advanced. Once lost, this damaged visual field can never be recovered.
Raised intraocular pressure (IOP) is a significant risk factor for developing glaucoma. IOP is a function of production of aqueous humor by the ciliary body of the eye and its drainage through the trabecular meshwork and all other outflow pathways including the uveoscleral pathway. Aqueous humor is a complex mixture of electrolytes, organics solutes, and other proteins that supply nutrients to the non-vascularized tissues of the anterior chamber of the eye. It flows from the ciliary bodies into the posterior chamber, bounded posteriorly by the lens and the ciliary zonule and bounded anteriorly by the iris. Aqueous humor then flows through the pupil of the iris into the anterior chamber, bounded posteriorly by the iris and anteriorly by the cornea. In the conventional aqueous humor outflow path, the trabecular meshwork drains aqueous humor from the anterior chamber via Schlemm's canal into scleral plexuses and the general blood circulation. In open angle glaucoma there is reduced flow through the trabecular meshwork. In angle closure glaucoma, the iris is pushed forward against the trabeular meshwork, blocking fluid from escaping.
Uveoscleral outflow is a non-conventional pathway that is assuming a growing importance in the management of glaucoma. In uveoscleral outflow, aqueous humor enters the ciliary muscles from the anterior chamber and exits through the supraciliary space and across the anterior or posterior sclera. Uveoscleral outflow may contribute significantly to total aqueous humor outflow.
Currently, glaucoma therapies aim to reduce IOP by either limiting the production of aqueous humor or by increasing the outflow of aqueous humor. Medications such as beta-blockers, carbonic anhydrase inhibitors, etc., are used as the primary treatment to reduce the production of aqueous humor. Medications may also be used as the primary therapy to increase the outflow of the aqueous humor. Miotic and cholinergic drugs increase the trabecular outflow, while prostaglandin drugs, for example, Latanoprost and Bimatoprost, increase the uveoscleral outflow. These drugs, however, are expensive and have undesirable side effects, which can cause compliance-dependent problems over time.
Surgery may also be used to increase the outflow or to lower the production of aqueous humor. Laser trabeculoplasty is the application of a laser beam over areas of the trabecular meshwork to increase the outflow. Cyclocryotherapy and laser cyclophotocoagulation are surgical interventions over the ciliary processes to lower the production of aqueous humor. Although they may be effective, these destructive surgical interventions are normally used as a last resource in the management of glaucoma due to the risk of the severe complication of phthisis bulbi. Other adverse side affects of cyclodestructive surgical procedures may include ocular hypotony and inflammation of the anterior eye segment, which may be associated with an increased incidence of macula complications. Still other adverse side affects include transient hyphaema and exudates in the anterior chamber, uveitis, visual loss, and necrotizing scleritis.
In laser transscleral cyclophotocoagulation, a continuous wave (CW) of high intensity infrared laser energy is directed toward selected portions of the pars plicata region of the ciliary body, structures under the scleral layers and the overlying conjunctiva. Selected portions of the ciliary body and related processes are permanently destroyed, thereby decreasing the overall production of aqueous humor. Laser energy may be directed through air to a patient seated at a special slit lamp. Alternatively, laser energy may be delivered through the use of fiber optic handpieces placed in contact with the patient's eyeball. In both laser energy delivery methods, however, accurately and repeatedly directing a laser beam a subsurface non-visible target such as the ciliary body can be challenging for a surgeon. Thus, contact handpiece probes (for example, the G-Probe available through IRIDEX Corporation of Mountain View, Calif. and described in U.S. Pat. No. 5,372,595, the full disclosure of which is incorporated herein by reference in its entirety) have been designed to facilitate the aiming of a laser toward the pars plicata region of the ciliary body. The G-Probe, for example, has special contours that facilitate consistent placement and aiming of the probe relative to external landmark structures of the eye, thereby guiding the correct treatment and decreasing the likelihood of incidental laser exposure to unintended structures. However, the risk of phthisis bulbi due to the permanent destruction of portions of the ciliary body still remains unavoided.
In light of the above, there is a need for laser-based methods and devices for the treatment of glaucomatous eyes which avoid many of the shortcomings described above.
BRIEF SUMMARY OF THE INVENTION
Embodiments of the present invention provide systems, devices, and methods for treating an eye, in particular examples, a glaucomatous eye. An amount of laser energy is delivered to the pars plana of the eye by a hand-holdable device. This device comprises a hand-holdable elongate member and a contact member disposed on an end of the elongate member. A contact surface of the contact member is placed in direct contact with the eye so that a reference edge of the contact member aligns with an external reference feature of the eye, usually the limbus, and a treatment axis defined by the elongate member may form a predetermined, non-zero angle with the optical axis of the eye. Typically, amounts of laser energy are applied to the eye in an annular pattern positioned significantly posterior to that typically used for cyclodestructive procedures, thus avoiding most or all photocoagulation of the ciliary bodies. The delivered laser energy dose is still sufficient to effect a reduction of intraocular pressure. This reduction may endure for long periods after treatment. Thus, this invention effects a long-term reduction in intraocular pressure while reducing or avoiding permanent destruction of aqueous producing structures in the eye and undesired thermal damage to adjacent tissue structures, both of which are typical of conventional laser cyclophotocoagulation procedures.
Accordingly, an object of the present invention is to provide an improved laser energy delivery handpiece.
Another object of the present invention is to provide a laser energy delivery handpiece with a handpiece axis that is substantially perpendicular to the eye, i.e., substantially normal to the surface of the eye.
Another object of the present invention is to provide a laser energy delivery handpiece that has a contact surface with a single radius of curvature across the contact surface.
Still another object of the present invention is to provide a laser energy delivery handpiece that has a contact surface with substantially no sharp edges.
A further object of the present invention is to provide a laser energy delivery handpiece with a contoured contact surface and a protruding hemispherical laser output tip.
Still a further object of the present invention is to provide a laser energy delivery handpiece
Another object of the present invention is to provide a laser energy delivery handpiece that allows the surgeon to precisely target the intended intraocular structures, such as the pars plana and pars plicata, and avoid misdirected applications by positioning it over the sclera in reference to a stable external anatomical landmark such as the limbus.
A further object of the present invention is to provide a laser energy delivery handpiece that helps a surgeon to keep the direction of the laser beam precisely pointed toward the internal intraocular, invisible target.
Yet another object of the present invention is to provide a laser energy delivery handpiece that allows delivery of treatment either with a series of individual precisely-spaced applications and/or with continuously sliding 180° or 360° arc motions
Still another object of the present invention is to provide a laser energy delivery handpiece that allows the surgeon to keep a consistent scleral indentation in order to maximize the transmission of the laser energy through the conjunctiva-sclera layers, and to minimize the variations of the divergence of the laser beam reaching the targeted ciliary body structures, from the posterior pars plicata through the pars plana.
These and other objects of the invention are achieved in a laser energy delivery handpiece characterized by an axis and adapted to receive a fiber optic for laser surgery on a patient's eye. The eye has a shaped sclera, a limbus and an optic axis. Portions define a contact surface that conforms to the shape of the sclera at the limbus when the axis of the handpiece forms a predetermined angle relative to the external surface of the eye. The contact surface conforms to the shape of the sclera at the limbus when the axis of the handpiece is substantially perpendicular to the eye.
In another embodiment of the present invention, a laser energy delivery handpiece receives a fiber optic for laser surgery on an eye and has an input end, an output end, a top, a bottom and sides. The fiber optic has an optic axis. The eye has a shaped sclera, limbus, and an optic axis. The handpiece includes a body for holding the fiber optic and a contoured end portion. The contoured end portion has an end surface with an opening for the fiber optic. The end surface conforms to the shape of the sclera at the limbus when the optic axis of the fiber optic is substantially perpendicular to the eye.
An aspect of the invention provides a laser treatment method for an eye, the eye having a pars plana posterior to a pars plicata and a pre-laser treatment intraocular pressure. An amount of pulsed laser energy is delivered to the pars plana of the eye. The amount is insufficient to effect therapeutic photocoagulation and is sufficient to maintain a reduction from the pre-laser treatment intraocular pressure. Typically, the amount is sufficient to maintain the reduction from the pre-laser treatment intraocular pressure more than 5 months after the pulsed laser energy is delivered. The amount may be sufficient to increase uveoscleral outflow. The amount of energy will typically be delivered without direct posterior eye pain alleviating agent delivery, and without excessive pain.
Generally, a laser delivery tip of a probe is positioned in contact with an outer surface of the eye and the amount of pulsed laser energy is delivered from the positioned probe so that the pulsed laser energy is oriented toward a first pars plana region and such that permanent thermal damage to the pars plicata is avoided. The eye has an optical axis, and the probe will typically be oriented so that the pulsed laser energy is angularly offset from the optical axis when the tip of the probe is positioned in contact with the surface of the eye. The probe may define a treatment axis along which the pulsed laser energy is delivered, and the probe will typically be positioned so that the treatment axis is generally perpendicular with the surface of the eye when the tip of the probe is positioned in contact with the surface of the eye.
To position the tip of the probe in contact with the surface of the eye, a reference structure of a contact surface of the probe may be positioned in alignment with a reference feature of the eye. The laser delivery tip will be disposed along the contact surface so that the pulsed laser energy is delivered posteriorly to a limbus of the eye by over 2 mm. The first pars plana region to where the pulsed laser energy is delivered may be posterior to the limbus by over 3 mm. The reference feature of the eye will typically comprise the limbus, and the reference structure of the contact surface will typically comprise an edge separated from the laser delivery tip by over 2 mm. The edge extends between opposed lateral placement sides of the contact surface. The pulsed laser energy is delivered to the first pars plana region while the probe is held at a fixed position against the eye. The probe may be incrementally moved laterally, with reference to the sides of the contact surface, around the limbus so as to sequentially treat a plurality of circumferentially offset regions of the pars plana. The offset regions define angular widths about the ocular axis of from 5 to 20 degrees. The pulsed laser energy may be delivered to the first pars plana region for at least about 1 second.
The pulsed laser energy will generally comprise pulsed infrared laser energy, for example, laser energy having a wavelength of 810 nm. The total laser energy directed to the pars plana will generally be less than 75 J. In some embodiments, the pulsed laser energy may be delivered from a plurality of fixed probe locations. Each pulse will typically have an energy of less than 1 mJ, and total laser energy directed to the pars plana may be less than 40 J. The pulsed laser energy will typically have a duty cycle of about 50% or less, or even a duty cycle of about 20% or less.
In many embodiments, a first portion of the pulsed laser energy is directed to a first arc about the optical axis of the eye. The first arc will typically be disposed on a superior region of the eye. A second portion of the pulsed laser beam may be directed toward a second arc about the optical axis of the eye, the second arc being spaced away from the first arc and disposed along an inferior region of the eye.
In some cases, the tip of the probe may be positioned in contact with the surface of the eye by sliding the tip of the probe in alignment with the pars plana during delivery of the pulsed laser energy.
Another aspect of the invention provides a method of reducing excessive intraocular pressure in an eye. A pulsed laser beam is transmitted to an annular pattern of tissue regions of an eye by the following steps. A tip of a probe is positioned in contact with the surface of the eye in a position at least 3 mm posterior of the limbus. The pulsed laser beam is directed from the positioned tip of the probe from the position toward an associated tissue region of the eye such that associated tissue region is treated and the coagulation within the eye is inhibited. The tip of the probe is re-positioned in contact with the surface of the eye in another position disposed at least 3 mm posterior of the limbus and circumferentially offset from the treated region about an optical axis of the eye and the pulsed laser beam is again directed from the probe to an associated tissue region until the circumferential series of tissue regions have been treated. The pulsed laser beam is delivered while the probe is maintained at each of the positions toward the associated tissue regions of the eye such that an aggregate amount of the pulsed laser beam delivered to the tissue regions alleviates the excessive intraocular pressure more than five months after the tissue regions have been treated.
Another aspect of the invention provides a method for treating an eye by reducing intraocular pressure. A tip of a probe is positioned in contact with the surface of the eye so that the tip of the probe is posterior the limbus of the eye by a desired distance. The tip of the probe is moved across the surface of the eye while the tip of the probe is maintained at the desired distance posterior the limbus of the eye. Pulsed laser energy is delivered toward a region of the eye posterior to the limbus while the tip of the probe is slid across the eye and maintained in contact with the surface of the eye.
Another aspect of the invention provides a hand-holdable device for delivering optical energy to treat an eye. The device comprises a hand-holdable elongate member and a contact member disposed on an end of the elongate member. The hand-holdable elongate member defines a treatment axis and is adapted to receive an optical fiber for delivering optical energy along the treatment axis. The contact member comprises a reference element and defines a contact surface. The contact surface is placed in direct contact with the eye and the reference element is aligned with a reference feature of the eye. The contact surface conforms with a region of the surface of the eye and the treatment axis forms a predetermined, non-zero angle with the optical axis of the eye.
The contact surface can be placed in direct contact with the eye and the reference element can be aligned with a reference feature of the eye such that the treatment axis is perpendicular to the surface of the eye.
The contact surface will typically conform to the shape of the sclera of the eye at the limbus of the eye when the contact surface is placed in direct contact with the eye and the reference element is aligned with the reference feature of the eye.
The device may further comprise an optical energy source coupled to the elongate member. The delivered optical energy may comprise light energy from one or more light emitting diodes of the optical energy source. Typically, the delivered optical energy may comprise light energy from one or more lasers of the optical energy source. The delivered optical energy may be pulsed and have a duty cycle of about 50% or less or even about 20% or less.
The hand-holdable device will typically be adapted to deliver optical energy to a region of the eye posterior to the limbus when the contact surface is placed in direct contact with the eye and the reference element is aligned with a reference feature of the eye. The region of the eye posterior to the limbus may be selected from the group consisting of the pars plana of the eye, the pars plana—pars plicata junction of the eye, and the posterior portion of the pars plicata of the eye.
The contact surface of the contact member may define a protruding optical energy delivery tip disposed along the treatment axis.
Typically, the reference feature comprises a reference edge shaped to conform with the limbus of the eye.
An optical energy output aperture may be spaced away from the reference edge by at least about 3 mm to facilitate optical irradiation over at least one of the pars plana of the eye, the pars plana-pars plicata junction, and the posterior portion of the pars plicata of the eye.
In many embodiments, the contact surface may comprise a first side relief and a second side relief opposite the first side relief. The first side relief and the second side relief are adjacent the reference element of the contact surface with a width of the contact surface therebetween. The width of the contact surface is sized to contact a treatment region of the eye along a plurality of circumferentially adjacent treatment regions forming an arc centered about the optical axis of the eye. The circumferentially adjacent treatment regions spaced apart from each other by from 5° degrees to 30° degrees, for example, by about 10° degrees.
Another aspect of the invention provides a device for delivering optical energy to treat an eye, the eye having a pars plana. The device comprises a handpiece, a contact member, and a laser tip. A contact member is disposed on an end of the handpiece. The contact member comprises a target tissue reference element and a treatment site spacing reference element and defines a contact surface. The laser delivery tip is adapted to couple with an optical energy source. The laser delivery tip is positioned relative to the target tissue reference element such that when the contact surface is placed in direct contact with an outer surface of the eye with the target tissue reference element aligned with a reference feature of the eye and optical energy is delivered from the laser delivery tip, the optical energy is directed toward the pars plana at an associated treatment site. The laser delivery tip is positioned relative to the treatment site spacing reference element such that a circumferential series of treatment sites are defined when the contact surface is repeatedly placed in direct contact with an outer surface of the eye with the target tissue reference element aligned with a reference feature of the eye and the treatment site spacing reference element aligned with a feature of a prior treatment and delivering an amount of pulsed laser energy to the pars plana of the eye at an associated treatment site. Delivery of an amount of pulsed laser energy from the circumferential series of treatment sites to the pars plana that is insufficient to effect therapeutic photocoagulation can be sufficient to maintain a reduction from the pre-laser treatment intraocular pressure, for example, by increasing uveoscleral outflow.
In another aspect of the invention, a handpiece which is adapted to direct and deliver optical energy in a predetermined direction and is suitable for delivery of optical energy to a patient's eye is provided. The predetermined direction is defined as the optical axis of the handpiece. The eye has a shaped sclera, a cornea, a limbus, and an optical axis. The handpiece incorporates pieces, portions or features that aid in the repeatable application of the handpiece with respect to certain features of the patient's eye. These reference features may be either permanent or temporary. They are provided with respect to treatment angle or direction of the optical output axis, with the treatment axis essentially not parallel to the optical axis of the patient's eye. They may be provided with one or more of the following parameters: locational position, indentation pressure, or depth spacing between discrete treatment sites.
In many embodiments, the method of delivery of optical energy from its source to its treatment target includes one or more optical fibers.
In many embodiments, the source of optical energy delivered is intended to be one or more lasers.
In many embodiments, the source of optical energy delivered is intended to be one or more light emitting diodes (LEDs).
In many embodiments, the treatment angle/direction is essentially normal, i.e., perpendicular, to the reference surface. The reference surface may be, for example, the sclera or the cornea.
In many embodiments, the feature facilitating placement with respect to a reference surface is one or more curves or facets approximating a portion of a sphere. The feature facilitating placement with respect to a reference surface may be one or more curves or facets approximating a portion of a concave sphere.
In many embodiments, the locational reference is at least partly derived from the limbus, i.e., the ocular region of intersection and transition between the corneal and scleral curves.
In many embodiments, the specific dimensional reference from the limbus is 0 to 4 mm, and may be in a direction anterior or posterior to the limbus.
In many embodiments, the reference for indentation depth or pressure is at least partly derived from the scleral surface.
In many embodiments, the indentation depth measured from the reference surface in its natural position is between 0 and 1.5 mm.
In many embodiments, the reference for indentation depth or pressure is at least partly derived from the corneal surface.
In many embodiments, the reference for spacing between adjacent treatment sites is at least partly derived from one or more previous treatment sites. The spacing between adjacent treatment sites may be such so as to permit 1 to 6 application sites per clock-hour, i.e., 5 to 30 degree angular spacing, or 12 to 72 sites per full treatment circumference.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 , 2 and 4 illustrate various embodiments of a contact probe of the present invention;
FIG. 3 illustrates elements of the eye in relation to a contact probe of the present invention;
FIG. 5 shows a cross section of a contact probe according to embodiments of the present invention;
FIG. 5A shows a front view of a contact probe according to embodiments of the present invention;
FIG. 6A-6E shows a method of treating the eye using a contact probe according to embodiments of the present invention; and
FIG. 7 shows a chart of exemplary experimental results of a conducted study using devices and methods according to embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In embodiments of the present invention, a laser energy delivery handpiece 100 is provided that is specifically designed for the efficient transconjunctival/transscleral delivery of laser energy, for example, infrared laser energy from a pulsed 810 nm diode laser, over the posterior region of the pars plicata, over the pars plana-pars plicata junction, and/or over the pars plana. Optical energy from other sources, for example, light emitting diodes (LEDs), may be delivered as well.
A footprint contact surface 110 of the handpiece 100 is designed so that a fiber optic 120 coupled to the handpiece 100 has a protruding hemispherical tip 125 that is about 3 mm posterior to the limbus at any 360° location, when in normal contact with the conjunctiva/sclera and with the small radius next to the limbus, in particular, the outer edge of the limbus.
The footprint contact surface 110 is designed to ensure a radial orientation of the laser beam so that the laser energy is always directed substantially perpendicular to the conjunctiva/sclera point of indentation.
In various embodiments, the laser beam output tip 125 protrudes from 0.25 mm to 1.0 mm, preferably 0.75 mm, beyond the contact surface.
The indentation of the laser beam output tip 125 maximizes the transmission of infrared laser energy through the conjunctiva and sclera and provides the beam divergence to irradiate all ciliary body structures from the anterior (pars plicata) through the posterior (pars plana) portions of the ciliary body.
The footprint contact surface 110 is designed to allow the surgeon to administer the treatment either with a continuously 360° sliding motion over the conjunctiva overlying the pars plana or, with a series of individual applications with precisely defined angular spacing or radial displacements.
The footprint contact surface 110 can provide a radial displacement of 5° or 10° or 20°, and the like for a treatment density over a 360° radial area at the treatment site with, 72 or 36 or 18 applications respectively. In some embodiments, a lateral edge 160 to an indentation mark of the laser beam output tip 125 spaces each application by 10° over the sclera and allows 36 individual applications in the 360° radial treatment area.
In some embodiments, the footprint contact surface 110 slides around the treatment area while the laser continuously delivers laser energy as opposed to individual spaced applications described in the previous embodiment.
The continuously emitted laser energy that is delivered while the footprint contact surface slides over the sclera can be seen as a paint delivered with a sliding brush.
Both modalities of the prior paragraph are intended to treat the intraocular structures defined by the surgeon. When applied ab-externo with continuously sliding motion, for example in two steady strokes, with an upper 180° in one move and the lower 180° in another move, a low power pulsed laser emission is “painted” over the intended structures, for example, the ciliary body. This provides an irradiation for all pigmented cells in a movement analogous to a paintbrush of photothermal energy sweeping over the eyeball with the power and sweeping time determined by the surgeon.
FIG. 1 illustrates a laser energy delivery handpiece 100 according to embodiments of the present invention. Laser energy delivery handpiece 100 comprises an elongate body 101 and an end portion 130 disposed on one end of the elongate body 101 . Laser energy delivery hand piece 100 defines a treatment axis 105 and is adapted to receive a fiber optic 120 for laser surgery on a patient's eye E. The eye E has a shaped sclera, a limbus and an optical axis 200 . End portion 130 of the laser energy delivery handpiece 100 define a contact surface 110 that conforms to the shape of the sclera at the limbus when the axis 105 of the handpiece forms a predetermined angle 600 relative to the optical axis 200 of the eye E. The contact surface 110 conforms to the shape of the sclera at the limbus when the axis of the handpiece 100 is substantially perpendicular to the conjunctiva-sclera point of indentation of the eye E.
The contact surface 110 may have a single radius of curvature across the contact surface 110 and no sharp edges.
In some embodiments of the present invention, the laser energy delivery handpiece 100 has an input end, an output end, a top, a bottom and sides. Elongate body 101 holds the fiber optic 120 and end portion 130 is contoured.
In some embodiments, the footprint of the contact surface 110 shows the position of a protruding hemispherical laser beam output tip 125 , or other non-blunt geometry, with respect to a limbal placement edge 115 , e.g., the short side of the contact surface 110 . Limbal placement edge 115 has a contact surface contour that conforms to the limbus and is generally circularly concave with a radius of about 5.25-6.0 mm. The laser beam output tip 125 is, in many embodiments, at 3.0 mm distance from the limbal placement edge 115 to facilitate the optimal irradiation over the eye's pars plana—pars plicata junction and/or over the eye's pars plana, from the limbus 20 points to the anterior portion of the pars plana in the normal anatomy of the human eye as illustrated in FIG. 3 .
The two lateral placement contoured edges 160 , e.g., the longer sides of the footprint, indicate a 5°-20°, and more particularly a 10° radial displacement from the laser beam output tip 125 . The edges 160 may comprise side reliefs, one on each edge, extending from contact surface 110 . Also, the edges 160 may each define lines which intersect at the center of curvature of limbal placement edge 115 .
FIG. 2 shows the laser energy delivery handpiece 100 positioned against the eye E with the short limbal placement edge 115 next to the limbus and directing the laser energy radially to the eyeball center over the pars plana-pars plicata junction, generally indicated by the axis 105 . Alternatively, the distance between short limbal placement edge 115 and tip 125 will be such that the laser energy is directed to the eyeball center over the pars-plana or any structure posterior the limbus.
FIG. 3 shows the surgical eye anatomy relevant to the handpiece. This laser therapy may target intraocular structures that span from the posterior pars plicata to the pars plana. Alternatively, the pars plana may be targeted and the pars plicata, ciliary body, and other ciliary processes avoided. The short limbal placement edge 115 is always kept next to the external limbus line (CLJ cornea-limbus junction). In this way, protrusion of the laser output tip 125 , which is about 3 mm posterior the limbus, directs a diverging beam that irradiates a large portion of the posterior pars plicata and anterior pars plana. Alternatively, the laser output tip 125 may be spaced away from the short limbal placement edge 115 such that laser output tip 125 directs a diverging beam that irradiates the pars plana while avoiding the posterior pars plicata.
FIG. 5 shows a cross section of laser energy delivery handpiece 100 . Laser energy delivery handpiece 100 comprises elongate body 101 and end portion 130 . Handpiece 100 defines treatment axis 105 and houses fiber optic 120 so that fiber optic 120 directs optical energy along treatment axis 105 . End portion 130 comprises a contoured surface 110 having a radius of curvature shaped to conform with the shape of the sclera of the limbus of the eye when surface 110 is placed in contact with the surface of the eye E. As shown in FIG. 5A , contoured surface 110 comprises lateral edges 160 and a limbal placement edge 115 . Laser energy is delivered from protruding tip 125 protruding from contoured surface 110 . Protruding tip 125 is spaced away from limbal reference edge 115 at a predetermined distance, usually about 3 mm, e.g. 3.4 mm, from limbal reference edge 115 . The limbus of the eye E can serve as a reference point for the placement of handpiece 100 . Limbal reference edge 115 is placed adjacent the outward facing edge of the limbus such that opening 125 directs laser energy over the pars plana and/or pars plana-pars plicata junction and treatment axis 105 is parallel to the surface of the eye.
FIGS. 6A-6E show an exemplary method of using laser eye delivery handpiece 100 to delivery laser energy to treat an eye. As shown in FIG. 6A , handpiece 100 is positioned at a first treatment site so that contoured surface 110 is in contact with the sclera of the eye E and limbal reference edge 115 is adjacent the limbus, the region of the eye between the cornea and the sclera. Treatment axis 105 , as defined by handpiece 100 , forms a predetermined angle, for example, a 40° degree angle, with optical axis 200 of the eye E. Tip or opening 125 is spaced posterior the limbus with a distance 505 which may be, for example, about 3 mm. Laser energy is directed through tip or opening 125 to direct laser energy to the pars plana.
In an exemplary embodiment, the directed laser energy comprises pulsed laser energy from an infrared laser that can be operated in pulsed as well as continuous wave emission modes. For example, the pulsed continuous wave infrared laser has about a 30% duty cycle, with an “on” time of about 500 μs and an “off” time of about 1100 μs, about a 15% duty cycle, with an “on” time of about 300 μs and an “off” time of about 1700 μs, or about a 10% duty cycle, with an “on” time of about 200 μs and an “off” time of about 1800 μs. Careful selection of the laser energy pulse “on” and “off” times can avoid undesired thermal damage to a target by allowing the target to cool during the “off” time of the laser before the next pulse of laser energy is delivered during the “on” time. The duty cycle may be selected so that cumulative thermal buildup, caused by insufficient cooling during the “off” time of the laser beam, is avoided. Thus, laser damage can be reduced to a minimum level sufficient to trigger a biological response needed for lowering of intraocular pressure (IOP).
In the exemplary procedure described with reference to FIGS. 6A-6E , a duty cycle of 15% is used. The power of the laser is set at 1500 mW and the pulse “on” time is 300 ms.
As shown in FIG. 6B , laser energy is directed toward a first application site 601 . Afterwards, handpiece 100 is repositioned, for example, by moving handpiece 100 over, to a second treatment region adjacent the first treatment region. Handpiece 100 may be moved by sliding it over to the second treatment region from the first treatment region while maintaining contact surface 110 in contact with the surface of the eye. Or, handpiece 100 may be removed from contact from the surface of the eye at the first position and placed in contact with the eye again at the second position. Edges 160 may have side reliefs which may indent the surface of the eye, with the indentations providing a reference to help reposition handpiece 100 . At the second position, handpiece 100 is again positioned so that limbal reference edge 125 is adjacent the limbus.
As shown in FIG. 6C , laser energy is directed toward a second application site 602 . Thus, first site 601 and second site 602 are equidistant from the optical axis 200 of the eye E. This process of repositioning handpiece 100 and directing laser energy toward the pars plana is repeated for a third spot, a fourth spot, and so forth. For example, as shown in FIG. 6D , laser energy is directed toward a first treatment site at 320° on a right eye, then toward a second treatment site at 330°, and then successively clockwise every 10° until a site at 90°, e.g., toward sites at 340°, 350°, 360°, 10°, 20°, 30°, 40°, 50°, 60°, 70°, 80°, and then 90°, thereby creating a first 130° arc of treatment sites on the superior side of the eye E. Thus, a series of individual applications with precisely defined angular spacing or radial displacements are made. A second 130° arc of treatment sites on the inferior side of the eye E may then be created, starting from directing laser energy toward the site at 220° and then toward successively counter-clockwise sites every 10° until a site at 100°.
As shown in FIG. 6E , a similar procedure of directing laser energy toward a plurality of treatment points can be made on the left eye. Laser energy is directed toward a point at 40° and then successively counterclockwise until a point at 270°, creating a first 130° arc of treatment points. Then, laser energy can be directed toward a point at 140° and then successively clockwise every 10° until a point at 260°. In some embodiments, laser energy may be exposed to each point for about 1.0 seconds at a power of 1.5 W. The duty cycle of the laser energy may be 10%, with an “on” time of about 200 μs and an “off” time of about 1800 μs for each pulse of a train of about 500 pulses delivered to each application site with about 1.0 second exposure durations. The eye E may also be treated at more or less treatment points at different areas, for example, the eye E may be treated so that a superior arc and an inferior arc of each of 150° or even 180° can be created. For example, 20 stationary applications over 360° may be made, with 5 stationary applications per quadrant. Treatment points may also be alternatively spaced apart from each other by other angles besides 10°, for example, by providing handpieces with different distances between edges 160 . The pulsed laser systems and methods may comprise a MicroPulse™ Laser System and method.
In other embodiments, handpiece 110 may be slid or “painted” over a targeted region of the eye all the while laser energy is being emitted. For example, tip 115 may first be positioned about 3 mm posterior the limbus at the 10 o'clock or 300° position of the eye and gradually slid clockwise until the 2 o'clock or 60° position, all the while exposing the targeted region of the eye, e.g., the pars plana, with pulsed laser energy. Thus, if the width of surface 110 spans 30°, a superior treatment arc of 150° can be created. A inferior treatment arc of 150° can likewise be created by positioning tip 115 about 3 mm posterior the limbus at the 8 o'clock position or 240° and gradually sliding handpiece 110 until it reaches the 4 o'clock position or 120°, all the while exposing the targeted region of the eye, e.g., the pars plana, with pulsed laser energy. In exemplary embodiments, the duration of laser energy exposure for each treatment arc may be 50 seconds and the power of the laser may be 2 Watts. A total of 31,250 pulses at a rate of 625 pulses per second may be made during the 50 seconds. Each pulse may have an energy of 1.0 mJ. The size of the treatment arcs may vary. The treatment arcs, for example, may comprise a 180° superior arc and a 180° inferior arc.
EXPERIMENTAL SECTION
Experiment A
An initial study using a handpiece with a contact probe similar to those described above was conducted at the National University Hospital in Singapore. In the study, treatment procedures similar to those described above were conducted on a number of glaucomatous eyes. This initial study tracks glaucomatous eyes for about 6 months, the treated eyes being treated with the aforementioned handpiece and a treatment procedure using pulsed laser energy.
Patients with advanced glaucoma refractory to maximum tolerated medical and surgical treatment and a visual acuity of worse than 6/60 were included in the study. Patients with recent eye surgery within 3 months of enrollment, active ocular inflammation or inability to give informed consent were excluded.
The procedure was performed by a single surgeon to patients under local anesthesia. The contact probe was designed for accurate positioning of a fiber optic at 3.4 mm behind the limbus of the eye.
The laser settings were 2000 mW, applied over a total duration of 100 s, with a pulse duration of 0.6 s and a pulse interval of 1.1 s. Shots were applied over 360° avoiding the 3 o'clock and 9 o'clock regions and any areas of thinning.
The main outcome measure was success of treatment, defined as a 30% or more reduction of IOP from baseline or an IOP of less than 21 mm Hg at 6 month follow-up.
23 eyes of 23 patients were treated. The patients had a mean age of 62.9±20.3 years. The mean duration of follow-up was 5.3±1.5 months. The mean pre-treatment IOP was 37.1±9.5 mm Hg.
TABLE 1 below summarizes mean IOP before and after treatment at 1 day, 1 week, 1 month, 3 months, and 6 months post-op. All mean post-treatment IOPs were significantly lower than the pre-treatment IOPs (paired Student's t-test, p<0.001).
TABLE 1
POST-OP IOP MEASUREMENTS
Time Point
Meant IOP (mm Hg)
Mean IOP Reduction (%)
Baseline
37.1 ± 9.5
—
1 day post-op
28.7 ± 10.8
24.0 ± 17.1
1 week post-op
25.6 ± 9.8
30.9 ± 18.7
1 month post-op
22.2 ± 7.0
38.2 ± 19.6
3 months post-op
22.9 ± 8.9
35.4 ± 24.2
6 months post-op
23.7 ± 9.7
37.6 ± 19.4
The rate of success of the treatment was defined as a 30% or more reduction from baseline or a final IOP of less than 21 mm Hg at the 6 th month follow-up visit. The success rate was 38% at 1 day, 57% at 1 week, 76% at 1 month, 80% at 3 months and 69% at 6 months. None of the patients had hypotony or loss in their best corrected visual acuity.
Experiment B
A similar study using a handpiece with a contact probe similar to those described above was conducted also at the National University Hospital in Singapore. In the study, treatment procedures using pulsed laser energy similar to those described above were conducted on a number of glaucomatous eyes. This study tracks the treated eyes for up to 18 months.
The MicroPulse™ procedure was performed by a single surgeon in the outpatient setting. Regional anesthesia with peribulbar or retrobulbar injection of 2% lidocaine was given prior to the procedure. Scleral transillumination was used to identify the position of the ciliary body as well as any areas of thinning A diode laser emitting ball-lens tip contact probe, which is similar to those described above, was applied axially at the limbus. This probe housed a quartz fiberoptic of 600 μm in diameter. Its end protrudes 0.7 mm from the handpiece. The probe was specifically designed to allow positioning of the fiberoptic at 3.4 mm behind the surgical limbus, i.e., the distance from the reference edge of the contact surface of the probe to the fiberoptic was 3.4 mm. The laser settings were 2000 mW, over a total duration of 100 s, with a train of repetitive pulses each with a pulse duration of 0.5 ms and a pulse interval of 1.1 ms. The treatment was applied by “painting” or uniformly sliding the probe over 360°, avoiding the 3 and 9 o'clock meridians and any area of thinned sclera. Total energy delivered to the ciliary body was 60-90 J.
The amount of intraoperative pain experienced by the patient was recorded and additional regional anesthesia was administered as required. Postoperatively, topical prednisolone acetate 1% was prescribed four times daily along with oral mefenamic acid for 5 days. Follow-up examinations were performed at 1 day, 1 week, 1 month, 3 months, 6 months, 12 months, and 18 months. Pain scoring, visual acuity, Goldman applanation tonometry, slit lamp biomicroscopy and dilated fundus examinations were carried out at every visit. Retreatment over 360 degrees was performed between 1 to 3 months if IOP reduction was less than 20%.
Statistical analysis was performed using SPSS software version 15.0. Means were compared using the two-tailed paired Student's t-test, with p<0.05 being considered significant.
46 eyes of 44 patients were evaluated in this study. The mean age of the patients was 63.2±16.0 years. There were 36 men (81.8%). Right eyes of 17 (38.6%) patients, left eyes of 23 (52.3%) patients and both eyes of 2 patients underwent MicroPulse™ treatment with TSCPC. TABLE 2 below shows the distribution of glaucoma diagnoses. Four eyes received retreatment between 1 to 3 months after the initial laser.
TABLE 2
DISTRIBUTION OF GLAUCOMA DIAGNOSES
Type of Glaucoma
No. (%)
Neovascular glaucoma
17 (38.6%)
Primary open angle glaucoma
10 (22.7%)
Primary angle closure glaucoma
10 (22.7%)
Others
7 (16.0%)
TABLE 3 below summarizes mean IOP before and after treatment at 1 day, 1 week, 1 month, 3 months, 6 months, 12 months, and 18 months post-op. All mean post-treatment IOPs were significantly lower than the pre-treatment IOPs (paired Student's t-test, p<0.001). The mean duration of follow-up was 16.2±4.5 months.
TABLE 3
POST-OP IOP MEASUREMENTS
Mean reduction in IOP
Time Point
Mean IO (mm Hg)
from baseline (%)
Baseline
39.1 ± 12.7
—
1
day
31.1 ± 13.5
21.6
1
week
28.1 ± 12.1
28.1
1
month
27.6 ± 12.8
28.4
3
months
27.2 ± 12.8
23.5
6
months
26.0 ± 13.4
27.2
12
months
26.5 ± 12.6
27.3
18
months
26.9 ± 11.8
30.5
As shown in FIG. 7 , the decrease in IOP appears to be gradual and sustained over 6 months. All patients who required systematic acetazolamide (n=6) prior to the treatment were able to discontinue the drug by the first postoperative day. The mean number of topical anti-glaucoma medication was reduced from 1.8±1.1 to 1.4±1.1 at 6 months follow up (p=0.003).
During the procedure, 15 patients (34.0%) reported some pain but found it to be tolerable and did not require additional anesthesia. Two patients (4.0%) required additional regional anesthesia. Post procedure, 7 patients (15.9%) reported mild pain on the first day. None required oral analgesia beyond the first day of treatment. All patients had mild postoperative inflammation at day 1 in the form of 1+ anterior chamber cells with slight conjunctival hyperemia. This inflammation resolved by 2 weeks post treatment in 40 patients (90.9). None of the patients experienced deterioration of their best-corrected visual acuity at final follow-up. One patient who had no light perception before the MicroPulse™ procedure underwent evisceration at 1 month for corneal perforation secondary to infection of a pre-existing bulbous keratopathy. No patient developed hypotony, defined as an IOP of less than 5 mm Hg.
The IOP lowering efficacy of the studied method is comparable to conventional ciliary body photo-coagulation. The rapidity of IOP reduction, seen as early as 1-day post treatment, is an additional advantage over traditional laser treatment. The rapid reduction in IOP seen may be due to enhanced outflow facility from the uveal and suprachoroidal spaces as the novel probe targets the ciliary body epithelium of the pars plicata and/or the pars plana. Low laser pulses allow for repetitive series of sub-threshold intensity pulses of energy to be delivered with rest periods in between. “Painting” may also allow for a more even distribution of treatment and effect compared to conventional laser treatment over stationary application sites. A biological response may be triggered to lower IOP and yet excessive thermal damage to the ciliary epithelium and processes is avoided, as seen in histological specimens after conventional laser treatment. The limitation of adjacent tissue damage seen in the MicroPulse™ procedure may also explain the absence of complications such as hypotony.
It is to be understood that the above description is intended to be illustrative and not restrictive. Many embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.
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Systems, devices, and methods for treating a glaucomatous eye are provided. An amount of pulsed laser energy is delivered to the pars plana of the eye by a hand-holdable device which comprises a hand-holdable elongate member and a contact member disposed on an end of the elongate member. A contact surface of the contact member is placed in direct contact with the eye so that a reference edge of the contact member aligns with the limbus and a treatment axis defined by the elongate member is angularly offset from the optical axis of the eye. The amount of pulsed laser energy delivered is insufficient to effect therapeutic photocoagulation but is sufficient to increase uveoscleral outflow so as to maintain a reduction from pre-laser treatment intraocular pressure. Amounts of pulsed laser energy will be transmitted to a circumferential series of tissue regions of the eye.
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FIELD OF THE INVENTION
[0001] The presently disclosed subject matter relates to processes for the synthesis of the Factor Xa anticoagulant fondaparinux, and related compounds. The subject matter also relates to protected pentasaccharide intermediates and to an efficient and scalable process for the industrial scale production of fondaparinux sodium by conversion of the protected pentasaccharide intermediates via a sequence of deprotection and sulfonation reactions.
BACKGROUND
[0002] Vascular thrombosis is a cardiovascular disease indicated by the partial or total occlusion of a blood vessel by a clot containing blood cells and fibrin. In arteries, it results predominantly from platelet activation and leads to heart attack, angina or stroke, whereas venous thrombosis results in inflammationand pulmonary emboli. The coagulation of blood is the result of a cascade of events employing various enzymes collectively known as activated blood coagulation factors. Heparin, a powerful anticoagulant, has been used since the late 1930's in the treatment of thrombosis. In its original implementation, tolerance problems were noted and so reduced dosage was suggested to reduce bleeding and improve efficacy. In the early 1970's, clinical trials did indeed indicate acceptable tolerance was obtainable whilst still preserving antithrombotic activity. Unfractionated heparin (UFH) is primarily used as an anticoagulant for both therapeutic and surgical indications, and is usually derived from either bovine lung or porcine mucosa. Amongst the modern uses of unfractionated heparin include management of unstable angina, as an adjunct to chemotherapy and anti-inflammatory treatment, and as a modulation agent for growth factors and treatment of hemodynamic disorders. In the late 1980's, the development of low molecular weight heparins (LMWHs) led to improvements in antithrombotic therapy. LMWHs are derived from UFH by such processes as chemical degradation, enzymatic depolymerization and y-radiation cleavage. This class of heparins has recently been used for treatment of trauma related thrombosis. Of particular interest is that the relative effects of LMWHson platelets are minimal compared to heparin, providing an immediate advantage when treating platelet-compromised patients.
[0003] The degree of depolymerization of UFH can be controlled to obtain LMWHs of different lengths. Dosage requirements for the treatment of deep vein thrombosis (DVT) are significantly reduced when employing LMWH as opposed to UFH, although in general the efficacy of both therapeutics seems to be comparable. In addition, LMWH can be effective as an alternative therapeutic for patients who have developed sensitivity to UFH. Unfortunately, there has recently been a great deal of concern in the use of LMWH due to the perceived potential for cross-species viral contamination as a result of the animal source of the parent UFH.
[0004] One way of avoiding the possibility of cross-species contamination, is to prepare heparins by chemical synthesis. This method would also provide the opportunity to develop second generation heparins or heparinoids, which can be tailored to target particular biological events in the blood coagulation cascade. An investigation to determine the critical structural motif required for an important binding event in a coagulation cascade involving heparin, dates back to the 1970's. Some structural features of heparin were defined, but the binding domains of interest remained essentially undefined. Research conducted by Lindahl and co-workers (Lindahl, et al., Proc. Natl. Acad. Sci. USA, 1980, Vol. 77, No. 11, 6551-6555; Reisenfeld, et al., J. Bioi. Chem., 1981, Vol. 256, No. 5, 2389-2394) and separately by Choay and co-workers (Choay, et al., Annals New York Academy of Sciences, 1981, 370, 644-649) eventually led to the determination that a pentasaccharide sequence constituted the critical binding domain for the pro-anticoagulant cofactor antithrombin Ill (AT-Ill). After determination of the critical heparin sugar sequence, complete chemical syntheses were embarked upon to further prove the theories. Complete syntheses of the pentasaccharide binding domain were completed at similar times by Sinay and co-workers and by Van Boeckel and co-workers (Sinay, et al., Carbohydrate Research, 132, (1984), (C5-C9). Significant difficulties were encountered during both these reported syntheses. The synthesis by Van Boeckel and co-workers provided a method on a reasonable scale (156 mg of final product) and with improved yields compared to the Sinay synthesis, but still only provided an overall yield of 0.22%, (compared with 0.053% for the Sinay synthesis).
[0005] Fondaparinux sodium, or methyl O-2-deoxy-6-O-sulfo-2-(sulfoamino)-α-D-glucopyranosyl-(1→4)-O-β-D-glucopyranuronosyl-(1→4)-O-2-deoxy-3,6-di-O-sulfo-2-(sulfoamino)-α-D-glucopyranosyl-(1→4)-O-2-O-sulfo-α-L-idopyranuronosyl-(1→4)-2-deoxy-6-O-sulfo-2-(sulfoamino)-α-D-glucopyranoside, decasodium salt, has the following structural formula:
[0000]
[0006] Fondaparinux sodium is a chemically synthesized methoxy derivative of the natural pentasaccharide sequence, which is the active site of heparin that mediates the interaction with antithrombin (Casu et al., J. Biochem., 197, 59, 1981). It has a challenging pattern of O- and N-sulfates, specific glycosidic stereochemistry, and repeating units of glucosamine and monic acids (Petitou et al., Progress in the Chemistry of Organic Natural Product, 60, 144-209, 1992). It is obtained according to the process described in EP 084,999 and U.S. Pat. No. 4,818,816.
[0007] Fondaparinux sodium is derived from a chemical synthesis having more than 50 steps. This process makes it possible to obtain crude fondaparinux sodium, which is a mixture consisting of fondaparinux sodium and other related oligosaccharides. The fondaparinux sodium content of this mixture, evaluated by anion exchange high performance liquid chromatography (HPLC), is approximately 70%. Several steps of purification by column chromatography and by precipitation are necessary in order to obtain fondaparinux sodium having better purity, however, even with these several purification steps the purity still does not exceed 96.0%. Furthermore, the large number of steps required for synthesis, involving the aforementioned column chromatography purification and long reaction times, makes it very difficult to standardize industrial batches.
[0008] Given the complexity of the structure of fondaparinux sodium and its synthesis intermediates, many impurities can form in the course of the synthesis. In addition, the slightest variation in the operating conditions results in batches of crude fondaparinux sodium being obtained which contain related but undesirable products in considerable amounts. These related products, which do not have anti-Xa activity or which have very slight activity, have a chemical structure and physicochemical characteristics which are very similar to fondaparinux sodium, and cannot be eliminated satisfactorily by the purification methods indicated above. Moreover, it has been observed that some of these products are readily degradable when they are subjected to sterilization by methods such as autoclaving, and thus produce additional impurities.
[0009] Fondaparinux sodium, the active principle in a pharmaceutical specialty product, must satisfy certain quality criteria and standards and must in particular be as highly pure as possible. As a result, industrial batches which contain related products in considerable amounts cannot be used for preparing pharmaceutical specialty products. Thus, it is important to have highly pure fondaparinux sodium compositions, and in particular industrial amounts of such compositions, and also a process for obtaining them.
[0010] Sugar oligomers or oligosaccharides such as fondaparinux are assembled using coupling reactions, also known as glycosylation reactions, to “link” sugar monomers together. The difficulty of this linking step arises because of the required stereochemical relationship between the D-sugar and the C-sugar, as shown below:
[0000]
[0011] The stereo chemical arrangement illustrated above is described as having a configuration at the anomeric carbon of the D-sugar (denoted by the arrow). The linkage between the D and C units in fondaparinux has this specific stereochemistry. There are, however, competing β and α-glycosylation reactions.
[0012] The difficulties of the glycosylation reaction in the synthesis of fondaparinux are well known. In 1991 Sanofi reported a preparation of a disaccharide intermediate in 51% yield having a 12/1 ratio of 13/a stereochemistry at the anomeric position (Duchaussoy et al., Bioorg . & Med. Chem. Lett., 1(2), 99-102, 1991). In Sinay et al., Carbohydrate Research, 132, C5-C9, 1984, yields on the order of 50% with coupling times on the order of 6 days are reported. U.S. Pat. No. 4,818,816 (see e.g., column 31, lines 50-56) discloses a 50% yield for the glycosylation.
[0013] U.S. Pat. No. 7,541,445 is even less specific as to the details of the synthesis of this late-stage fondaparinux synthetic intermediate. The '445 patent discloses several strategies for the assembly of the pentasaccharide (1+4, 3+2 or 2+3) using a 2-acylated D-sugar (specifically 2-allyloxycarbonyl) for the glycosylation coupling reactions. However, the strategy involves late-stage pentasaccharides that all incorporate a 2-benzylated D sugar. The transformation of acyl to benzyl is performed either under acidic or basic conditions. Furthermore, these transformations, using benzyl bromide or benzyl trichloroacetimidate, typically result in extensive decomposition and the procedure suffers from poor yields. Thus, such transformations (at a disaccharide, trisaccharide, and pentasaccharide level) are typically not acceptable for industrial scale production.
[0014] Examples of fully protected pentasaccharide are described in Duchaussoy et al., Bioorg. Med. Chem. Lett., 1 (2), 99-102, 1991; Petitou et al., Carbohydr. Res., 167, 67-75, 1987; Sinay et al., Carbohydr. Res., 132, C5-C9, 1984; Petitou et al., Carbohydr. Res., 1147, 221-236, 1986; Lei et al., Bioorg. Med. Chem., 6, 1337-1346, 1998; Ichikawa et al., Tet. Lett., 27(5), 611-614,1986; Kovensky et al., Bioorg. Med. Chem., 1999, 7, 1567-1580, 1999. These fully protected pentasaccharides may be converted to the O- and N-sulfated pentasaccharides using the four steps (described earlier) of: a) saponification with LiOH/H 2 O 2 /NaOH, b) O-sulfation by an Et 3 N—S0 3 complex; c) de-benzylation and azide reduction via H 2 /Pd hydrogenation; and d) N-sulfation with a pyridine-S0 3 complex.
[0015] Even though many diverse analogs of the fully protected pentasaccharide have been prepared, none use any protective group at the 2-position of the D unit other than a benzyl group. Furthermore, none of the fully protected pentasaccharide analogs offer a practical, scalable and economical method for re-introduction of the benzyl moiety at the 2-position of the D unit after removal of any participating group that promotes glycosylation.
[0016] Furthermore, the coupling of benzyl protected sugars proves to be a sluggish, low yielding and problematic process, typically resulting in substantial decomposition of the pentasaccharide (prepared over 50 synthetic steps), thus making it unsuitable for a large (i.e., kilogram or more) scale production process.
[0000]
[0017] It has been a general strategy for carbohydrate chemists to use a base-labile ester-protecting group at the 2-position of the D unit to build an efficient and stereoselective glycosidic linkage. To construct the linkage carbohydrate chemists have previously employed acetate and benzoate ester groups, as described, for example, in the review by Poletti et al., Eur. J. Chem., 2999-3024, 2003.
[0018] The ester group at the 2-position of D needs to be differentiated from the acetate and benzoates at other positions in the pentasaccharide. These ester groups are hydrolyzed and sulfated later in the process and, unlike these ester groups, the 2-hydroxyl group of the D unit needs to remain as the hydroxyl group in the final product, fondaparinux sodium.
[0019] Some of the current ester choices for the synthetic chemists in the field include methyl chloro acetyl (MCA) and chloro methyl acetate (CMA). The mild procedures for the selective removal of theses groups in the presence of acetates and benzoates make them ideal candidates. However, MCA/CMA groups have been shown to produce unwanted and serious side products during glycosylation and therefore have not been favored in the synthesis of fondaparinux sodium and its analogs. For by-product formation observed in acetate derivatives see Seeberger et al., J. Org. Chem., 2004, 69, 4081-93. Similar by-product formation is also observed using chloroacetate derivatives. See Orgueira et al., Eur. J. Chem., 9(1), 140-169, 2003.
[0020] Therefore, as will be appreciated, there are several limitations and drawbacks in current processes used for the synthesis of fondaparinux sodium. Thus, there is a need in the art for new synthetic procedures that produce fondaparinux and related compounds efficiently, in high yield and with highly stereoselective purity, and which employ less expensive reagents and fewer hazardous materials.
SUMMARY OF THE INVENTION
[0021] The processes presently disclosed address the limitations and drawbacks known in the art and provide a unique, reliable, efficient and scalable synthesis of compounds such as fondaparinux sodium. The present inventors have surprisingly found that in the synthesis of fondaparinux, the use of unique and improved reaction conditions and purification techniques allows for a highly efficient glycosylation reaction, thereby providing late-stage intermediates or oligosaccharides (and fondaparinux-related oligomers) in high yield and in high β/α ratios. In particular, glycosylation between two disaccharide units and tetrasaccharide and monosaccharide units can occur with high coupling yields (>65%) of the isomer, rapidly (for example, in an hour reaction time), and with no detectable α-isomer upon column chromatography purification. The new purification techniques permit elimination of column purification steps which are not suited to commercial production processes. The improved reaction conditions disclosed herein eliminate the lengthy and costly processes currently employed for the production of fondaparinux sodium and related intermediates, resulting in smooth and feasible processes which are acceptable for industrial scale production. In accordance with one aspect a first step involves acetolysis of chloro acetyl disaccharide sugar (CADS) carried out in the presence of acetic anhydride and trifluoroacetic acid (TFA) at ambient temperature. The resultant product residue, crystallized from ether instead of column chromatography, gives product in high yield and high purity.
[0022] A critical step of the disclosed processes which impacts all steps of the process is the bromination of acetylated CADS sugar, carried out in a mixture of moisture-free halogenated solvents such as methylene chloride, ethylene chloride and chloroform and ethyl acetate or butyl acetate in the presence of titanium bromide under argon atmosphere at reflux for 6 hrs. After work up, the residue is crystallized from a polar solvent such as methanol, ethanol, isopropanol, etc. instead of column chromatography, resulting in product in high yield and high purity.
[0023] Using the methods disclosed herein, far less solvent quantities are required than are used in prior art processes. Moreover, selectively purifying compounds at critical steps during the process surprisingly results in high yields and produces a final fondaparinux sodium product having a purity greater than 99.8% by HPLC, which is greater than that achievable using any prior art process. For example, in accordance with one aspect, distilling off the solvent dimethylformamide during preparation of the O-sulfonated pentasaccharide (L) surprisingly increased the yield of the final product by about 50%.
[0024] These and other aspects of the invention will be apparent to those skilled in the art.
DETAILED DESCRIPTION OF THE INVENTION
[0025] In the following description, for purposes of explanation, specific numbers, materials and configurations are set forth in order to provide a thorough understanding of the invention. It will be apparent, however, to one having ordinary skill in the art that the invention may be practiced without these specific details. In some instances, well-known features may be omitted or simplified so as not to obscure the present invention. Furthermore, reference in the specification to phrases such as “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of phrases such as “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
[0026] The following examples are merely illustrative of the present invention and should not be construed as limiting the scope of the invention in any way as many variations and equivalents that are encompassed by the present invention will become apparent to those skilled in the art upon reading the present disclosure.
EXAMPLES
[0027] In the synthesis of Fondaparinux sodium, the monomers XII, XVIII, XXVII, XXXVIII, XXXXI and dimers XIX, XX, XL described herein may be made either by processes described in the art or, by a process as described herein. The XII and XVIII monomers may then linked to form a disaccharide XX, XXXIX and XXVII monomers may then linked to form a disaccharide XL, XLIII and XX dimers may then linked to form a tetrasaccharide, XLVII tetramer and XLV monomer may be linked to form a pentasaccharide (XLVIII) pentamer. The XLVIII pentamer is an intermediate that may be converted through a series of reactions to fondaparinux sodium. This strategy described herein provides an efficient method for multi-kilogram preparation of fondaparinux in high yields and highly stereoselective purity.
Synthetic Procedures
[0028] The following abbreviations are used herein: Ac is acetyl; MS is molecular sieve; DMF is dimethyl formamide; Bn is benzyl; MDC is dichloromethane; THF is tetrahydrofuran; TFA is trifluoro acetic acid; MeOH is methanol; RT is room temperature; Ac 2 O is acetic anhydride; HBr is hydrogen bromide; EtOAc is ethyl acetate; Cbz is benzyloxycarbonyl; CADS is chloro acetyl disaccharide; HDS is hydroxy disaccharide; NMP is N-methylpyrrolidone.
Methyl 3-O-benzyl-4-O-monochloro acetyl-β-L-idopyranuronate
[0029]
Route of Synthesis for α-Methyl-6-o-acetyl-3-o-benzyl-2-(benzyloxy carbonyl)amino-2-deoxy-α-D-glucopyranoside
[0030]
Methyl 6-O-acetyl-3-O-benzyl-2-(benzyloxy carbonyl)amino-2-deoxy-4-O-(methyl-2-O acetyl-3-O-benzyl-α-L-idopyranosyluronate)-glucopyranoside
[0031]
Route of Synthesis for 1,6-Anhydro-2-azido-3-O-acetyl-2-deoxy-beta-D-glucopyranose
[0032]
Route of synthesis for Methyl 2,3-di-O-benzyl-4-O-chloroacetyl-beta-D-glucopyranuronate
[0033]
Route of synthesis for 3-O-Acetyl-1,6-anhydro-2-azido-4-O-2,3-di-O-benzyl-4-O-chloroacetyl-beta-D-glucopyranosyl methyluronate-beta-D-glucopyranose
[0034] (or)
3-O-Acetyl-1,6-anhydro-2-azido-2-deoxy-4-O-(methyl 2,3-di-O-benzyl-4-O-chloroacetyl-beta-D-glucopyranosyluronate)-beta-D-glucopyranose
[0035]
Route of Synthesis for 1,6-Anhydro-2-azido-3,4-di-O-benzyl-2-deoxy-beta-D-glucopyranose
[0036]
Synthesis of Disaccharide XLIII
[0037] Disaccharide XLIII was prepared in 2 synthetic steps from CADS sugar (XL) using the following procedure:
[0000]
[0038] CADS sugar XL was acetylated at the anomeric carbon using AC 2 O and TFA to give acetyl derivative XLII. This step was carried out using the reactants CADS, AC 2 O and TFA, stirring in an ice water bath for about 5-24 hours, preferably 20 hours, and evaporating to residue under vacuum. Residue was recrystallized in ether. Acetyl CADS (XLII) was brominated at the anomeric carbon using titanium tetra bromide in MDC andethylacetate and stirring at 20° C.-50° C. for 6-16 hours, preferably 6 hours, to give the bromo derivative, (XLIII) after work-up and recrystallization from solvent/alcohol.
Synthesis of the Monosaccharide (XLV)
[0039] The monosaccharide (XLV) was prepared in 2 synthetic steps from monomer (XLI) using the following procedure:
[0000]
[0040] Mono sugar (XLI) was acetylated at the anomeric carbon using AC 2 O and TFA to give acetyl derivative (XLIV). This step was carried out using the reactants Mono sugar (XLI), AC 2 O and TFA, stirring in an ice water bath for about 5-24 hours, preferably 24 hours, and evaporating to residue under vacuum. Residue was recrystallized in ether. Acetyl Mono sugar (XLIV) was brominated at the anomeric carbon using titanium tetra bromide in MDC and ethyl acetate and stirring at 20° C.-50° C. for 6-20 hours, preferably 16 hours, to give the bromo derivative, (XLV) after work-up and recrystallization from ether.
Synthesis of the Hydroxy Tetrasaccharide (XLVII)
[0041] The hydroxy tetrasaccharide (XLVII) was prepared in 2 synthetic steps from disaccharide (XLIII) and HDS (XX) using the following procedure:
[0000]
[0042] Disaccharide (XLIII), was coupled with disaccharide (XX) in the presence of silver carbonate, silver per chlorate and 4 A° MS in MDC and stirred at ambient temperature for 5-12 hrs, preferably 4-6 hours, in the dark followed by work-up and purification in water/methanol to give the tetrasaccharide (XLVI). The d echloroacetylation of tetrasaccharide (XLVI) was carried out in THF, ethanol and pyridine in the presence of thiourea at reflux for 6 to 20 hrs, preferably 12 hours, to give the hydroxy tetrasaccharide (XLVIII).
Synthesis of the Pentasaccharide (XLVIII)
[0043] The pentasaccharide (XLVIII) was prepared in 2 synthetic steps from monosaccharide (XLV) and tetrasaccharide (XLVII) using the following procedure:
[0000]
[0044] Monosaccharide (XLV), was coupled with tetrasaccharide (XLVII) in the presence of 2,4,6-collidine, silver triflate and 4 A° MS in MDC and stirred at −10° C. to −20° C. for 1 hr in the dark followed by work-up and purification by column chromatography to give the pentasaccharide (XLVIII).
Synthesis of OS Pentasaccharide (L)
[0045] The OS pentasaccharide (L) was prepared in 2 synthetic steps from pentasaccharide (XLVIII) using the following procedure:
[0000]
[0046] Pentasaccharide (XLVIII) was deacetylated in the presence of NaOH in mixture of solvents of MDC, methanol and water at 0° C. to 35° C., for 1-2 hrs followed by work-up and distillation to obtain deacetylated pentasaccharide (XLIX) which was subjected to O-sulfonation in DMF in the presence of SO 3 -trimethylamine (TMA) at 50° C. to 100° C., preferably 50° C.-55° C., for 6-24 hrs, preferably 12 hours, followed by salt removal through Sephadex® resin and column chromatography purification, then pH adjustment by dilute NaOH to give OS pentasaccharide (L).
Synthesis of fondaparinux sodium (LIII)
[0047] Fondaparinux sodium (LIII) was prepared in 3 synthetic steps from O—S pentasaccharide (L) using the following procedure:
[0000]
[0048] The intermediate L was then hydrogenated to reduce the two azides and N-CBz protection on sugars XLVIII, XX and XLV to amines and the reductive deprotection of the six benzyl ethers to their corresponding hydroxyl groups to form the intermediate deprotected pentasaccharide (LI). This transformation occurs by reacting L with 10% palladium/carbon catalyst with hydrogen gas for 6-9 days, preferably 9 days. The amino groups on deprotected pentasaccharide (LI) were then sulfonated using the pyridine-sulfur trioxide complex in sodium hydroxide, allowing the reaction to proceed for 2 hours to provide fondaparinux free acid (LII) which is purified and is subsequently converted to its salt form. The crude mixture was purified using an ion-exchange chromatographic column (Dowex 1×2-400 resin) followed by desalting using a methanol treatment and purification by water/NaCl/methanol to give the final API, fondaparinux sodium.
Experimental Procedures
Preparation of Benzylation of Diacetone-D-Glucose (I)
[0049] 25 kg of diacetone-D-glucose at RT was charged into a reactor then 250.0 L of toluene, 25 L of NMP followed by 2.5 kg of tetra-n-butylammonium bromide (TBAB) were charged into the reaction mass at RT and the reaction was stirred for 15-20 minutes at RT. Next, 11.5 kg of sodium hydroxide was charged into the reactor and the reaction mass was stirred for 20-25 minutes at RT, then 18.25 kg of benzyl chloride was slowly added into it and the reaction was stirred for 5-7 hrs, preferably 7 hours, at RT then 18.25 L of methanol was charged into the reaction mass and the reaction was stirred for 15-20 minutes at RT. Water work-up and evaporation yielded 21.5 kg of compound (I).
Deprotection of Compound (I)
[0050] 21.5 kg of compound (I) was charged at RT into the reactor followed by addition of 110 kg of acetic acid and 25 L of water in to the reaction mass at RT and the reaction was stirred for 6-8 hrs at 40° C.-45° C. The reaction mass was cooled down to RT and subjected to two hexane washes and the product was extracted in MDC. The organic layer was again washed with NaHCO 3 solution and brine solution. Evaporation yielded 19.0 kg of compound (II)
[0000] Oxidation of compound (II)
[0051] 375 L of THF and 19 kg of compound (II) were charged in a reactor with 125 L of water at RT. The reaction mass was cooled to 0° C.-−5° C. 40 kg of NaHCO 3 , 27.5 kg of dichlorodimethylhydantoin (DDH) and 187.5 gm of tetramethylpiperidinol N-oxyl (TEMPO) were added into the reaction mass. The reaction mass was stirred for 6-8 hrs at 0° C.-−5° C. then diluted with sodium thiosulphate solution, washed with hexane and the pH of the aqueous layer was adjusted to 2-3 with HCl solution and the product extracted with MDC. The organic layer was washed with water then brine solution, dried over sodium sulfate, and after evaporation yielded 17.50 kg of compound (III).
Esterification of Compound (III)
[0052] 127.5 L of acetone was charged at RT into a reactor, then 17 kg of compound (III) was charged into the reaction mass at RT and the reaction was stirred for 5-10 minutes at RT. 23.5 kg of potassium carbonate was then added and the reaction was stirred for 10-15 minutes at RT, then 7.31 kg of dimethyl sulphate was slowly added into it and the reaction was stirred for 1-2 hrs at RT. 382.5 L of water and 68 L of MDC was then added and the reaction mass was stirred for 10-15 minutes at RT. Separated layers. After further extraction of aqueous layer with MDC, finally the organic layer was washed with water and dried over sodium sulfate. After evaporation the yield was 12.3 kg of compound (IV).
O-protection of Compound (IV)
[0053] 36 L of MDC and 12 kg of compound (IV) were charged in a reactor at RT under nitrogen atmosphere and the reaction mass was cooled to −30° C.-−35° C., then 4.2 kg of pyridine were slowly added. The reaction mass was again cooled to −45° C.-−50° C., then 10.56 kg of triflic anhydride was slowly added into it. The reaction mass was stirred for 15-30 minutes at −45° C.-−50° C., then the reaction mass was quenched into hexane and filtered. The clear filtrate was dried over sodium sulfate, and after evaporation yielded 10.4 kg of compound (V).
[0000] Deprotection and Isomerisation of compound (V)
[0054] 10.4 kg of compound (V) was charged at RT into a reactor then 36 L of DMF and 14.40 kg of sodium TFA was charged into the reaction mass at RT and the reaction was stirred for 2-3 hrs at 75° C.-80° C., then the reaction mass was cooled down to RT. After MDC/water work-up and evaporation yielded 9.8 kg of product. It was stirred with methanol at RT for 12 hrs then distilled off completely to yield 7.2 kg of compound (VI).
[0000] Deprotection and ring expansion of compound (VI)
[0055] 29.05 kg of TFA was charged into a reactor then cooled to 10° C.-15° C. 2.1 L of water and compound (VI) were charged slowly into the reaction mass at 10° C.-15° C. and the reaction was stirred for 1-2 hrs at 10° C.-15° C. The reaction mass was quenched in water and MDC, the pH of the aqueous layer was adjusted to 7.5-8.5 with potassium carbonate solution. Both organic and aqueous layers were separated and the aqueous layer was extracted twice with MDC. All organic layers were dried over sodium sulfate, and after evaporation yielded 4.75 kg of compound (VII).
[0000] Acetylation of compound (VII)
[0056] 18.45 kg of pyridine and 4.5 kg of compound (VII) were charged into a reactor then cooled to 0° C.-5° C. 8.32 kg of acetyl chloride was charged slowly into the reaction mass at 0° C.-5° C. The reaction mass temperature was raised to RT and the reaction was stirred for 8-10 hrs at RT. The reaction mass was diluted with water/MDC, extracted with MDC and slowly the pH of the reaction mass adjusted to 1-2 with HCl solution. The organic layer was washed with water, dried over sodium sulfate, and after evaporation, the residue was purified in a silica column using the following gradient profiles: 20:80 to 30:70 (EtOAc/hexane). The pure fractions were pooled and evaporated to yield 1.35 kg of compound (VIII).
Bromination and Orthoesterification of Compound (VIII)
[0057] 6 L of MDC and 8.4 kg of HBr in acetic acid were charged into a reactor under nitrogen atmosphere, then cooled to −5° C.-5° C. A solution of 1.2 kg of compound (VIII) in MDC was slowly added into the reaction mass at −5° C.-5° C. The reaction was stirred for 2 hrs at −5° C.-5° C., the reaction mass was quenched in cold water, and the pH of the reaction mass was adjusted to 7.0-8.0 with sodium bicarbonate solution. The organic and aqueous layers were separated. The organic layer was washed with brine solution, dried over sodium sulfate, and after evaporation, the reaction mass was cooled to RT. 0.24 kg of 4 A° MS was then charged into reactor under nitrogen atmosphere. A solution of 1.56 L of collidine and 1.8 L of t-butanol in MDC was slowly charged into the reaction mass at RT. The reaction was stirred for 12 hrs at RT then the reaction mass was quenched into water and filtered. Organic and aqueous layers were separated and the pH of the organic layer was adjusted to 4-4.5 with potassium bisulphate. The organic and aqueous layers were separated again and then adjusted to 7.0-8.0 with NaHCO 3 solution. Organic and aqueous layers were separated and the organic layer was washed with brine solution, dried over sodium sulfate, and after evaporation, the residue was purified in a silica column using the following gradient profiles: 20:80 to 30:70 (EtOAc/hexane). The pure fractions were pooled and evaporated to yield 0.62 kg of compound (X).
Deacetylation of Compound (X)
[0058] 3.0 L of methanol, 0.12 kg of 4 A° MS and 0.6 kg of compound (X) were charged into a reactor under nitrogen atmosphere then cooled to −20° C. to −25° C. The reaction was stirred for 3-4 hrs at −20° C. to −25° C., the reaction mass was diluted with MDC and filtered through Celite® filter, and washed with water. The organic layer was washed with brine solution, dried over sodium sulfate, and after evaporation the yield was 0.4 kg of compound (XI).
Chloroacetylation of Compound (XII)
[0059] 3.0 L of MDC and 0.4 kg of compound (XI) were charged into a reactor under nitrogen atmosphere then cooled to 0° C.-5° C. 0.48 L of pyridine was charged into the reactor then cooled to −20° C. to −25° C. A solution of 0.2 kg of CAC in MDC was slowly charged into the reaction mass at −20° C. to −25° C. The reaction was stirred for 20-30 minutes at −20° C. to −25° C. The reaction mass was diluted with MDC and quenched into cold water. The organic and aqueous layers were separated and the organic layer was washed with KHSO 4 solution, NaHCO 3 solution and brine solution, and dried over sodium sulfate. After evaporation, the residue was purified in a silica column using the solvent system: 20:80:1 (EtOAc/hexane/TEA). The pure fractions were pooled and evaporated to yield 0.35 kg of compound (XII).
N-Protection of Glucosamine Hydrochloride
[0060] A solution of 11.7 kg of NaHCO 3 in 130 L water at RT was charge into a reactor. 10 kg of glucosamine hydrochloride was then charged into the reaction mass at RT and the reaction was stirred for 25-30 minutes at RT. 9.5 kg of benzyl chloroformate was slowly charged into the reaction mass at RT and the reaction was stirred for 3 hrs at RT and filtered. Wet product was treated with water and methanol to yield 9.1 kg of compound (XIII).
O-Methylation of Compound (XIII)
[0061] 124 L of 1% methanolic HCl and 9.0 kg of compound (XIII) at RT were charged into a reactor and the reaction was stirred for 14 hrs at 60° C.-65° C. The reaction mass was cooled down to RT, and 1.8 kg of NaHCO 3 was slowly added into the reaction mass to maintain the pH between 6.5-7.5. The reaction mass was cooled down to 0° C.-5° C., the reaction was stirred for 20-25 minutes at 0° C.-5° C. then filtered. After evaporation, the residue was stirred with hexane for 1 hr at RT and solid product was isolated by filtration yielding 6.3 kg of compound (XIV).
O-Protection of Compound (XIV)
[0062] 30 kg of benzaldehyde were charged at RT into a reactor, then 6 kg of compound (XIV) were charged into the reaction mass at RT and the reaction was stirred for 15-20 minutes at RT. 2.7 kg of zinc chloride was charged into the reaction mass at RT and the reaction was stirred for 24 hrs at RT. 30 L of methanol was charged into the reactor and the reaction mass was stirred for 15-20 minutes. The reaction mass was cooled down to 0° C.-5° C., the reaction was stirred for 45-60 minutes at 0° C.-5° C., and solid product was isolated by filtration to yield 4.2 kg of compound (XV).
O-Benzylation of compound (XV)
[0063] 40 L of 1,4dioxane and 4.0 kg of compound (XV) were charged at RT into a reactor, then the reaction was stirred for 15-20 minutes at RT. 1.6 kg of KOH and 3.2 kg of benzyl bromide were slowly added into the reactor at RT, the reaction was stirred for 15-30 minutes at RT, then the reaction was refluxed for 4 hrs. The reaction mass was cool down to RT, water was slowly added into the reaction mass, the reaction was stirred for 2 hrs at RT and solid product was isolated by filtration yielding 3.3 kg of compound (XVI).
O-Deprotection of compound (XVI)
[0064] 9 kg of acetic acid, 3 kg of compound (XVI) and 6 L of water were charged into a reactor at RT and the reaction was stirred for 15-20 minutes at RT. The reaction was stirred for 3-4 hrs at 90° C.-100° C., the reaction mass was cool down to RT, 15 L of water was slowly added into the reaction mass at RT and the reaction was stirred for 10-15 minutes at RT. Solid product was isolated by filtration yielding 1.65 kg of compound (XVII).
[0000] Acetylation of compound (XVII)
[0065] 4.5 kg of MDC, 1.5 kg of compound (XVII) and 1.05 kg of pyridine were charged into a reactor and then cooled to −50° C. to −55° C. 0.36 kg of acetyl chloride was charged slowly under nitrogen atmosphere in to the reaction mass at −50° C. to −55° C. The reaction was stirred for 30 minutes at −50° C. to −55° C., the temperature of the reaction mass was raised to 0° C.-5° C., the reaction mass was worked up with water/MDC, extracted with MDC and the pH of the reaction mass slowly adjusted to 2-3 with HCl solution. The organic layer was washed with NaHCO 3 and water at 0° C.-5° C. and dried over sodium sulfate. After evaporation, the residue was purified in EtOAc/hexane to yield 0.75 kg of compound (XVIII).
Condensation of Monosaccharide (XII) and Monosaccharide (XVIII)
[0066] 4.5 L of chlorobenzene, 0.3 kg of monosaccharide (XVIII) and 0.039 kg of pyridinium perchlorate were charged into a reactor and the reaction mass was heated to 125° C.-130° C. Water was removed by azeotropic distillation; the reaction was stirred for 1 hr at 125° C.-135° C. A solution of 0.30 kg of monosaccharide (XII) in chlorobenzene was charged slowly in to it, then the reaction was stirred for 2-3 hrs at 125° C.-135° C. The reaction mass was cooled down to 80° C.-85° C. and the solvent distilled off completely to yield 0.35 kg of Disaccharide (XIX).
Preparation of HDS-(XX)
[0067] 1.2 L of methanol, 1.8 L of pyridine, 0.35 kg of disaccharide (XIX) and 0.06 kg of thiourea were charged into a reactor and heated to 90° C.-100° C. and stirred for 1 hr at 90° C.-100° C. The reaction mass was cooled down to RT and worked up with water/MDC, extracted with MDC, and the organic layer was washed with KHSO 4 , NaHCO 3 and brine solution, and dried over sodium sulfate. After evaporation, the residue was purified in a silica column using the solvent system: 30:70 (EtOAc/hexane). The pure fractions were pooled and evaporated to residue which was purified in EtOAc/DIPE, yielding 0.110 kg of HDS(XX).
Preparation of Compound (XXII) from D (+) Glucose
[0068] 427.5 kg of acetyl chloride and 150 kg of D (+) glucose were charged into a reactor and cooled to 0° C.-5° C. A solution of 13.5 ml of acetic acid and 1.5 ml of H 2 SO 4 was charged slowly into the reaction mass at −0° C.-5° C. The reaction was stirred for 30 minutes at 0° C.-5° C., and the temperature slowly raised to RT, then to 70° C.-75° C. The reaction was stirred for 2 hrs at 70° C.-75° C., then the reaction mass was cooled down to RT. 450 kg of HBr in acetic acid was charged slowly into the reaction mass at RT. The reaction was stirred for 2 hrs at RT. Separately, 675 L of water and 450 kg of sodium acetate trihydrate were charged into a reactor. To this reactor a solution of 22.5 kg of copper sulphate in water was added slowly, then cooled to 0° C. to −5° C. 195 kg of zinc dust and 435 kg of AcOH were added into the reaction mass at 0° C. to −5° C. To this reaction mass, the above brominated R/M was slowly charged at 0° C. to −5° C., then cooled to 0° C. to −5° C. The reaction was stirred for 2 hrs at 0° C. to −5° C. then filtered through Celite® filter and worked up with water/MDC, extracted with MDC and the organic layer was washed with NaHCO 3 and water, and dried over sodium sulfate. After evaporation, the residue was purified in IPA to yield 68 kg of compound (XXII).
Preparation of Compound (XXIII)
[0069] 1406 L of methanol and 125 kg of compound (XXII) were charged into a reactor and cooled to 5° C.-10° C. The pH of the reaction mass was slowly adjusted to between 9-9.5 with sodium methoxide solution at 5° C.-10° C. The reaction was stirred for 3-4 hrs at RT then cooled to 5° C.-10° C. The pH of the reaction mass was adjusted to between 6.5-7.5 with AcOH solution in methanol at 5° C.-10° C. and the solvent was distilled off completely, then cooled to RT. 200 L of acetonitrile, 181.25 kg of 4 A° MS and 200 kg of Bis(tis-n-butyl tin) oxide was charged into the reactor and the reaction was heated to reflux refluxed for 5 hrs. The reaction mass was cooled down to 0° C.-5° C. 173.5 kg of iodine was charged slowly into the reaction mass at 0° C.-5° C. The reaction was stirred for 3-4 hrs at RT then filtered through Celite® filter, the solvent was distilled off completely and worked up with hexane/sodium thiosulphate solution and then extracted with EtOAC and dried over sodium sulfate. After evaporation, the residue was purified in IPA to yield 26 kg of compound (XXIII).
Preparation of Compound (XXIV)
[0070] 250 L of DMF, a solution of 0.95 kg of NaHCO 3 in water, 18 kg of sodium azide and 25 kg of compound (XXIII) were charged into a reactor. The reaction was stirred for 10-12 hrs at RT then heated to 118° C.-122° C. and stirred for 2-3 hrs at 118° C.-122° C. The reaction mass was cooled down to 40° C.-50° C. and 150 L of methanol was charged into it. The reaction was stirred for 20-30 minutes then filtered. After evaporation, the residue was dissolved in EtOAC and filtered. Clear filtrate was distilled off completely and the EtOAC treatment repeated one more time. The residue was purified in a silica column using the gradient profiles: 20:80 to 50:50 (EtOAc/hexane). The pure fractions were pooled and evaporated to yield 10.60 kg of compound (XXIV).
Preparation of Mono Sugar (XLI)
[0071] 25 L of toluene, 2.5 kg of compound (XXIV), 2.5 L of N-methylpyrrolidone (NMP) and 0.25 kg of TBAB were charged into a reactor. The reaction was stirred for 10-15 minutes at RT then 3.75 kg of KOH was charged into it and the reaction cooled to 0° C.-5° C. 5 kg of benzyl chloride was added slowly at 0° C.-5° C. The reaction was stirred for 4-6 hrs at RT and 5 lit of methanol was charged into the reactor. The reaction was stirred for 20-30 minutes then 12.5 lit of water was added. The organic layer was washed with water, dried over sodium sulfate, and after evaporation, the residue was dissolved in EtOAC and filtered. Clear filtrate was distilled off completely and the EtOAC treatment was repeated one more time. The residue was purified in a silica column using the gradient profiles: 0:10 to 10:90 (EtOAc/hexane). The pure fractions were pooled and evaporated to residue which was purified in DIPE to yield 1.8 kg of Mono sugar (XLI).
Preparation of Compound (XXIX)
[0072] Charge 2.0 kg of allyl alcohol in a round bottom flask (RBF) at ambient temperature and cool to 0-5° C. Pass dry HCl gas (0.06 kg) into the reaction mass at 0-5° C. Charge 1.0 kg of D(+) glucose into the RBF at 0-5° C. Slowly raise the reaction mass temperature to 70-75° C. Maintain the reaction mass temperature at 70-75° C. for 5 hrs. Cool the reaction mass to ambient temperature. Adjust the pH to 8.0-9.0 by adding ammonia solution at ambient temperature. Distill off allyl alcohol from the reaction mass. Cool the reaction mass. Charge 0.5 L of acetone into the reaction mass. Distill off solvent and charge 2.0 L of acetone into the reaction mass. Raise the reaction mass temperature to 50-55° C. Stir for 30-45 minutes. Settle the reaction mass for 45-60 minutes. Separate the layers. Charge the bottom layer in the RBF and extract with acetone three more times. Charge all organic layers in the RBF. Distill off solvent completely under vacuum at or below 50° C. Cool the reaction mass to ambient temperature. Charge 0.20 L of dimethyl formamide into the reaction mass, stir the reaction mass for 30-45 minutes. Distill off solvents. Charge 3.0 L of dimethyl formamide into the reaction mass. Stir the reaction mass for 15-20 minutes. Charge 0.674 kg benzaldehyde dimethyl acetal and p-toluene sulfonic acid into the reaction mass. Raise the reaction mass temperature to 100-105° C. Apply low vacuum and maintain the reaction mass for 2 hrs at 100-105° C. under mild vacuum. Distill off solvents completely and cool the reaction mass to 30-40° C. Charge 0.50 L of methanol. Distill off solvent completely. Charge 0.70 L of methanol into the reaction mass and raise the reaction mass temperature to reflux for 25-30 minutes. Cool the reaction mass to 0-5° C. Filter the reaction mass and wash the cake with 0.10 L of methanol. Dry the product for 5 hrs. Yields 0.3 kgof compound (XXIX).
Preparation of Compound (XXX)
[0073] Charge 10.0 L of toluene into a RBF at ambient temperature into a reactor vessel. Charge 1.0 kg of compound (XXIX) into RBF at ambient temperature. Charge 1.0 L of N-methyl-2-pyrrolidone and 0.10 kg of tetra butyl ammonium bromide (TBAB) into the reaction mass at ambient temperature. Stir the reaction mass for 15-20 minutes. Slowly charge 0.65 kg of sodium hydroxide into the reaction mass at ambient temperature. Stir the reaction mass for 15-20 minutes. Slowly add 1.25 kg of benzyl chloride into the reaction mass at ambient temperature over a period of 1-2 hrs. Maintain the reaction mass for 10-12 hrs at ambient temperature. Add 0.75 L methanol into the reaction mass. Add 4.0 L of water in reaction mass; raise the temperature of reaction mass to 40-45° C. Stir the reaction mass for 15-20 minutes at 40-45° C. Separate the layers. Extract the aqueous layer with 10.0 L toluene. Organic layer wash with water to get neutral pH. Charge the organic layer in RBF and distill off solvent completely under vacuum at or below 50° C. Add 6.0 L methanol into the reaction mass then cool the reaction mass to ambient temperature, stir for 1-2 hrs. Filter the product and wash with methanol. Unload the product and dry it. Dry weight=1.1 kg of compound (XXX).
Preparation of Compound (XXXI)
[0074] Charge 1.0 kg of compound (XXX) and 10.0 L of methanol in a RBF at ambient temperature. Add a solution of p-toluene sulfonic acid in water into reaction mass. Raise the temperature of the reaction mass to 70-75° C. and maintain it for 1-2 hrs. Distill off the solvent and cool the residue. Add water and dichloromethane to the residue and separate the layers. Wash the organic layer with water. Distill off the solvent completely to get residue. Weight of residue=0.70 kg of compound (XXXI).
Preparation of Compound (XXXII)
[0075] Charge 1.0 kg of compound (XXXI) and 4.0 L of pyridine in a RBF at ambient temperature. Add 0.95 kg of trityl chloride into the reaction mass. Slowly raise the temperature of the reaction mass to 80-85° C. and maintain the temperature for 2-3 hrs at 80-85° C. Cool the reaction mass to 50-55° C. and add 0.50 kg of acetyl chloride into the reaction mass. Maintain the temperature for 1-2 hrs at 55-60° C. Distill off pyridine completely to get residue. Add 6.0 L of methanol to the residue and cool to 5-10° C. Stir the reaction mass for 1-2 hrs at 5-10° C. and filter the product. Dry the product. Dry weight=1.20 kg of compound (XXXII).
Preparation of Compound (XXXIII)
[0076] Charge 1.0 kg of compound (XXXII), 0.50 L of dichloromethane, 2.0 L of water and 8.40 kg of acetic acid in a RBF at ambient temperature. Raise the temperature of the reaction mass to 40-45° C. Maintain the reaction mass for 6-7 hrs. at 40-45° C. Quench the reaction mass with water. Filter the solid and charge the reaction mass into RBF. Extract the reaction mass with dichloromethane, wash the organic layer with water. Distill off solvent completely to get residue. Weight of residue=0.50 kg of compound (XXXIII).
Preparation of Compound (XXXIV)
[0077] Charge 1.0 kg of compound (XXIII and 5.0 L of acetone in a RBF. Add Jones reagent in reaction mass at ambient temperature (exothermic reaction). Maintain the reaction mass for 30-45 minutes at 40-45° C. Cool the reaction mass to 15-20° C. and quench the reaction mass with water. Extract the reaction mass with dichloromethane. Wash the organic layer with water and dry using sodium sulfate. Distill off solvent completely to get residue. Residue weight=0.90 kg of compound (XXXIV).
Preparation of Compound (XXXV)
[0078] Charge 3.0 L of dimethyl sulfoxide and 0.98 kg of potassium t-butoxide into a RBF. Raise the reaction mass temperature to 95-100° C. Prepare a solution of compound (XXXIV) in dimethyl sulfoxide (1.0 kg of compound (XXXIV) in 2.0 L DMSO). Add this solution to the above reaction mass at 95-115° C. Raise the reaction mass temperature to 118-122° C. and maintain the temperature for 1-2 hrs. Cool the reaction mass to ambient temperature. Quench the reaction mass in water. Filter the reaction mass through Celite® filter bed. Wash the filtrate with hexane. Adjust the pH of the aqueous layer to 2.0-2.5 with conc.HCl and extract with dichloromethane. Was h the organic layer with water and dry using sodium sulfate. Distill off the solvent completely to get residue. Weight of residue=0.70 kg of compound (XXXV).
Preparation of Compound (XXXVI)
[0079] Charge 1.0 kg of compound (XXXV), 5.0 L of acetone, 0.74 kg of potassium carbonate and 0.34 kg of dimethyl sulphate into a RBF. Stir the reaction mass for 2 hrs at 30-40° C. Filter the reaction mass through Celite® filter. Charge the filtrate and distill off solvent completely to get residue. Charge water and dichloromethane into residue. Stir for 15-30 minutes, separate organic layer. Wash the organic layer with water and dry using sodium sulfate. Distill off solvent completely to get residue of compound (XXXVI).
Preparation of Compound (XXXVII)
[0080] Charge 1.0 kg of compound (XXXVI) and 1.0 L of dichloromethane in a RBF. Cool the reaction mass to 0-10° C. Add 0.42 kg of chloro acetyl chloride at 0-10° C. Add 1.80 L of pyridine in reaction mass at 0-10° C. Maintain the reaction mass for 1-2 hrs at 0-10° C. Quench the reaction mass with water and extract the product with dichloromethane. Charge organic layer and water in RBF. Adjust the pH of the reaction mass with concentrated HCl to 2.0-3.0. Separate the organic layer and charge in RBF. Add water in organic layer and adjust the pH of reaction mass with sodium bicarbonate to 7.0-8.0. Separate layers and wash organic layer with water. Dry organic layer using sodium sulfate and filter it. Charge filtrate in RBF and distill off solvent completely to get residue. Residue weight=0.70 kg of compound (XXXVII).
Preparation of Compound (XXXVIII)
[0081] Charge 1.0 kg of compound (XXXVII), 10.0 L of acetone, 5.0 L of water and 1.15 kg of mercuric oxide into a RBF. Stir the reaction mass for 15-30 minutes. Prepare mercuric chloride solution in acetone (1.45 kg mercuric chloride in 9.0 L of acetone). Slowly add this solution into above reaction mass at ambient temperature. Maintain the reaction mass for 30-60 minutes at ambient temperature. Filter the reaction mass through Celite® filter bed and adjust the reaction mass to pH 8.0-9.0. Filter the reaction mass and distill off acetone. Extract aqueous layer with ethyl acetate. Wash organic layer with sodium chloride and dry the organic layer using sodium sulfate. Distill off solvent completely to get residue. Purify the crude product using silica column chromatography with ethyl acetate:hexane. (10:90 to 20:80) A product containing fractions is pulled out and solvent is distilled off completely to get residue. Product crystallized in isopropyl ether. Weight of product=0.20 kg of compound (XXXVIII).
Preparation of Compound (XXV)
[0082] Charge 1.0 kg of compound (XXIV) compound and 10.0 L of dichloromethane in a RBF at ambient temperature. Cool the reaction mass to 15-20° C. Add 0.80 kg of imidazole and 0.97 kg of tert-butyldimethylsilyl ether (TBDMS) chloride into the reaction mass at 15-20° C. Raise the reaction mass temperature to ambient temperature. Maintain the reaction mass for 10-12 hrs at ambient temperature. Quench the reaction mass with water. Wash organic layer subsequently with dilute hydrochloride solution and dilute sodium bicarbonate solution. Distill off solvent completely, then cool the reaction mass to ambient temperature. Weight of product=1.1 kg of compound (XXV).
Preparation of Compound (XXVI)
[0083] Charge 1.0 kg of compound (XXV) and 2.28 kg of pyridine in a RBF at ambient temperature. Add 1.0 kg of acetyl chloride to reaction mass at ambient temperature. Maintain the reaction mass for 5-6 hrs at ambient temperature. Quench the reaction mass with ice cold water. Wash the organic layer subsequently with dilute hydrochloride solution and dilute sodium bicarbonate solution. Distill off solvent completely, then cool the reaction mass to ambient temperature. Charge hexane in residue, cool the reaction mass temperature to 10-15° C. and maintain reaction mass temperature for 20-30 minutes. Filter the product and wash with hexane. Dry the product for 5-6 hrs. Weight of product=0.70 kg of compound (XXVI).
Preparation of Compound (XXVII)
[0084] Charge 4.91 kg of trifluoroacetic acid in a RBF at ambient temperature. Cool the reaction mass to 10-15° C. Slowly add 0.80 L of water into the reaction mass below 20° C. Charge 1.0 kg of compound (XXVI) into reaction mass below 20° C. Maintain the reaction mass for 5-6 hrs at ambient temperature. Charge dichloromethane into reaction mass and adjust the reaction mass pH to 8.0-9.0 with potassium carbonate solution. Extract aqueous layer with dichloromethane. Dry the organic layer using sodium sulfate. Distill off solvent completely to get crude product. Purify product by column chromatography. Run the column with ethyl acetate:hexane (10:90 to 20:80). Charge all product-containing fractions into RBF and distill off solvent completely to get product. Weight of product=0.50 kg of compound (XXVII).
Preparation of Disaccharide (XL)
[0085] Charge 1.50 kg of triphenyl phosphine and 5.0 L of dimethyl formamide in a RBF at ambient temperature. Cool the reaction mass to 0-10° C. Slowly add 1.0 kg of bromine into the reaction mass at 0-10° C. Slowly raise the reaction mass temperature to 58-60° C. Maintain the reaction mass for 30-45 minutes at 58-60° C. Cool the reaction mass to ambient temperature and add diisopropyl ether. Filter the product and wash with diisopropyl ether. Charge wet cake of above product in RBF and add 4.0 L of dichloromethane into the RBF. Prepare a solution of compound (XXXVIII) in dichloromethane and slowly add this solution into the above reaction mass at ambient temperature. Maintain the reaction mass for 1.0 hour at ambient temperature. Filter the reaction mass and charge filtrate into RBF. Adjust the reaction mass to a pH of 8.0-9.0 by using sodium bicarbonate solution. Wash the organic layer with water and dry using sodium sulfate. Distill off the solvent completely under vacuum to get residue. Triturate residue with diisopropyl ether to remove unwanted salt. Distill off filtrate completely to get crude compound (XXXIX). Charge 1.50 L of dichloromethane and 0.70 kg of compound (XXVII) into a RBF at ambient temperature. Add 0.15 kg of molecular sieves into the reaction mass at ambient temperature. Stir the reaction mass 15-20 minutes. Slowly add 0.70 kg of mercuric bromide into the reaction mass at ambient temperature. Maintain the reaction mass 6-8 hrs under nitrogen. Prepare compound (XXXIX) solution in dichloromethane. Slowly add the above-prepared compound (XXXIX) solution into the reaction mass under nitrogen over a period of 1-2 hours. Maintain the reaction mass for 10-12 hours at ambient temperature. Filter the reaction mass and quench with ammonia solution. Filter the solid and filtrate wash with water. Dry the organic layer on sodium sulfate and distill off solvent completely to get residue. Triturate the residue with methanol and stir the reaction mass for 1 hour. Filter the solid and wash with methanol. Treat filtrate with water and separate the product layer. Purify the crude product by column chromatography using ethyl acetate:hexane (0:100 to 20:80) Charge all product-containing fractions into a RBF and distill off solvent completely to get residue. Charge ethyl acetate and diisopropyl ether into the residue. Stir the reaction mass for 20-30 minutes. Dry the product for 4-6 hrs. Weight of product=0.20 kg of disaccharide (XL).
Preparation of Compound (XLII)
[0086] 100 gm of CADS (XL) was charged at 20° C.-30° C. into a 2.0 lit RBF under nitrogen atmosphere, then 1.0 L of acetic anhydride was charged, followed by 200 ml of TFA, into the reaction mass at RT and the reaction was stirred for 6 hrs at RT. After evaporation, the residue was stirred with DIPE for 1 hr at RT and solid product was isolated by filtration to yield 95.5 gm of XLII.
[0087] NMR spectrum confirmed the expected structure.
Preparation of Compound (XLIII)
[0088] 95 gm of acetylated CADS (XLII) was charged at 20° C.-30° C. into a 12.0 L RBF under nitrogen atmosphere with 1.9 L MDC followed by 950 ml ethyl acetate at RT. The reaction mass was stirred for 5-10 min. at RT. To this clear solution, 231.45 gm of titanium bromide were added at RT. The temperature of the reaction mass was raised to 40° C.-45° C. and stirred for 6 hrs. Then the reaction mass was diluted with cold water (1.9 L) and 1.5 L of MDC. The reaction mass was stirred for 10-15 min., both layers were separated and the aqueous layer was extracted with 950 ml of MDC. Both organic layers were combined and dried over sodium sulfate. After evaporation, the residue was recrystallized with 950 ml of IPA for 3 hrs at RT. The solid was filtered & washed with IPA, then DIPE, yielding 52 gm of compound XLIII.
[0089] NMR spectrum confirmed the expected structure.
Preparation of Compound (XLIV)
[0090] 648 gm of Mono sugar (XLI) was charged at 20° C.-30° C. into a 12.0 L RBF under nitrogen atmosphere. Then 6.48 L of acetic anhydride followed by 1.3 L of TFA were charged into the reaction mass at RT and the reaction was stirred for 8-10 hrs at RT. After evaporation, the residue was stirred with DIPE for 1 hr at RT and solid product was isolated by filtration, yielding 550 gm of compound (XLIV).
[0091] NMR spectrum confirmed the expected structure.
Preparation of Compound (XLV)
[0092] 550 gm of acetylated Mono sugar (XLIV) was charged at 20° C.-30° C. into a 30.0 L reactor under nitrogen atmosphere with 11 L MDC followed by 100 ml ethyl acetate at RT. The reaction mass was stirred for 5-10 min. at RT. To this clear solution, 779 gm of titanium bromide was added at RT. The reaction mass was stirred for 16 hrs, then the reaction mass was diluted with water (11 L) and 5.5 L of MDC. The reaction mass was stirred for 10-15 min. Both layers were separated and the aqueous layer was extracted with 2.75 L of MDC. Both organic layers were combined and dried over sodium sulfate. After evaporation, the residue was recrystallized with 5.5 L of DIPE for 1 hr at RT. The solid was filtered & washed with DIPE, yielding 469.1 gm of compound (XLV).
[0093] NMR spectrum confirmed the expected structure.
Preparation of Tetrasaccharide (XLVI)
[0094] 346 gm of bromo CADS (XLIII) with 6.92 L of MDC were charged in a 12 L RBF under argon atmosphere at RT with 207 gm of 4 A° MS. Stirred for 5-10 minutes at RT. When the moisture of the reaction mass was less than 0.05%, then 235 gm of HDS (XX) were charged into it at RT. The reaction mass was stirred at RT for 15-30 minutes, then 176 gm of silver carbonate were added followed by 48.4 gm of silver perchlorate anhydrous added into it at RT in the dark. The reaction mass was stirred for 6 hrs then diluted with 2.08 L of MDC and filtered through a Celite® filter bed, then washed with MDC. Clear filtrate was washed with 10% KHSO 4 solution, then process water, dried over sodium sulfate, and after evaporation, the residue was purified with methanol/water to yield 574 gm of tetrasaccharide (XLVI).
Preparation of Tetrasaccharide (XLVII)
[0095] 4.22 L of THF, 0.98 L of ethanol, 422 gm of tetrasaccharide (XLVI), 1.3 L of pyridine and 29.5 gm of thiourea were charged in a 12 L RBF at RT and stirred for 10-15 minutes at RT. The temperature of the reaction mass was raised to 70° C.-80° C. and the reaction mass was stirred at 70° C.-80° C. for 12 hrs. The reaction mass was cooled down to 60° C.-65° C., then the solvent was distilled out completely. The residue was dissolved in 2.96 L of MDC and washed with 10% KHSO 4 solution, then brine solution, dried over sodium sulfate, and after evaporation yielded 398 gm of tetrasaccharide (XLVII).
Preparation of Pentasaccharide (XLVIII)
[0096] 8.73 L of MDC and 325 gm of 4 A° MS were charged in a 22 L RBF under argon atmosphere at RT. The reaction mass was stirred at RT for 15-30 minutes, then 406 gm of tetrasaccharide (XLVII) and 406 gm of monosaccharide (XLV) were added. The reaction mass was cooled to −10° C. to −20° C., then 223 ml of 2, 4, 6-collidine and 710 gm of silver triflate were added into the reaction. The reaction mass was stirred for 1 hr in the dark at −10° C. to −20° C. then diluted with 4.67 L of MDC and filtered through a Celite® filter bed and washed with MDC. The clear filtrate was washed with 10% KHSO 4 solution then process water, dried over sodium sulfate, and after evaporation, the residue was purified in a silica column using the following gradient profiles: 20:80 to 50:50 (EtOAc/hexane). The pure fractions were pooled and evaporated to give 250 gm of pentasaccharide (XLVIII).
[0097] The impure fractions were pooled and evaporated. The residue was purified in a silica column using the following gradient profiles: 20:80 to 50:50 (EtOAc/hexane). The pure fractions were pooled and evaporated to give pentasaccharide (XLVIII).
[0098] NMR spectrum confirmed the expected structure.
Preparation of Deacetylated Pentasaccharide (XLIX)
[0099] 1.06 L of MDC and 245 gm pentasaccharide (XLVIII) were charged in a 12 L RBF at RT, then 3.67 L methanol and 1.07 L of water were added and the reaction mass was stirred for 15-30 minutes at RT. Then a solution of NaOH (564 gm in 2.75 L water) was charged into it at RT and the reaction mass was stirred at RT for 2 hrs. The reaction mass was then diluted with 3.22 L of MDC and 3.22 L of water. Then the pH was adjusted with dilute HCl solution, the organic layer separated and the aqueous layer was extracted with 4.9 L of MDC and washed with brine solution, dried over sodium sulfate, and after evaporation, the residue was purified with IPA/EtoAc/hexane, acetone/water and methanol/water yielding 220 gm of deacetylated pentasaccharide (XLIX)
Preparation of O-sulfonated Pentasaccharide (L)
[0100] 3.7 L of DMF, 370 gm of deacetylated pentasaccharide (XLIX), and 418 gm of SO 3 -TMA complex were charged in a 12 L RBF at RT. The temperature of the reaction mass was raised to 50° C.-55° C. and the reaction mass was stirred at 50° C.-55° C. for 12 hrs. The reaction mass was cooled down to 20° C.-30° C. then diluted with 1.85 L of methanol and layered on top of a column packed with Sephadex® LH-20 resin in methanol:MDC (1:1). The column was run with the same solvent system and required product fractions were collected. After evaporation, the residue was purified in a silica column using the following gradient profiles: 0:100 to 100:0 (methanol/MDC). The pure fractions were pooled and evaporated and the residue was again dissolved in 1.22 L of methanol and pH adjusted to 8-10 with dilute NaOH solution. After evaporation the yield was 300 gm of O-sulfonated pentasaccharide (L).
[0101] 370 ml of DMF, 37 gm of deacetylated pentasaccharide (XLIX), and 41.8 gm of SO 3 -TMA complex were charged in a 2 L RBF at RT. The temperature of the reaction mass was raised to 50° C.-55° C. The reaction mass was stirred at 50° C.-55° C. for 12 hrs. The solvent was distilled off completely to get residue then residue dissolved in 200 ml of methanol:MDC (1:1) and layered on top of a column packed with Sephadex® LH-20 resin in methanol:MDC (1:1). The column was run with the same solvent system and the required product fractions collected, and after evaporation, the residue was purified in a silica column using the following gradient profiles: 0:100 to 100:0 (methanol/MDC). The pure fractions were pooled and evaporated and the residue was again dissolved in 120 ml of methanol and pH adjusted to 8-10 with dilute NaOH solution. After evaporation, the yield was 40 gm of O-sulfonated pentasaccharide (L).
Preparation of Deprotected Pentasaccharide (LI)
[0102] (a) 760 ml of water, 2.44 L of methanol, 300 gm O-sulfonated pentasaccharide (L) and 225 gm 10% Pd—C were charged in an autoclave at RT, then hydrogen gas pressure was applied up to 20-60 psi and stirred for 24-72 hrs at RT. The catalyst was then removed by filtration and the clear filtrate was distilled off completely. The residue was dissolved in 760 ml of water and 2.44 L of methanol, then 225 gm fresh 10% Pd—C was added in the autoclave at RT and hydrogen gas pressure then applied up to 20-60 psi and stirred for 24-72 hrs at RT. The catalyst was then removed by filtration and the clear filtrate was distilled off completely. The residue was dissolved in 760 ml of water and 2.44 L of methanol, then 225 gm fresh 10% Pd—C was added in the autoclave at RT and hydrogen gas pressure was applies up to 20-60 psi and stirred for 24-72 hrs at RT. The catalyst was then removed by filtration and the clear filtrate was distilled off completely, yielding 145 gm of deprotected pentasaccharide (LI)
[0103] (b) A solution of O-sulfonated pentasaccharide (L) in methanol-water (4:0.5 ml) was hydrogenated in the presence of 10% Pt-C (40 mg) for 5 days. UV spectroscopy was used to indicate whether the reaction was complete, the reaction product was then filtered and concentrated. Subsequent methanol purification gave deprotected pentasaccharide (LI).
Preparation of Fondaparinux sodium (LIII)—N-sulfonation of Deprotected Pentasaccharide (LI) methyl O-2-deoxy-3,6-di-O-sulfo-2-(sulfoamino)-α-D-glucopyranosyl-(1→4)-O-2-O-sulfo-α-L-idopyranurosyl-(1→4)-2-deoxy-6-O-sulfo-2-(sulfoamino)-α-D-glucopyranoside,decasodium salt
[0104] A solution of deprotected pentasaccharide (LI) (145 gm) in water (2.54 V) was adjusted to a pH of 9.5-10.5 with 1 N NaOH solution. SO3-pyridine complex (156 gm) was added into 3 lots every 15 min, the pH being maintained at 9.5-10.5 by automatic addition of 1 N NaOH. The mixture was stirred for 2 hrs at RT, during this aqueous NaOH (1N solution) was added to maintain pH at 9.5-10.5. After neutralization to pH 7-7.5 by addition of HCl solution, the mixture was evaporated using vacuum. The residue was dissolved in water (1.6 L) at RT, to this solution was added acetone (1.6 L) at RT. The reaction mass was cooled to 5° C.-10° C. and stirred for 1 hr. The solid was filtered and washed with cold acetone:water (1:1). The clear filtrate was distilled off completely under vacuum below 55° C. The residue was dissolved in water (1.6 L) at RT, and to this solution was added acetone(1.6 L) at RT. The mixture was cooled to 5 to 10° C. and stirred for 1 hr. The solid was filtered and washed with cold acetone/water (1:1). The clear filtrate was distilled off completely under vacuum below 55° C. The residue was dissolved in water (0.7 L) and charcoal (40 gm) was added at RT. The mixture was stirred for 30 min at RT then filtered. To the filtrate was added charcoal (40 gm) at RT. The mixture was stirred for 30 min at RT then filtered. To the filtrate was added charcoal (40 gm) at RT. The mixture was stirred for 30 min at RT then filtered. The pH of the clear filtrate was adjusted to 8.0-8.5 with 1N NaOH solution and distilled off completely under vacuum below 55° C. The residue was dissolved in 0.5 M NaCl solution and layered onto a column of Dowex® 1×2-400 resins using a gradient of NaCl solution (0.5 to 10M). The product fractions were combined and distilled off under vacuum below 55° C. up to 1-2 L volume. The solid was filtered off and the clear filtrate was distilled off under vacuum below 55° C. up to slurry stage and subjected to azeotropic distillation with methanol two times. The solid residue was stirred with methanol (2.13 L) at RT for 1 hr and the solid was filtered off and washed with methanol. The wet solid was again stirred with methanol (2.13 L) at RT for 1 hr and the solid was filtered off and washed with methanol. The wet solid was again stirred with methanol (2.13 L) at RT for 1 hr and the solid was filtered off and washed with methanol. The above solid was dissolved in water and the pH adjusted to 4-4.5 with 1N HCl solution and charcolized three times with 26 gm of charcoal at RT for 15-30 minutes and filtered off To the clear filtrate was added 0.39 kg of NaCl, then methanol was added (35 volume) at RT and the mixture was stirred for 15-30 minutes. The solution was decanted and the sticky mass was stirred with methanol (0.65 L) at RT for 15-30 minutes. The solid was filtered off and dissolved in water, and the pH adjusted to 8-8.5 with 1N NaOH solution. The solution was filtered through 0.45 micron paper & distilled off completely under vacuum below 55° C. The solution was subjected to azeotropic distillation with methanol to give highly pure fondaparinux sodium (97.17 gm) (HPLC purity 99.7%).
[0105] SOR Results
[0106] Three batches of product made in accordance with the present processes provided the following stereoisomeric optical rotation results:
[0107] Specification: Between +50.0° and +60.0°.
[0108] Batch-1=+55.1°
[0109] Batch-2=+55.7°
[0110] Batch-3=+55.4°.
[0111] While the preferred embodiments have been described and illustrated it will be understood that changes in details and obvious undisclosed variations might be made without departing from the spirit and principle of the invention and therefore the scope of the invention is not to be construed as limited to the preferred embodiment.
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Processes are disclosed for the synthesis of the Factor Xa anticoagulant fondaparinux and related compounds. Protected pentasaccharide intermediates and efficient and scalable processes for the industrial scale production of fondaparinux sodium by conversion of the protected pentasaccharide intermediates via a sequence of deprotection and sulfonation reactions are provided.
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FIELD OF THE INVENTION
[0001] The present invention relates to systems and methods of installing, configuring, and controlling various HVAC systems used to condition structures through the use of a building automation and control system. Specifically, the mapping or association of variable air-volume control elements located throughout a structure to any associated sources of conditioned airflow.
BACKGROUND OF THE INVENTION
[0002] Building automation systems (BAS) are used to coordinate, manage, and automate control of diverse environmental, physical, and electrical building subsystems, particularly HVAC and climate control but also including security, lighting, power, and the like. One example of a building automation system and architecture that provides an intelligent control system via a dynamically extensible and automatically configurable architecture is disclosed in U.S. Publication No. 2007/0055760, of common assignee with the present application.
[0003] One common element in many BAS installations are variable air-volume (VAV) elements that typically include one or more air sources and air distribution boxes, also known as VAV boxes, that are used to supply only as much conditioned air to a space as is necessary to maintain the desired environmental conditions in that space. A large building or campus can contain multiple air sources that deliver air to multiple VAV boxes that in turn control the air flow to individual spaces in a given building. For many reasons, one of which being the simple variance in size or volume of each space to be conditioned, it is necessary to configure or balance the amount of air each VAV box provides to an assigned space. Balancing the system to provide the appropriate amount of airflow can help to improve the efficiency of the building's environmental controls as well as maintain the comfort of any occupants of the space. While balancing a VAV system with a single air source and a few associated VAV boxes is relatively straightforward, the complexity of the task increases substantially when multiple air sources are tied to multiple VAV boxes in a large system. Even though the relationship between each individual VAV box and its corresponding air source in a multi-air-source building may be clearly depicted in a building's design documents, transferring those relationships into a digital BAS environment requires laborious programming or data entry that is subject to human error as well as discrepancies that may exist between the design documents and the actual building configuration and wiring.
[0004] A variety of techniques exist for balancing VAV boxes and air sources. Examples include those described in U.S. Pat. Nos. 5,251,815 and 5,341,988, each having a common assignee with the present application. Another discussion of a variable air-volume balancing system is disclosed in U.S. Pat. No. 5,605,280 to Hartman. However, even with these techniques, fully configuring a large system is still generally a labor-intensive task that varies with each system implementation, and requires the manual programming or association of VAV boxes to each air source. In the case of multiple air sources that supply multiple VAV boxes in a multi-space building the associated relationships can become even more complex and require additional efforts to achieve the proper balance in the system. Upgrading, expanding, and updating or removing VAV system components are also complex tasks, as the existing BAS must be reconfigured and rebalanced to recognize and incorporate any changes.
[0005] Accordingly, a need remains for an intelligent BAS having the capability to automatically map and associate the various VAV boxes located in a structure with multiple air sources providing conditioned air to that structure.
SUMMARY OF THE INVENTION
[0006] The present invention substantially addresses the above-identified needs by providing a system and method that integrates multiple air sources, or VAV boxes, their associated controls and environmental sensors with a BAS controller that can determine an association of VAV boxes with one or more individual air sources. This association can facilitate the automatic balancing of the airflow each VAV box provides to an installed space that can also have an association with one or more VAV boxes in another embodiment.
[0007] When a single air source feeds multiple VAV boxes the system can be represented in a one-to-many association or relationship. Multiple air sources can also be routed through a common set of ducts resulting in a system with a many-to-many relationship between air sources and VAV boxes.
[0008] An embodiment of the invention includes systems and methods for determining the airflow relationship between one or more air sources and a plurality of VAV boxes connected to a BAS controller. The BAS determines the associations by operating the BAS system in a range of configurations that can include utilizing individual air sources across a range of airflow settings and cycling each of the VAV boxes, such that a determination can be made either by monitoring a sensor associated with the VAV box, a duct pressure sensor, or an environmental monitor or sensor positioned in a space supplied by air that passes through one or more VAV boxes. The BAS controller is communicatively coupled to each of the air sources, VAV boxes, and any monitors or sensors allowing changes recorded by the sensors to be correlated to the actuation of an individual air box or the increase or decrease in the speed or flow rate of one or more air sources. The correlation between sensor changes and component actuation provides the BAS controller with evidence of the relationship between the various components allowing a determination of what elements should be associated with each other.
[0009] For example, instead of a field technician manually programming and associating each VAV box with the air source providing it with conditioned air, a BAS controller such as the TRACER SC controller, which is available from Trane International Inc., manipulates the fan speed of the air source and the position of the damper in the VAV boxes while monitoring the pressure in the ducts and the airflow through those VAV boxes. When any particular air source starts or changes, associated duct pressure sensors and VAV airflow sensors will register a change. Similarly, when the air source is held to a constant speed, opening and closing individual VAV dampers will be detected by variations in the duct pressure for that duct system. By interactively repeating these processes for all air sources in a HVAC system each air source can be associated with the VAV boxes in its duct system.
[0010] The above summary of the invention is not intended to describe each illustrated embodiment or every implementation of the present invention. The figures and the detailed description that follow more particularly exemplify these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The embodiments of the present invention may be more completely understood in consideration of the following detailed description of various embodiments in connection with the accompanying drawings, in which:
[0012] FIG. 1 is a schematic depiction of a system with a single air source and multiple VAV boxes.
[0013] FIG. 2 is a schematic depiction of a second system with a single air source and multiple VAV boxes.
[0014] FIG. 3 is a schematic depiction of a system with multiple VAV boxes associated with a single space.
[0015] FIG. 4 is a schematic depiction of a system with multiple air sources.
[0016] FIG. 5 is a flow diagram of an exemplary embodiment of VAV box association.
[0017] FIG. 6 is a flow diagram of an exemplary embodiment of VAV box correlation.
[0018] While the present invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the present invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The systems and methods of the invention can be utilized in a local or widely distributed building automation system (BAS), from a space or building level to an enterprise level, encompassing virtually any structure, cluster, campus, and area in between. The systems and methods are particularly suited for a dynamically extensible and automatically configurable BAS and architecture, such as those disclosed in U.S. patent application Ser. No. 11/208,773, filed Aug. 22, 2005, entitled “Dynamically Extensible and Automatically Configurable Building Automation System and Architecture”; U.S. patent application Ser. No. 11/316,687, filed Dec. 22, 2005, entitled “Building Automation System Facilitating User Customization”; U.S. patent application Ser. No. 11/316,699, filed Dec. 22, 2005, entitled “Building Automation System Facilitating User Customization”; U.S. patent application Ser. No. 11/316,702, filed Dec. 22, 2005, entitled “Building Automation System Facilitating User Customization”; U.S. patent application Ser. No. 11/316,695, filed Dec. 22, 2005, entitled “Building Automation System Data Management”; U.S. patent application Ser. No. 11/316,697, filed Dec. 22, 2005, entitled “Building Automation System Data Management”; U.S. patent application Ser. No. 11/316,698, filed Dec. 22, 2005, entitled “Building Automation System Data Management”; U.S. patent application Ser. No. 11/316,703, filed Dec. 22, 2005, entitled “Building Automation System Data Management”; and U.S. patent application Ser. No. 11/316,410, filed Dec. 22, 2005, entitled “Dynamically Extensible and Automatically Configurable Building Automation System and Architecture,” all of which are assigned to the assignee of the claimed inventions, and are herein incorporated by reference.
[0020] A typical structure equipped with a BAS configured to control a single air source 10 supplying conditioned air to multiple VAV boxes 12 though a duct 14 is depicted in FIG. 1 . A VAV box 12 can include one or more dampers 16 to regulated the flow of air from a duct 14 or conduit into an associated space 18 through a diffuser 20 . Dampers 16 can be actuated by a control mechanism 22 associated with each VAV box 12 in response to changes detected by one or more sensors 24 located either in or near the VAV box 12 itself such as air flow rates, duct pressure monitors, or to environmental monitors 26 such as thermometers, thermostats, humidity sensors or other devices located in the space 18 being supplied with conditioned air through the VAV box 12 .
[0021] An exemplary control mechanism 22 for a VAV box can include a circuit configured to drive a solenoid capable of either fully opening or closing a damper 16 located in the VAV box 12 depending on the presence or absence of an electrical signal. Alternatively, the control mechanism 22 can include a more advanced programmable logic controller (PLC) capable of communicating through a network or dedicated communication link with the BAS controller 30 . The control mechanism 22 can preferably adjust the position of the damper 16 with a stepper motor, or other appropriate actuator, to any of a plurality of positions between fully closed and fully open in response to commands from the BAS controller 30 . Alternatively, the control mechanism 22 can adjust the damper 16 based on a comparison of measurements provided by one or more sensors 24 , coupled to the control mechanism 22 , and reference values provided to the control mechanism by the BAS controller 30 .
[0022] The various sensors 24 and monitors 26 , as well as the control mechanisms 22 , can be connected to a central BAS controller 30 in a variety of ways, including wired or wireless networks 32 employing one or more networking protocols. FIG. 1 depicts a structure employing a combination of both wired and wireless components. First space 34 includes a wired sensor 24 located proximate to the VAV box 12 . Second space 36 includes both a wired sensor 24 proximate to the VAV box and a wireless environmental monitor 26 installed in the second space 36 . Third space 38 include a wireless environmental monitor 26 but is not equipped with a VAV box sensor. The wired sensor 24 that is located internally to VAV box 12 that can be configured as being responsible for monitoring space 34 . Second space 36 and third space 38 present illustrations where the wireless environmental monitors 26 can also monitor an individual space either alone or in conjunction with a wired sensor 24 .
[0023] In second space 36 , the only relationship between the VAV box 23 and the environmental sensor 26 is their physical association with the second space 36 . While it may be intuitive to the human eye that these two elements are related when viewed in FIG. 1 , the relationship is not immediately clear to a central BAS controller 30 that is only able to view the VAV box 12 and the environmental sensor 26 as simply two of a potentially very large number of discrete components connected to the system. In a system with only a single air source 10 and air-source controller 40 , the association between the air-source 10 and each of the VAV boxes 12 is straightforward as only a single air source can be associated with each of the VAV boxes 12 . As discussed below this relationship becomes more complex when multiple air sources and their associated controllers are coupled to a BAS controller 30 .
[0024] One embodiment of the invention can enable a BAS controller 30 to automatically determine the relationship between a VAV box 12 and any appropriate environmental monitors 26 located in the space served by the VAV box 12 . This feature can greatly reduce the amount of effort required to configure and balance BAS installations as it helps to reduce or eliminate the amount of space descriptive data that must be manually entered into the system as well as potentially overcoming errors introduced during the construction or HVAC installation process such as mislabeled or improperly configured wiring between components.
[0025] FIG. 2 depicts a space configuration 50 where a single air source 52 supplies conditioned air to multiple VAV boxes ( 52 54 56 58 ). Each individual VAV box in turn supplies a single space ( 60 62 64 66 ). Because there is only a single air source 52 the relationship between each of VAV boxes and the air source 52 is clear. Balancing of each VAV boxes can then be performed to configure the setting for each space. The automatic association of an individual VAV box 54 to a specific space is possible when a space 60 is equipped with environmental monitor 26 and the location of that monitor 26 is provided to the BAS controller 30 that is in wireless communication with the monitor 26 . It is understood that other network or communication links between the BAS controller 30 and the other components of the system can be included, however they are not shown here for clarity. During the balancing process, either immediately upon installation or at a later time, the BAS controller 30 can be configured to observe the changing condition of the space 60 based on data provided by environmental monitor 26 and correlate those changes to any adjustment in the amount of conditioned air based on the settings of the air supply 52 and VAV box 54 that would have a high likelihood of affecting the monitored condition in the space 60 .
[0026] FIG. 3 presents a space configuration 70 where three separate VAV boxes ( 72 74 76 ) are associated with individual spaces ( 78 80 82 ) respectively and at least two VAV boxes ( 84 86 ) are providing conditioned air to a single space 88 . In this example, an embodiment of the invention can determine that two VAV boxes ( 84 86 ) are supplying a single space 88 based on a variety of conditions. The first possibility as discussed above would be the presence of an environmental sensor such as a digital thermometer in the space 88 that would provide temperature feedback to the BAS continuously or at periodic intervals. For example, if the BAS first correlates the first VAV box 84 with the space 88 by supplying a maximum amount of cool air into the space 88 and observing a drop in temperature as reported by the digital thermometer, and then detects that when the second VAV box 86 is also actuated from a closed to an open position the temperature in the space 88 drops further, or at a faster rate over an appropriate period of time. In this example the BAS controller can recognize each VAV box as having a “soft” association with the space and neither VAV box individually has a “hard” association that clearly indicates a one-to-one relationship between the VAV box settings and the conditions of the space. The BAS controller can recognize that further automated tests may be necessary to ascertain the full relationship between the VAV boxes ( 84 86 ) and the space 88 in order to rule out any external factors that could be causing the change in temperature in the space 88 . The further tests could include similar testing over a longer period of time or alternating the various configurations of the two VAV boxes ( 84 86 ) and confirming that the changes to the environmental condition of the space 88 match or correlate to what the BAS is programmed to expect to happen based on the changes in VAV box or air source 52 settings.
[0027] Alternatively, the BAS system can monitor the airflow and duct pressure associated with the VAV boxes ( 84 86 ). A space 88 that is supplied with conditioned air from multiple VAV boxes can produce different feedback characteristics in air pressure and flow rates than a similar space that is only supplied by a single VAV box. For example, if the two VAV boxes ( 84 86 ) are initially configured in the fully-closed position, pressure and flow measurements are acquired by sensors located in the VAV boxes or nearby ducts by the BAS, and then a single first VAV box 84 is transitioned to the half-open position, and the pressure and flow measurements are reacquired a baseline condition is established. If the first VAV box 84 is transitioned back to the fully-closed position and the second VAV box 86 is transitioned to the half-open position, and the pressure and flow measurements are reacquired a second baseline condition is established. If these two baseline conditions are nearly identical it can indicate to the BAS controller that either the two VAV boxes are supplying nearly identical spaces, or that the two VAV boxes could be supplying conditioned air to the same space. This question can be resolved by transitioning both VAV boxes ( 84 86 ) into the half-open position where the initial baselines were established and reacquiring the pressure and flow measurements. Absent other external factors, these reacquired measurements will vary from the original baseline measurements due to the doubling of the amount of conditioned air supplied to the space when both VAV boxes ( 84 86 ) are opened, indicating a high likelihood that both VAV boxes ( 84 86 ) are associated with the same individual space 88 .
[0028] The association of two VAV boxes ( 84 86 ) with a single space 88 can also be determined or verified in conjunction with the above procedure by correlating a change in flow rate or duct pressure measured at a first VAV box 84 in the open position when a second VAV box 86 is transitioned to the open position. While these measurements can change even if two VAV boxes with a common air source 52 are supplying conditioned air to two separate spaces one skilled in the appropriate art will appreciate that the changes in these measurements will vary based on whether or not the two VAV boxes are associated with the same or with different spaces. The observation of these two distinct data measurement profiles can provide a further indication to a BAS controller what actual relationship exists between the various VAV system components.
[0029] FIG. 4 depicts a configuration where multiple spaces 18 , VAV boxes 12 , and air sources ( 100 102 ) are present. In this example embodiment a first air source 100 and a second air source 102 supply air through a duct system 104 to a plurality of VAV boxes 12 . Each VAV box 12 is associated with an individual space 18 . Unlike the examples above, the presence of more than one air source creates an additional variable for the BAS controller to correlate. The BAS controller can utilize the feedback techniques from any environmental monitors 26 located in the individual spaces or any airflow or pressure sensors 24 associated with the VAV boxes 12 , in addition to any data available from the air source controller 40 such as fan speed, air pressure, flow rates, or other air handling capacity data to determine the relationship between the air sources ( 100 102 ) and the VAV boxes 12 . As with the earlier examples, the relationship may appear clear on paper to the human eye but the BAS controller can only determine whether it is connected to a system with two air sources that share a common duct path to multiple air VAV boxes as show in FIG. 4 , or a system with two separate air sources connected by separate ducts path to multiple air VAV boxes, by taking multiple measurements with the system configured in a variety of operating settings and correlating the results. In a single structure equipped as if both the systems of FIG. 2 and FIG. 3 were present with separate duct paths between two air sources and the VAV boxes, where all the components were coupled to a single BAS controller, the BAS controller can first operate one air source while the other is off and observe that only a subset of the sensors or monitors near each of the VAV boxes records the change due to the operation of the first air source. A similar test performed with the second air source can confirm the results obtained from the first air source and also highlight any VAV boxes that returned anomalous results after all air sources have been cycled.
[0030] Returning to FIG. 4 , in addition to being able to manipulate the position of the VAV box 12 damper positions a properly configured BAS can also manipulate the fan speed of any air sources ( 100 102 ) to which it is connected. By monitoring the airflow through each VAV box with sensors 24 , and the duct pressure in the ducts connecting each air source to one or more VAV boxes with pressure sensors 106 , the BAS controller can determine how each of the VAV boxes in a structure are physically connected to one or more air sources ( 100 102 ). This capability reduces the need for time consuming and error prone manual programming of the associations by field service technicians.
[0031] FIG. 5 depicts a flow diagram of an exemplary processes for associating multiple VAV boxes with one or more air sources by iterating through each air source and each VAV box damper position and monitoring the various sensors connected to the system. When the system has iterated through each of the possible air source and VAV box settings the results of the sensor reading changes are analyzed for correlations between individual sensors and specific air source and VAV box configurations. In the case where the opening of a single VAV box damper correlates directly with sensor changes in the VAV box, or a monitor located in a space with a hard association to the VAV box, and this change was only detected when a single air source was active the system can definitively associate the VAV box with the single active air source.
[0032] FIG. 6 depicts a flow diagram of an exemplary processes for correlating individual VAV boxes with one or more air sources. In the case where only a single air source is present in the system all VAV boxes whose activation corresponded to a change in sensor readings are associated with the air source. Any VAV boxes that did not correlate to a change in sensor readings are flagged for further testing, manual association, or inspection for possible equipment malfunction. When there are multiple air-sources present in the system, a soft association is made between any VAV box whose activation corresponded with a change in a sensor reading and the active air source at the time the VAV box was activated. Once the soft-associations are made a check can be performed to determine if any VAV boxes are only associated with a single air source. A hard-association can be then assigned to any VAV boxes that have only a single air source association. In the case of a VAV box having soft-associations with multiple air sources further testing can optionally be conducted to confirm the configuration.
[0033] It will be appreciated by those skilled in the art that the above examples can also be practiced on a new unoccupied building or structure, as well as an existing installation that may be occupied and where a minimum amount of airflow must be maintained to each space served by each individual VAV box. In the situation where an installation is occupied an embodiment of the invention can be adapted to only conduct testing to determine air source and VAV box associations during off-peak hours, or by constraining the VAV box and air source settings to ranges that will produce sensor detectable condition variances without subjecting the occupants of a space to an unacceptable environment.
[0034] The foregoing descriptions present numerous specific details that provide a thorough understanding of various embodiments of the invention. It will be apparent to one skilled in the art that various embodiments, having been disclosed herein, may be practiced without some or all of these specific details. In other instances, known components have not been described in detail in order to avoid unnecessarily obscuring the present invention. It is to be understood that even though numerous characteristics and advantages of various embodiments are set forth in the foregoing description, together with details of the structure and function of various embodiments, this disclosure is illustrative only. Other embodiments may be constructed that nevertheless employ the principles and spirit of the present invention. Accordingly, this application is intended to cover any adaptations or variations of the invention. It is manifestly intended that this invention be limited only by the following claims and equivalents thereof.
[0035] For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of Section 112, sixth paragraph of 35 U.S.C. are not to be invoked with respect to a given claim unless the specific terms “means for” or “step for” are recited in that claim.
[0036] All of the patents and patent applications disclosed herein, including those set forth in the Background of the Invention, are hereby incorporated by reference. Any incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of non-priority documents above is further limited such that no claims included in the documents are incorporated by reference herein and any definitions provided in the documents are not incorporated by reference herein unless expressly included herein.
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A system and method including the ability of a building automation system controller to automatically determine which VAV boxes are physically associated with which air sources in a building or facility with multiple air sources by coordinating the individual or simultaneous manipulation of the fan speed of the air sources or the VAV damper positions, while obtaining data from networked sensors that measure VAV box airflow or duct pressure or the environmental conditions of a space being supplied with air from one or more VAV boxes.
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FIELD OF THE INVENTION
The invention relates to a textile winding machine and more particularly to a transport system for recirculating tube support members in a textile winding machine.
BACKGROUND OF THE INVENTION
In automatic textile winders operating in conjunction with automatic spinning machines, it is important to be able to automatically monitor the condition of the bobbin tubes as they are recirculated to determine defects in the performance of the machine and identify the particular station at which defects occur.
German Patent Disclosure DE 39 11 799 A1 discloses a transport system for bobbin tube support members in a textile winder, the tube support members having posts for transporting bobbins on tubes. These tube support members each have an information transfer means incorporating data pertaining to the bobbins or bobbin tubes. This may, for instance, involve data providing information identifying which station of a spinning machine has produced a given bobbin. In this way, it can be determined which spinning station is malfunctioning, e.g., is producing bobbins with deficiencies in quality. This same prior disclosure also describes furnishing the information on the yarn batch.
This prior disclosure, however, cannot remove tube transport support members carrying defective bobbins and therefore requires human intervention to remove bobbins to prevent system malfunction. If a bobbin cannot be prepared with the automatic preparing means of the machine, or in other words if the yarn end cannot be pre-placed properly to be engaged by yarn receiving devices at a textile winding station, then such a bobbin may recirculate continuously on its tube support member in the closed transport system. Particularly when a batch is being processed in which this defect occurs multiple times, such constantly recirculating defective bobbins unnecessarily reduce the capacity of the winder and thus lower the output of the textile winder. A textile winding machine which provides for the removal of defective bobbins without human intervention is, therefore, desired.
SUMMARY OF THE INVENTION
The object of the invention is to enable improved monitoring of the transport units in closed transport systems of textile winders.
This and other objects of the present invention are accomplished by a textile winding machine having a transport system for recirculating bobbin tube support members carrying empty bobbins, and diverting tube support members carrying partially unwound bobbins, and tubes having remnant windings of yarn thereon into diverting paths. Each bobbin has an information transfer device carried thereon which contains data pertaining to the bobbin tube on which it is carried, wherein at least one reading device is present in the transport system for reading the information transfer device. The transport system comprises a storage path for storing tube support members carrying bobbin tubes; means for diverting tube support members to the bobbin storage path; and a control unit connected to the reading device for controlling the diverting device to divert tube support members carrying bobbins which tube support members or bobbins carried thereon are determined by said control unit in conjunction with the reading device to the storage path to have predetermined storage path conditions.
The transport system may also include a delivery path for delivering tube support members to the winding stations of the winding machines and a return path for returning tube support members from the winding stations, an ancillary transport path extending between said return path and the delivery path for transport of tube support members therebetween. The control device may have a counting device for ascertaining multiple returns of the same tube support member. The counting device has a limit switch that is adjustable to a predetermined number of the multiple returns.
The information transfer device may comprise a memory chip and a memory means coupled contactlessly to the chip by an associated antenna and may further comprise a counting device coupled to the memory device for writing bobbin data on the associated tube support member. The counting device may be disposed in an area for transferring bobbins to tube support members.
The control unit may actuate the control of the diverting device in response to the inability to detect data of an information transfer device.
The textile winding machine of the present invention may further comprise winding sections of the winder for processing different batches of bobbins having yarn weights differing from one another; at least one electronic yarn clearer, coupled to at least one winding station computer in the vicinity of the winding station having adjustable tolerance ranges for the correct yarn weight for a given batch; a threshold value switch on each of the at least one winding station computers that can be activated if a tolerance is exceeded and which causes the immediate stoppage of the winding station; and a writing device in each winding station for recording as an abnormality in the information transfer device of the bobbin the exceeding of the tolerance range by the yarn weight of the bobbin.
The at least one winding station computer may be connected to a memory containing the tolerance ranges of the other batches prepared on the textile winder, in the form of data in memory for transmission to the writing device for writing the appropriate batch into the information transfer device of the tube support member; and wherein the writing device is a read/write memory device for monitoring the storage in memory of the batch data and to record any inability to accomplish the writing.
The textile winder may be subdivided into winding sections for processing different batches with yarn weights differing from one another and may further comprise branch paths branching from a common delivery path to the winding stations; at least one diverter located in the vicinity of the beginning of the branch paths and each diverter being coupled to one second reading device for delivering the bobbins in correct batches; and a bypass path branching from the delivery path for transporting tube support members having information transfer device which are not legible by second reading device.
The textile winding machine of the present invention may further comprise a third reading device coupled to a display device, said third reading device being disposed at said storage path for determining the type of defect of the tube support members or bobbins in the storage path.
The invention will be described below in further detail in terms of an exemplary embodiment, in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
The single FIGURE is a schematic view of the transport system of the textile winder of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The transport system of the preferred embodiment of the present invention recirculates tube support members 6 to, through, and from winding stations 18 of a textile winder 2. Two transfer loops 48,48' connect the transport system to two spinning machines (not shown). From the spinning machines, bobbins 3 are delivered on bobbin tube support members 5 to respective exchange paths 29,29'. Along these exchange paths 29,29', which are common to the transfer loops 48,48', tube support members 5 of the spinning machines are transported in association with tube support members 6 of the winder with the bobbins 3 on tubes 4 being transferred therealong from the tube support members 5 of the spinning machine to the tube support members 6 of the winder, and empty tubes 4 being transferred from the tube support members 6 of the winder to tube support members 5 of the spinning machine. At the end of the exchange paths 29,29', the tube support members 5 of both spinning machine circuits with the empty tubes 4 return to the respective ring spinning machines for winding of yarn thereon at the spinning stations.
The tube support members 6 of the winder circuit, carrying empty tubes 4, travel along the transfer loops 48,48' to and through the respective exchange paths 29,29', at which the empty tubes are exchanged for tubes with full bobbins thereon, which are then conveyed to the main transport system. Since such exchange operation is conventional and has been described with all the equipment necessary to perform the exchange in, for example, German Patent Application DE 40 34 824 A1, no detailed description is necessary.
Diverters 50,50' are disposed at the entrances of the transfer loops 48, 48' and can be actuated by upstream reading devices 49, 49'. These reading devices 49, 49' make it possible to identify the batch of the arriving tube support member 6 at a given time, and by the coupled diverters 50, 50', they effect the diverting of tubes to the ring spinning machine that is producing the batch with which the tube has been associated. Batches of bobbins may differ by such parameters as yarn weight.
Downstream of the exchange paths 29,29', counting devices 28, 28' are provided, which have sensors (not shown) that ascertain the passage therepast of bobbins 3 on tube support members 6 and increment the counting devices 28, 28'. Since the bobbins 3 move past the sensors of the counting devices in the same order as that in which they were doffed from the spinning stations of the spinning machines, the result of counting matches the appropriate spinning station of the spinning machine. Naturally, once the bobbins 3 have all been transferred to the winder 2, it is necessary to reset the applicable counting device to zero, so that then after the doffing, the match between the counting result and the number of the spinning station will be assured, beginning again at 1. The counting devices 28,28' are coupled to writing devices 27,27', which write the counting result, corresponding to the number of the spinning stations, on the associated tube support member 6. At the same time, the writing devices are intended to erase the information on the respective tube support member that refers to the bobbin 3 transported on it previously. Accordingly, the tube support member 6 leaves the corresponding writing station carrying only the information of the number of the spinning station that produced the bobbin 3 newly placed on it, and the batch identification.
The further transport of the tube support members 6 with full bobbins 3 takes place over a delivery path 7 and diverging paths 8,9 to a distribution path 16. Controlled diverters 14 and 15 are disposed at the beginning of the diverging paths 8,9 and assure that the tube support members 6 with bobbins 3 will be distributed with the appropriate batches to the two diverging paths 8,9. Upstream of the diverters 14,15, there are reading devices 22,23, which read the batch identification on the information carrier of the particular tube support members being moved past them and position the adjacent diverter accordingly. The delivery path 7 extending onward beyond the divergence of the diverging path 9 then merges with a bypass path 10, which feeds into the beginning of a tube return path 11. This bypass path 10 is intended to prevent tube support members 6 that cannot be associated with a batch by either the reading device 22 or the reading device 23 from being delivered to any winding section. Those tube support members 6 then later reach a reading means 24 such as a read-only (ROM) or read/write memory at the end of the tube return path 11, which detects the nonlegibility of the batch identification and diverts them to a bobbin storage path 31.
Bobbin preparation units 12,13 are disposed at the diverging paths 8,9. Once again, this type of an assembly is conventional. It is long known for bobbins to be prepared in several stages by units connected one after another (see, for example, German Patent Disclosure DE 39 19 526 A1).
The distribution path 16 adjoining the diverging paths 8,9 has a conveyor belt driven reciprocally for delivery of tube support members 6 with the bobbins 3 to the various winding stations 2 in such a way that supply positions of crosswise transport paths 17 are refilled constantly. This distribution principle is known and described in German Patent Disclosure DE 38 43 554 A1, for example.
In the case of subdivision into textile winding sections, in this case two sections, a barrier is disposed at the parting line between the two sections (this parting line is not shown here), along the distribution path 16. As a result of this barrier, the tube support members 6 which have been delivered to the winding section intended for them through the respective diverging paths 8,9 are retained in the appropriate section. This provision is known and likewise described in German Patent Disclosure DE 38 43 554 A1.
The crosswise transport paths 17 lead from the distribution path 16 through winding stations 18 to the aforementioned tube return path 11, which is common to all the winding stations. At this point, it should be noted that for the sake of simplicity, only individual tube support members 6 have been shown, while in actuality, there are normally two or three tube support members with bobbins 3 waiting along the crosswise transport paths 17 between the distribution path 16 and the winding positions 18.
Once the bobbins 3 have been unwound, the tube support members 6 with their tubes 4 leave the respective winding station 18 and are delivered along the return path 11 back to the associated transport transfer loop 48,48' for tube exchange along the exchange paths 29,29'.
A read/write type memory device 19 is disposed in each winding station. It reads the spinning station number written on the information transfer means of the applicable tube support members 6 by the writing device 27,27' and sends it to a computer 21 associated with the individual winding station. Appropriate line connections are merely suggested here, for the sake of simplicity. In each winding station, there is an electronic yarn clearer 20, which checks the yarn traveling through it to a cross-wound bobbin, not shown, which is conventional and therefore known to those of skill in the art. This electronic yarn clearer 20 may detect deviations in the thickness of the yarn as well as nips and slubs. However, it also may detect a deviation in the yarn weight from the standard for the batch to be processed, over a relatively long length of yarn. The evaluation over a relatively long length of yarn makes it possible to distinguish deviations caused by slubs or nips from defective settings or other defects at the spinning station from batch deviations. To enable making such a distinction, it is naturally necessary for the standard yarn weight for the batches to differ from one another to an extent sufficient for detection of the difference.
If the yarn weight deviation or batch deviation is detected, then the winding station at which the deviation is detected is stopped immediately, with the winding station computer 21 being programmed in such a way that a predetermined length of yarn is drawn from the bobbin, a bobbin change is made, and the end of the yarn from the newly delivered bobbin 3 is spliced to an end of the yarn from the bobbin, this end still originating from the bobbin that was rewound for the incorrectly delivered bobbin. In this way, even without human intervention, incorrect delivery can be overcome without sacrificing quality and without requiring intervention by the operator.
According to the invention, however, it is provided in this case that an identification in the information carrier of the appropriate tube support member 6 be provided by the read/write memory means present at the winding station. This identification is later recognized at the aforementioned reading device 24 at the end of the return path 11, which actuates delivery of this tube support member 6 with its bobbin 3 to the storage path 31.
Another feature, which still further limits the necessity of human intervention, comprises writing the correct batch into the information transfer means, which is done by the read/write memory device 19 at the individual winding station. Since in this case only two batches are being processed, then it suffices if the other batch is simply written in. As a result, the delivery to the correct batch can then be done afterward without action on the part of the operator. However, in order to assure that another delivery to the wrong batch will not occur in the event that the rewriting proved impossible, it may be provided that the modified, newly encoded batch identification be test-read as a check and, if unsuccessful rewriting is found, a defect signal is written into the information transfer means. This defect signal can then be detected again at the reading device 24 to effect transfer of the tube support member 6 to the storage path 31. If the rewriting is successful, naturally no defect signal is written into the information transfer means.
In the event that more than two batches are processed in the textile winder, then, if automatic rerouting to the appropriate batch is desired, the storage of the other batch data in memory in the winding station computers is also necessary. A comparison of the yarn weight ascertained by the yarn clearer with the stored data then readily shows the correct batch association, which can be written into the information transfer means of the tube support member 6 by the read/write device 19.
Ancillary transport paths are provided off the return path 11 upstream of the transfer loops 48,48' to which tube support members 6 that are not to be circulated directly to one of the transfer loops 48,48' are diverted. Such diverted tube support members are those carrying tubes which for some reason have not been completely unwound in the winding stations and have either a sufficient amount of yarn to be recirculated to the winding station (partially unwound bobbins) or have only a few remnant windings of yarn thereon and require stripping of the remnant windings before the tube should be transported to the transfer loops 48,48'. In this way, only completely empty tubes are recirculated to the spinning machines.
In order to make a decision for diverting the tube support members 6 at this point, a bobbin scanner 47 is provided, which is capable of distinguishing between empty tubes, tubes with sufficient yarn windings for recirculation and tubes with only remnant yarn thereon. This bobbin scanner 47 actuates diverters 43,46, with diverter 43 diverting tube support members 6 with sufficient yarn for recirculation to an ancillary transport path 39 having a yarn end preparation device 44 therein. This bobbin preparation device 44 is of a conventional type especially appropriate for finding yarn ends in yarn windings in the combination on the tubes being diverted to assure that the end of the yarn can be grasped in the winding station to initiate unwinding thereof. It must be assumed here that such bobbins are rejected at the winding stations only if the yarn end could not be engaged by the yarn guide devices at the winding station.
If the bobbin scanner 47 has detected a tube with remnant yarn thereon, the diverters 43,46 are actuated to transfer the tube support member to a branch path 40, along which a tube stripping device 41 is disposed. The tube support member 6, with the tube cleaned, then travels by a converging path 42 back onto the tube return path 11 upstream of the scanner 47, which now detects no remnant yarn and thereupon allows the tube support member with the now empty tube to be delivered to the appropriate transfer loop 48,48.
If the same spinning station number written on an information transfer means of a tube support member 6 has been detected to have yarn thereon repeatedly at relatively short time intervals by the reading device 24 that is connected by an information line 24' to a control unit 30, then this is assumed to be an indication that processing of the bobbin at a winding station is not possible, for whatever reasons. An appropriate limit value is therefore incorporated in the control unit 30 so that when this limit value is reached, a diverter 38 is activated by the control unit to divert the corresponding tube support member to the storage path 31.
The diverter 43 is also connected to the control unit 30, in order to actuate diversion of a tube support member 6 from the tube return path 11 if the reading device 24 has found a defect in the transfer means. This may for example be the case if the batch identification could not be found at one of the reading devices 22,23 and if the tube support member 6 has reached the tube return path 11 by the detour path 10. The reading device 24 then likewise ascertains the unfindable batch identification, as a result of which the diverters 43,46 are actuated by the control unit 30. This tube support member 6 accordingly is diverted to the storage path 31 as well.
The same is true for the information transfer means identified in the winding stations, if the delivery to the winding section was not done correctly for the particular batch.
The storage path 31 includes a first stopper 32, which may be actuated by the control unit 30 to reference tube support members. The control unit 30 communicates over a data line 30' with a computer terminal 26, which is typically used in automatic winding machines. This terminal also has a display 25. The storage path stopper 32 can also be administered from this terminal.
This opening of the stopper 32 can be limited in terms of time in such a way that only one tube support member 6 is let through and is then stopped at a second stopper 34 located downstream of the first stopper 32. A read/write memory device 33 is disposed in this position and may be connected to the information transfer means of the tube support member 6.
The information transfer means may be, as is known to those of skill in the art, an electrically readable, erasable and codable memory chip, which can come into contact with the read/write memory by a concentrically disposed antenna, regardless of the angular position of the tube support member. The memory chip may advantageously be interchangeably disposed in the tube support member, as described and shown for example in conjunction with the disposition of the antenna in German Patent Application DE 40 41 713 A1.
From the terminal 26, access to information by the read/write memory device 33 is accomplished, making it possible to conclude what is the cause of the diversion of this tube support member. For example, if no defect can be found in the information transfer means, the conclusion must unequivocally be that the diversion can be ascribed to an overly high number of circulations of the tube support member in the transport system without the yarn being completely removed. In that case, the human operator must look for the defect in the bobbin. However, it is also possible to call up the association from the control unit 30 which ascertained the exceeding of the limit value in terms of the number of recirculations. These limit values correspond to a certain memorized spinning station number and can be associated accordingly.
The other defects have to do with the memory chip, which should advantageously be replaced by a new one. In that case, the opening of the second stopper 34 is triggered from the terminal, causing the tube support member then to proceed to a terminal storage path 36. This terminal path should be formed in such a way that it is easy to remove the tube support members. This kind of out-transfer point is normally not provided in the rest of the transport system, because the tube support members constantly remain in the system. At that point, the introduction of a new tube support member or of the same tube support member with a replaced information transfer means can be performed.
A diverter 37, likewise actuatable via the terminal 26 and the control unit 30, is provided so that tube support members can be returned to normal circulation at a converging point 35 with the ancillary transport path 39 if out-transfer from the system is determined to be unnecessary. This tube support member then travels through the special preparation device 44 to the delivery path 7 at a converging point 45.
The possibility also exists, if the applicable electronic yarn clearer 20 in the winding station has detected considerable deficiencies of quality in the rewound yarn, of again writing information into the information transfer means of the tube support member 6 that is later defined as an abnormality and leads to the diversion of the tube support member, if a suitable yarn quantity is still contained on it. As a result, it is possible for this bobbin to be separated out, rather than being redelivered to a winding station and causing further quality deficiencies. Moreover, the corresponding spinning station can be detected, to enable intervention at that station by performing appropriate maintenance or repair.
The present invention assures that defective bobbins will be recognized and taken out of the loop without undue human intervention, to enable the performance of appropriate maintenance or removal. The present invention provides for removal of defective tube support members and bobbins by diverting them from the system. It is therefore possible by diverting these bobbins to overcome the deficiency by hand and return the transport unit to the transport system again. The multiple trips around the system can be recognized, for instance if the information transfer means of the tube support member carries the number of the spinning station that produced the bobbin being transported. This tube support member then repeatedly moves past the reading device at relatively short intervals. In normal operation, the reading device would not be able to ascertain the same spinning station number again until one complete doffing has taken place in the spinning machine, and a bobbin produced subsequently by the same spinning station has been unwound.
If the information carrier is not accommodated so that it is protected in a recess of the tube support member, it may become mechanically damaged, which can possibly make the stored data unreadable or may make it unusable. Such tube support member must be separated out, to prevent incorrect deliveries in multi-batch processing or incorrect information on the spinning station number. If an electronic memory chip is used as the information carrier, then the chip may optionally be replaced.
Although it will certainly be the exception if the batch information contained in the tube support member information carrier does not match the batch of the bobbin being transported, nevertheless the invention takes care of this case as well. If the yarn clearer in the winding station finds, over a certain yarn length, that the yarn weight is outside the set tolerance range or standard for the batch to be processed in that particular bobbin section, then the winding station must be stopped immediately. This can be accomplished via a threshold value switch on each winding station computer which can be activated if a tolerance is exceeded and which causes the immediate stoppage of the associated winding station. If it were not, a cross-wound package would be produced by the winding machine that includes deviant yarn for the length of yarn of one bobbin. Shutting off the winding station prevents this kind of major quality deficiency. By noting the deviation of the stored batch data in the information carrier from the data recognized by the yarn clearer, the transport unit is separated out in this case as well, so that the information carrier may be replaced if necessary.
Another embodiment, in which the yarn weight ascertained is compared with the yarn weight of the other batches stored in memory which may be associated with each winding station computer to be processed in the bobbin winder, makes it possible without human intervention to reprogram the information carrier by the writing means 19, and as a result the tube support member in the transport system can next be delivered to the appropriate winding section. Checking the newly written data means that another delivery to the wrong bobbin winding section can be prevented. The identification of the reprogramming that cannot be properly done for the applicable batch is likewise detected by the reading device at the point of divergence to the storage path. The inability to accomplish rewriting of the information may also be recorded. Hence this transport unit is likewise delivered to be repaired by the human operator.
By means of a further reading device disposed at the end of the storage path and coupled to the display device, the operator can directly detect the type of defect found. He can then take the appropriate steps required.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof.
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A textile winding machine having a transport system for recirculating bobbin tube support members carrying empty bobbins, and diverting tube support members carrying partially unwound bobbins, and tubes having remnant windings of yarn thereon into diverting paths is disclosed. Each bobbin has an information transfer device which contains data pertaining to the bobbin tube on which it is carried. At least one reading device is present in the transport system for reading the information transfer device. The transport system comprises a storage path for storing tube support members; a device for diverting tube support members; and a control unit connected to the reading device for controlling the diverting device to divert tube support members which tube support members are determined by the control unit in conjunction with the reading device to the storage path to have predetermined storage path conditions. The transport system may also include a delivery path and an ancillary transport path extending between the return path and the delivery path for transport of tube support members therebetween. A counting device may be included and coupled to the memory device for writing bobbin data on the associated tube support member and may be disposed in an area for transferring bobbins to tube support members.
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BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to an improved wear-resistant coating for piston rings of internal combustion engines and a method for applying such a wear-resistant coating during the production of piston rings.
2. Related Art
Piston rings are sealing elements on the piston, for example in an internal combustion engine or a reciprocating compressor. In an internal combustion engine, piston rings close the gap between the piston head and the cylinder wall, sealing the combustion chamber. In modern combustion engines, three piston rings are generally used per cylinder, and their design varies depending on the installation location. The main task of the piston ring closest to the combustion chamber, also called the compression ring, is to create a seal and dissipate heat. The lowest ring, called the scraper ring, scrapes lubricating oil off of the cylinder wall and regulates the oil film on which the upper piston rings slide during the stroke. The middle ring helps to control the oil balance, and provides additional insulation from combustion gases.
As the piston moves up and down, the outer peripheral surface of the piston ring slides in a constant resilient abutment against the cylinder wall, and at the same time the piston ring also oscillates in its ring groove due to the rocking movements of the piston, in which its edges come to bear alternately on the top and bottom flank of the piston ring groove. As the gliding partners slide continuously over the respective other surface, the degree of wear depend on the material, and in the case of dry running can lead to seizing, scoring, and finally destruction of the engine.
In the manufacture of highly stressed parts of internal combustion engines, such as the piston rings described in the preceding, the materials most frequently used are cast iron or cast iron alloys. In highly stressed combustion engines, such as 4-stroke and 2-stroke engines, piston rings, particularly compression rings, are exposed to ever increasing loads. These include, for example, high compression peak pressure, high combustion temperature and reduced lubricating film, all of which act on the piston ring and have a decisive effect on the functional properties such as wear, scuff resistance, microwelding and corrosion resistance.
Higher peak firing pressures, lower emissions, and direct fuel injection represent further increasing loads on the piston rings. The consequences may be damage and plating of piston material, particularly on the lower piston ring flank.
As the mechanical and dynamic stresses on piston rings increase, more and more engine manufacturers are demanding piston rings demand of high grade steel (hardened and tempered alloy steel, such as material 1.4112). Steel materials have advantages better strength and toughness characteristics than cast iron, since there is no interference by free graphite in the microstructure. The materials used most frequently to manufacture steel piston rings are highly chromium-alloyed martensitic steels.
In order to further improve the behaviour of piston rings during operation, they undergo a surface treatment such as application of tin and copper layers to improve sliding properties, a coating of zinc or manganese phosphate layers for accelerated running-in behaviour, and burnishing to reduce the corrosion.
On the other hand, the sliding surfaces are also treated specifically to increase the inherent wear resistance thereof and reduce abrasion and adhesion wear, for example by chromizing, deposition of metal-ceramic composite layers or molybdenum layers, or by nitriding or nitro-carburizing A commercially available piston ring coating is known by the brand name MKP200 and contains a composite of molybdenum and Cr 2 C 3 —NiCr.
However, even with such coatings, piston rings still do not have enough resistance to wear, scuffing and corrosion resistance, particularly when one considers the future generations of engines with even higher operating loads. One reason, but not the only reason for this is the high porosity of the protective layers, about 10-15%, and a limitation of the proportion of wear-resistant components in the layer due to the spraying process used.
Another problem consists in that the piston rings of large-volume engines, requiring, for example, cylinder diameters of about 190 mm to about 1000 mm require layers that are sufficiently thick on the piston rings to ensure the desired service life of 30,000 hours. However, as the coatings become thicker, the problems associated with the differing coefficients of expansion of the materials used in the piston ring and the coating and the different thermal conductivity also become increasingly significant.
In order to reduce wear, and particularly piston ring freeplay in the piston groove, highly wear-resistant layer systems are needed that demonstrate good properties in balanced manner with regard to hardness, Young's modulus, shear strength, thermal stability, manufacturability and cost.
SUMMARY OF THE INVENTION
An object of the present invention is therefore to provide an improved wear protection layer and a coating method with which the/the wear properties of piston rings can be further improved.
This object is solved according to the invention with a wear-resistant layer that comprises the following elements in the proportions shown:
15-25% by weight Fe, 10-20% by weight W, 20-30% by weight Cr, 15-25% by weight Ni, 1-5% by weight Mo, 0.1 to 0.5% by weight P, 0.01-0.1% by weight B, 0.1-5% by weight C, 0.1-2% by weight Si.
The content of at least 30% iron and nickel in the composition and the layer results in a quasi-homogeneous system between the substrate and the coating, with the result that the thermal energy generated by mixed friction is dissipated more efficiently, particularly in the TDC or BDC area, and a uniform thermal relaxation process is assured by the temperature fluctuations present in the engine. Consequently, the wear protection layer has excellent thermal conductivity and only a minimal difference in the coefficient of thermal expansion compared with the piston ring itself. The use of Fe-based alloys as the piston ring base coating material together with molybdenum and Ni—Cr—P—Si—B compound and a carbide system, results in the production of a new type of piston ring.
THE DRAWINGS
FIG. 1 shows the microstructure of the TS-VI variant measured by SEM;
FIG. 2 shows the microstructure of the TS-V2 variant measured by SEM;
FIG. 3 shows that an increase in the phase 1 of TS-V2 causes an increase in carbide concentration;
FIG. 4 shows the ring and cylinder liner wear after testing outside the engine, lubricated in the ring/cylinder system;
FIG. 5 shows the values determined for scuffing resistance of variants TS-V1 and TS-V2.
DETAILED DESCRIPTION
The layer according to the invention generally comprises iron (Fe), tungsten (W in the form of WC), chromium (Cr in the form of Cr and Cr 2 C 3 ), nickel (Ni), phosphorus, boron (B), molybdenum, silicon (Si), and carbon (C, partially bound to Fe, W and Cr as carbide).
Iron (Fe) is present in a quantity of 15-25% by weight, preferably in a quantity from 17 to 25% by weight, more preferably 18-25% by weight, still more preferably 20 to 25% by weight, and most preferably 22 to 25% by weight.
Tungsten (W) is present in a quantity of 10-20% by weight, preferably in a quantity of 12-20% by weight, more preferably 14 to 20% by weight, still more preferably to 20% by weight, and most preferably 18 to 20% by weight.
Chromium (Cr) is present in a quantity of 20 to 30% by weight, preferably in a quantity from 22 to 30% by weight, more preferably 24-30% by weight, still more preferably 26-30%, and most preferably 28-30% by weight.
Nickel (Ni) is present in a quantity of 15-25% by weight, preferably in a quantity from 17 to 25% by weight, more preferably 18-25% by weight, yet more preferably 20-25%, and most preferably 22-25% by weight.
Phosphorus (P) is present in a quantity of 0.1-0.5% by weight, preferably in a quantity of 0.2-0.5% by weight, more preferably 0.3-0.5% by weight, yet more preferably 0.4-0.5%.
Boron (B) is present in a quantity of 0.01-0.1% by weight, preferably in a quantity from 0.02 to 0.08% by weight, more preferably from 0.03 to 0.05% by weight, still more preferably 0.04 to 0.05%.
Carbon (C) is present in a quantity of 0.1 to 5 weight % by weight, preferably in a quantity of 0.5 to 5% by weight, more preferably 1-5% by weight, still more preferably 1-2% by weight.
Molybdenum is present in a quantity of 1-5% by weight, preferably in a quantity of 2-5% by weight, more preferably 2-4% by weight, yet more preferably 2-3% by weight.
Silicon (Si) is present in a quantity of 0.1-2% by weight, preferably in a quantity of 0.5 to 2% by weight, more preferably 1-2% by weight, still more preferably 1.5-2%.
Optionally, (Nb) and oxygen (O) may be present in the inventive wear-resistant layer.
Niobium (Nb) may be present in a quantity of 10-15% by weight, preferably in a quantity of 11-15% by weight, more preferably 12 to 15% by weight, still more preferably 13-15% by weight, and most preferably 14-15% by weight.
Oxygen may be present in a quantity of 0.1-2% by weight, preferably in a quantity of 0.1-0.8% by weight, more preferably from 0.2 to 0.5% by weight, still more preferably 0.3 to 0.5% by weight, and most preferably from 0.4 to 0.5% by weight.
It should be understood that the ranges set forth above may be permutated in any desired combination.
The elements listed above, Fe, W, Cr and Nb may be present in the native form thereof, or as carbides. The proportion of carbides may be from 20 to 50% by weight, preferably 25-50% by weight, more preferably 30-50% by weight, still more preferably from 35 to 45% by weight.
In this case, the content of WC is in the range from 10 to 20% by weight, the content of Cr 2 C 3 is in the range from 10 to 25% by weight, and the content of NbC in the range from 5 to 15% by weight.
The preferred ranges for WC are 12-20% by weight, preferably 15 to 20% by weight, more preferably 15 to 18% by weight. The preferred ranges for Cr 2 C 3 are 12-23% by weight, preferably 15 to 20% by weight, more preferably 18 to 20% by weight. The preferred ranges for NbC are 7-15% by weight, preferably 9-15% by weight, more preferably 10 to 12% by weight.
It should be understood that, as for the ranges listed above for the elements themselves, any permutation of the preferred ranges, also in combination with the preferred ranges of the elements themselves, is also disclosed herewith.
It has been found that the use of carbides further increases the scuff and wear resistance of the composition/coating of the invention. In addition, the use of nickel in the specified ranges and in combination with the other elements in the specified ranges results in an improvement of the shear strength and elastic behaviour, which lends the piston ring greater durability, particular in respect of its movement in the piston groove.
The wear protection layer may be applied to the substrate by any suitable method, a thermal spray process being preferred. Particularly preferred in this context is the HVOF process (High Velocity Oxygen-Fuel process), i.e., a high-velocity flame spraying process. The ingredients to be used for producing the wear-resistant layer are employed in the form of powders. The application of the HVOF process results in a particularly dense thermal coating on the substrate to be coated and a particularly low porosity
The particle sizes of the powders used are generally in the range from 1-80 μm, preferably in the range 5-60 μm, more preferably in the range of 10-50 μm. The individual carbide particles preferably have a particle size from 0.1-5 μm, preferably a size in the range from 1-4 μm, and can be embedded in a NiCr matrix. The carbides may be present either through agglomerated and sintered particles or as primarily precipitated carbides.
The use of the iron-based alloy according to the invention as a piston base coating material together with molybdenum and tungsten carbide as a wear protection layer thus results in a new piston ring type having improved properties in terms of wear, scuffing and corrosion resistance.
The present invention further provides a piston ring coated with the wear protection layer. The piston ring to be coated can be any piston ring type, a compression ring, a scraper ring or the middle ring, made of either cast iron or steel. The piston ring is preferably coated with the wear protection layer in a thermal spraying process, preferably the HVOF process.
The thickness of the coating can be in the range from 20-1500 μm, preferably in the range from 20 μm to 1000 μm, more preferably 20-800 μm.
The hardness of the coating of a piston ring coated with the wear-resistant coating according to the invention may be from 550-950 HV 1 (Vickers hardness test).
Such coated piston rings are used mainly in internal combustion engines. However, the sulphur-containing oils that are generated during such use cause a reaction between the molybdenum in the wear protection layer of the piston ring and the sulphur to yield MoS 2 , which in turn is an excellent solid lubricant due to its crystalline structure. Through this reaction, the susceptibility to scuffing or seizing of the tribological system is improved. MoS 2 has a typical layer lattice consisting of an array of sulphur-metal-sulphur planes parallel to the hexagonal base plane (001). Within these planes there are strong covalent bonds. However, the planes are connected to each other only by weak van der Waals interactions. This graphite-like anisotropic layer structure determines the low material hardness and excellent cleavability along the (001) planes, with the result that excellent emergency running properties are achieved.
The following examples illustrate the invention and are not intended to be limiting thereof.
EXAMPLES
I. Wear Protection Layers
The following wear protection layer variants were prepared and compared with each other:
TS-VI: A composite of Mo and Cr 2 C 3 —NiCr (MKP200, commercially available industrial scale product manufactured by Federal-Mogul) as a reference, produced by plasma spraying
TS-V2: A 4-phase mixture
Phase 1: FeCr base+WC/Cr2C3-NiCr; Phase 2: Ni—Cr—P—Si—B compound; Phase 3: Molybdenum; Phase 4: NbC with a mixing ratio of 70/10/10/10 produced by HVOF
II. Test Conducted
The TS V2 layer was analysed with regard to chemical composition (Table 1), porosity and hardness (Table 2), microstructure ( FIGS. 1-3 ), and examined for wear and scuffing behaviour ( FIGS. 4 and 5 ).
Table 1 shows the chemical composition of the coating system used in the test (3 measurements V2a to V2c).
TABLE 1
Chemical composition of wear protection layers used in the test.
CHEMICAL COMPOSITION
Fe
W
Cr
Ni
Nb
Mo
C
Si
P
O
B
(% by weight)
22.9
13.8
25.5
21.6
12.7
2.7
1 0
0.5
0.3
1.0
0.05
22.0
12.0
25.7
22.5
12.8
3.7
1.2
0.8
0.3
1.0
0.07
23.6
13.2
25.1
22.1
11.8
3.0
1.4
0.6
0.3
1.1
0.06
The microstructure, porosity and hardness, as well as the wear and scuffing behaviour were also tested for the variants according to conventional methods. The values obtained are shown in Table 2.
TABLE 2
Values found for porosity and mechanical properties
Target carbide
Test
content
Hardness
Porosity
#
(% by weight)
HV1
%
TS-V1
20
390-660
9
TS-V2
30
764-888
1
This shows that the porosity of the layers according to the invention is greatly reduced compared with the comparison layer, and that an increase in the carbide concentration leads to an increase in the hardness of the wear-resistant layer.
The microstructure and phase distribution were also examined with scanning electron microscopy ( FIG. 1 ). This shows that variant I contains no molten particles, homogeneously distributed Cr 2 C 3 areas together with molybdenum in a nickel-chrome matrix. Examinations showed that porosity did not exceed 10%.
From FIG. 2 it may be seen that in the variant according to the invention, TS-V2, the carbides are distributed homogeneously, only a few partially molten particles are present, molybdenum and WC and Cr 2 C 3 areas in a NiCr matrix and NbC, and Ni are homogeneously distributed. Porosity is approximately 1%. The coarser, light areas corresponding to tungsten carbide, the very flat, also bright areas correspond to molybdenum, the medium grey areas are nickel, and the dark grey areas are Cr 2 C 3 or the FeCr-containing phases.
The larger coarse and light areas in FIG. 3 (corresponding to tungsten carbide) show that an increase in the content of FeCr base+WC/Cr 2 C 3 —NiCr leads to an increase in the carbide concentration in the wear protection layer.
Wear and scuffing tests were also conducted outside the engine. For this, a segment of a coated sliding member is fixed in a holder and oscillated with a constant force and speed over a counter-body in an oil bath. The results are shown in FIGS. 4 and 5 .
From FIG. 4 it may be seen that a significant improvement in wear resistance may be achieved compared to a protective layer known from the prior art by using the wear-resistant layer according to the invention, resulting in a reduction of the ring and cylinder liner wear by more than 90%.
Scuffing behaviour was also investigated. For this, basically the same experimental setup is used as for the wear test, with the difference that a low lubrication state is created and the load is increased at constant time intervals. The measurement was terminated as soon as the friction coefficient was reached >0.3. As may be seen in FIG. 5 , the inventive variant TS-V2 shows improved scuffing behaviour compared to the variant TS-VI. Without being bound by theory it is presently believed that this is due to the dense layer, caused by the HVOF technology in combination with the low melting point of the Ni—Cr—B—Si-component, the increased carbide content and the still present molybdenum in the HVOF layers.
In the non-motor tests, it was thus found that the inventive coatings for piston rings are better in terms of wear and scuffing behaviour than the current PVD-CrN-based coatings (F-M material specification GOE242), which are used in automotive and heavy duty engines.
From the experimental results it is clear that with this coating system a new type of piston ring has been created.
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The invention relates to a novel wear-protection layer for piston rings of internal combustion engines and a method for applying a wear-protection layer of this type during production of a piston ring. The protective layer is characterized inter alia by reduced wear and high resistance to scuffing.
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BACKGROUND OF THE INVENTION
The present invention relates to radio frequency (RF) amplifiers and particularly to a system for amplifying high power RF signals and to recovering a portion of the signal power normally lost in prior art signal amplifying and combining systems.
Many current communication systems, whether they are used for transmitting analog data or digital data, employ high power RF amplifiers as part of the signal transmission or transponder sections of the system. Frequently, the information to be communicated by these systems is transmitted through the technique of amplitude modulation, AM. Usually, AM refers to full carrier amplitude modulation containing the information to be transmitted (and received) but it should be understood herein that any modulation system which causes the instantaneous composite amplitude of the waveform to be varied in accordance with the information transmitted may be termed an AM system. Single-sideband signals can also be generated by this system using the well known technique of envelope elimination and restoration (EER). Kahn, L. R.: "Single-Sideband Transmission by Envelope Elimination and Restoration", Proc. IRE, 1952, 40, pp. 803-806.
The AM signal to be broadcast may be generated in many ways. In one way, as disclosed in U.S. Pat. No. 4,580,111 to Swanson, an amplitude modulator generates an amplitude modulated carrier signal by selectively combining varying numbers of other carrier signals. Swanson also discloses a circuit which provides plural carrier signals of like frequency and phase where the number of carrier signals provided is dependent upon the number of digital levels chosen. Swanson uses a combiner made up of a plurality of transformers to combine the plural carrier signals and provide a combined signal which is the desired amplitude modulated carrier signal. Other combiner circuits are also disclosed by Swanson, including: voltage addition combiners, current addition combiners, and transmission line combiners. Various of Swanson's embodiments combine carrier signals which are equal in magnitude, carrier signals which are weighted in a binary progression, and, carrier signals which have been frequency modulated.
In another prior art system, disclosed in U.S. Pat. No. 4,804,931 to Hulick, the amplitude modulator comprises a predetermined number of quadrature power hybrid devices configured as combiners and arranged in cascade so that the output of one combiner becomes one of the inputs of its adjacent combiner. A digital decoder responsive to a digital input signal controlled the inputs ports of the combiners. By selectively enabling the RF signal to the various input ports the combined signal a the output of the last of the cascaded combiners represents the desired output signals, which my be fed to an antenna for transmission. The use of quadrature combiners in systems such as those disclosed by Hulick often are inefficient because of losses in the quadrature combiners. (Theoretically 50 percent of the power is lost at one-quarter power out.) For example, if the amplitude of the two signals appearing at the input ports to the combiners are not the same, the output signal will be less than the sum of the two input signals, the balance being reflected back and/or being absorbed by the resistor at the isolated port (i.e., a dummy or reject load). Such systems often have their best efficiency when all the input ports are loaded, a condition which occurs only at the maximum peak power output.
It is accordingly an object of the present invention to provide a novel digital amplitude modulator with improved power efficiency.
It is a further object of the present invention to provide a novel method and apparatus for combining in-phase RF signals.
It is yet another object of the present invention to provide an RF signal combiner in which the output signal tracks the input signal in a linear fashion.
It is still another object of the present invention to provide an RF signal combiner in which portions of the RF signal normally lost due to input signal mismatches can be recovered and used to reduce combiner power losses.
These and other objects of the present invention will become apparent to those skilled in the art from a review of the following specification in conjunction with the drawing figures when accorded a full range of equivalents.
BRIEF DESCRIPTIONS OF THE DRAWINGS
FIG. 1 is a functional block diagram of one embodiment of an in-phase combiner system in accordance with the present invention;
FIG. 2 is a functional block diagram of a second embodiment of an in-phase combiner system in accordance with the present invention.
FIG. 3 is a chart illustrating the typical relationship between ideal output power and actual output power in a signal combiner system; and,
FIG. 4 is a functional block diagram of an embodiment of a power recovery system which can be used with the present invention;
FIG. 5 is a functional block diagram of an embodiment of a high linearity system which can be used with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An amplitude modulator which contains an in-phase combiner in accordance with the present invention is shown in FIG. 1. The modulator receives an RF signal at its input port 10. The signal arriving at the input port 10 is provided as the input to a splitter 12 which produces in-phase signals 14 of equal amplitude. Each of the in-phase signals 14 is applied to one of plural linear amplifiers 16. The amplifiers 16 provide differing amounts of power, and would normally be set for binomial increasing output (1, 2, 4, 8, 16, etc.). The characteristic impedance of the signal output from the amplifiers 16 may be changed by impedance transformers 18. The signals output from the amplifiers 16 and the impedance transformers 18 are combined by a series of binary combiners 24. The signal output from the last of the series of combiners 24 is the output signal of the system.
As depicted in the system of FIG. 1, the transformation ratios of the impedance transformers and the resistance of the combiner resistor 26 are dependent on (a) the characteristic impedance of the signal received from the amplifiers 16 and (b) the location of the combiner 26a-26d within the series of combiners. As is well known, the impedance of the signal output by the binary combiner 24 is related to the impedance of the signals input to the combiner 24 and is one-half the impedance of the input signals if both input and signals have the same impedance. Thus, in a 50Ω characteristic impedance system, the output of the first combiner 24a will have a 25Ω impedance signals. Similarly, the third and fourth combiners operate on 12.5Ω and 6.25Ω signals, respectively.
The combiner resistor 26a-26d should similarly be selected with respect to the characteristic impedance of the signal output from the amplifiers 16 and the position of the combiner 24a-24d within the series of amplifiers 16. Preferably, the combiner resistors 26a-26d should have a resistance equal to the sum of the characteristic impedance of the signals across which the resistor 26 is placed.
The operation of the modulator of FIG. 1 is controlled by a switch control 30 which controls the operation of each of the switches 32. The switch control 30 switches the various amplifiers 16 in and out of operation in a digital manner so that after the output signals from the amplifiers 16 are combined, an analog signal related to the input signal in a desired manner can be obtained.
Alternatively to the input signal 10 and splitter 14, a system in accordance with the present invention could use an RF signal generator which provides multiple in-phase signals to the plural amplifiers 16. The switch control 30 can alternatively be made responsive to a digital or other signal representative of the desired output signal.
In operation, the plural in-phase RF signals are provided to the input ports of the plural amplifiers 16, each to receive sufficient drive level to saturate their output (high efficiency operation). Only the RF signals associated with switches 32 in the closed position are received by the amplifier 16. Thus, the level of the output signal from the system can be directly controlled by the switch control 30. After amplification, each of the input RF signal is combined with another RF signal in one of the in-phase combiners 24. To provide isolation between the input RF signals, each of the combiners 24 includes a combiner resistor 26 having an impedance which matches the combined impedance of the signals being combined. Because each of the combiners 24 reduces the impedance of its output signal to one-half that of the input signals, the signal applied to the series combiners may require transformation by the impedance transformers 18 so that the characteristic impedance of the two signals input are equal for each of the combiners.
Each of the switches 32, switch controls 30, amplifiers 16, impedance transformers 18 and in-phase combiners 24 may be conventional elements known to those skilled in the art of RF signal combiners.
With reference to FIG. 2, a second embodiment of the present invention may include a combiner in which all of the amplifiers are substantially identical, having a power output of X. In the system of FIG. 2, where similar elements to those appearing in FIG. 1 are given the same reference numeral, one RF input signal may be provided to an input port 10 and to a splitter 14 and a switch control 30. The splitter 30 splits the signal received at its input port into plural in-phase signals which are applied to plural switches 32. Under the control of the switch control 30, selected ones of the switches 32 operate to provide the in-phase signals to amplifiers 16 and/or to plural sub-splitters 14. The sub-splitters 14 split the received signal into two equal, in-phase signals which are either amplified by amplifiers 16c, 16d or are further split and then amplified. After amplification, the amplified signals are combined by one or more combiners 24 to generate a signal which is a 2 N X power. Thus, each of the signal paths through the switches 32 provides for a predetermined number (2 N ) of driving signals. Subsequently, each of the paths of amplified signals is combined by a series of in phase combiners 24, connected as in the modulator of FIG. 1.
As will be appreciated by those skilled in the art, the modulator of FIG. 2 can operate in a fashion quite similar to the operation of the modulator of FIG. 1; however, the modulator of FIG. 2 utilizes substantially identical amplifiers and substantially reduces he need for impedance transformers. It will also be appreciated by those skilled in the art that a modulator in accordance with the present invention could use a combination of the amplification scheme of the modulators of FIG. 1 and FIG. 2.
With reference to FIG. 1 and FIG. 3, if the circuit of FIG. 1 is used to combine signals without compensation, the in-phase combiners will introduce significant losses, just as the Hulick prior art, such that the output power is not a direct binary sum of the amplifiers activated. In an in-phase combiner, unless equal and same polarity signals are simultaneously applied in the combiner resistor 26, there is a significant loss across the resistor 26. For example, if the 8 and 16 power amplifiers are both on, there is no or minimal current flow through the combiner resistor 26d, and thus no power loss in this segment. However, if the 8 power amplifier is off and the 16 power amplifier is on, there is a 50% loss of power in the resistor With reference to FIG. 3, the graph depicts the relationship between ideal power output and actual power output as a function of the number of amplifiers turned on in a system. Note that if all of the amplifiers are turned on, there are no or minimal power losses in the combiner resistors, ignoring amplifier and other non-related losses. However, as some of the amplifiers are turned off, losses in the resistors will be experienced. (Curve B on FIG. 3) These losses are predictable, however, and the switch control 30 can be constructed to turn on additional amplifiers to compensate for the predicted losses. As depicted in FIG. 3, the switch control 30 can be constructed to compensate for the losses by following a compensation curve (such as curve C in FIG. 3) in determining how many and which amplifiers to switch into operation.
The compensation scheme described above linearizes the system of FIGS. 1 and 2; however, the efficiency of the system is compromised by the losses in the in-phase combiner resistors 24. With reference to FIG. 4, some of the power lost in the combiner resistors may be recovered by a recovery circuit. In this recovery circuit, the RF input signal is applied to a sense circuit 60 to sense the characteristic impedance of the rectifier/switching regulator. The sensed impedance is supplied to a controllable switching regulator 62 to control the input impedance. Two diodes 64, 66 are coupled to the combiners resistor 26 through an RF transformer. The output of signal from the first switching regulator 62 is applied to a second switching regulator 68 which supplies a constant output voltage that is applied to the system power supply.
In operation, the diodes 64, 66 rectify the RF signal developed across the combiner resistor 24 and apply the rectified signal to the controllable switching regulator 62. The controllable switching regulator 62 is controlled by the input impedance sensor 60 to maintain the input impedance to the transmitter constant. The output signal of the controllable switching regulator 68 to provide a constant voltage to the system power supply. Thus, the RF energy which otherwise would have been lost by the combiner resistor is converted to a direct current signal and fed back to the system power supply, thereby lowering the overall power consumption of the system. Efficiencies of this recovery circuit above 65 percent have been demonstrated.
With reference to FIG. 5, a system in accordance with the present invention can be constructed to operate with a relatively high degree of linearity. In such a system, an input signal 60 to be transmitted can be applied to one of the input terminals of a comparator 62. The output signal from the comparator 62 is applied to an analog to-digital circuit 64 which selectively operates plural switches 66 depending on the amplitude of the signal from the comparator 62. An RF signal 68 is applied through the switches 66 in a fashion similar to that used in the circuit of FIG. 1, energizing selected ones of plural amplifiers 70. The signals generated by the amplifiers 70 are combined by the combiner 72 as taught by the present invention. The output signal from the combiner 72 may be filtered and envelope detected by an envelope detector 74 whose output signal is applied to the other input of the comparator 62. In operation, the use of the envelope detector can compensate for the varying signal loss in the combiner 72 so that the input signal 60 is modified to maintain a linear amplification system.
While preferred embodiments of the present invention have been described, it is to be understood that the embodiments described are illustrative only and the scope of the invention is to be defined solely by the appended claims when accorded a full range of equivalence, many variations and modifications naturally occurring to those skilled in the art from a perusal hereof.
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A system and method for combining RF signals by a series of in-phase combiners. The system uses a series of switched, high efficiency amplifiers which may be selectively operated to obtain a desired output signal, such as an Amplitude Modulated (AM) signal. The output signals of the amplifiers are combined by a series of in-phase combiners. In a high linearity system a feedback loop is used to correct for combiner losses. The RF power normally lost in the combiners is recovered and available to increase the overall combiner efficiency.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a U.S. National Stage Application of International Application No. PCT/EP2008/054037 filed Apr. 3, 2008, which designates the United States of America, and claims priority to German Application No. 10 2007 017 515.0 filed Apr. 13, 2007, the contents of which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
The invention relates to a method for determining a path distance value and a network node.
BACKGROUND
A network enables the transmission of messages between its nodes. In a network, not all nodes of the network are directly connected to all other nodes. A message from a sending node to a receiving node must therefore often be forwarded via one or several intermediate nodes in order to arrive at a receiving node from a sending node. The path from the sending node via the intermediate node to the receiving node is referred to here as a path or route.
A routing method is used to select a suitable path for a message from a large number of theoretically possible paths in the network. The routing method firstly determines at least one, expediently however a plurality of path candidates, along which the message could be transmitted. A path distance value, a so-called route metric, is subsequently assigned to the path candidate in each instance. The path distance value is a measure of the quality of a path candidate. The path distance value is in turn usually determined from link distance values, which are in turn a measure of the quality of the links in the respective path candidate. The direct individual connection of the two nodes in the network is referred to here as a link.
Usage costs for a link in the path or the number of links in a path can enter into the path distance value for instance. It is also possible to enter the values for a transmission quality along the path candidate or a link in the path candidate or values for the transmission speed of the path candidate or a link in the path candidate. The path candidate with the optimal path distance value is selected below as a path. The message can now be transmitted along this path.
The methods for determining the path distance value are referred to as routing metrics. A known routing metric is an ETX (Expected Transmission Count). With the routing metric ETX, the path with which the number of transmissions to be expected is the lowest is selected. Transmissions are understood here to mean both transmissions as well as retransmissions. A first transmission is the transmission of a packet via a link. A retransmission takes place if the first transmission was not successful. The first transmissions and the retransmissions are treated equally in the case of ETX.
Retransmissions are nevertheless disadvantageous in that they may require more time than first transmissions. ETX is therefore disadvantageous in that it does not determine the optimal path for certain types of data transmissions in certain scenarios. Such data transmissions may be Voice over IP (VoIP) or video telephony for instance. Other examples of such types of data transmissions are all types of data transmissions, in which packet repetitions have negative effects on the quality of data transmission, and are therefore sensitive to repetitions.
SUMMARY
According to various embodiments, a method for determining a path distance value as well as a network node can be specified, which allows and/or can implement an improved path selection for repetition-sensitive data transmissions.
According to an embodiment, a method for determining a path distance value for a path in a network, comprises the step of determining the path distance value based on a first probability that a data packet is successfully transmitted along the path during transmission, wherein a) a maximum number of transmission repetitions entering into the first probability for a data packet in the case of an individual connection between two network nodes of the network, and b) at least one data packet arrival rate entering into the first probability for one or several individual connections of the path.
According to a further embodiment, the method comprises the steps of:—determining a link distance value entering into the first probability in each instance for at least one individual connection of the path; and—determining the path distance value from the link distance value. According to a further embodiment, the link distance value can be determined based on a second probability that a data packet is successfully transmitted via the individual connection during a transmission. According to a further embodiment, a first data packet arrival rate for a first transmission direction of the individual connection may be entering into the second probability. According to a further embodiment, in addition or alternatively, a second data packet arrival rate for the second transmission direction of the individual connection which may be opposite to the first transmission direction entering into the second probability. According to a further embodiment, the link distance value can be determined from the first and second data packet arrival rate on the basis of a first product. According to a further embodiment, the link distance value can be determined by means of the following formula: L=1−(1−A 1 *A 2 )^(W+1); with: L link distance value; A 1 first data packet arrival rate; A 2 second data packet arrival rate; and W maximum number of transmission repetitions. According to a further embodiment, at least two link distance values can be determined and the path distance value being the product from the link distance values.
According to another embodiment, a network node may comprise a processing facility for determining a path distance value, which is embodied so as to implement a determination of a path distance value assigned thereto for a path, with the path distance value being determined based on a first probability that a data packet is successfully transmitted along the path during a transmission, with a) a maximum number of transmission repetitions entering into the first probability for a data packet in the case of an individual connection between two network nodes of the network and b) at least one data packet arrival rate entering into the first probability for one or several individual connections of the path.
According to yet another embodiment, a network may comprise at least one network node as described above.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details and advantages of the invention are explained in more detail on the basis of exemplary embodiments illustrated in the drawing, in which;
FIG. 1 shows a schematic network with three path candidates.
DETAILED DESCRIPTION
With the method according to various embodiments for determining a path distance value for a path, the path distance value is determined based on a first probability. The first probability specifies the probability that a data packet is successfully transmitted along the path during a transmission. This means that the first probability specifies the probability that no repeated transmission is needed with any link.
a) A maximum number of transmission repetitions enter into the first probability for a data packet in the case of an individual connection between two network nodes of the network and b) at least one data packet arrival rate enters into the first probability for one or several individual connections of the path.
The metric determined with the method is advantageous in that it enables an improved path selection for time-critical data transmissions.
It is expedient if the following steps are implemented with the method:
determining a link distance value entering into the first probability for at least one link of the path in each instance; determining the path distance value from the link distance value.
It is expedient here for a link distance value to be determined for at least two links of the path, preferably for each link of the path, in each instance. It is also expedient to determine the path distance value from at least two of the link distance values thus determined, particularly preferably from all link distance values thus determined.
In a further embodiment and development, the link distance value is determined based on a second probability that a data packet is successfully transmitted upon transmission via the link.
The link distance value is preferably determined for a first transmission direction of the link on the basis of a first data packet arrival rate, which enters into the second probability. In a particularly preferred embodiment, the link distance value is in addition or alternatively determined for a second transmission direction of the link which opposes the first transmission direction on the basis of a second data packet arrival rate, which enters into the second probability. Here the first and second data packet arrival rate essentially specify a probability with which a message sent via the link in the respective transmission direction is received by its destination.
The link distance value is preferably determined from the first and second data packet arrival rate on the basis of a first product. At least two link distance values are also preferably determined and the path distance value is determined from the link distance values on the basis of a second product.
The link distance value is advantageously determined by means of the following formula:
L= 1−(1− A 1 *A 2)^( W+ 1)
with “high” being meant by A and:
L link distance value
A 1 first data packet arrival rate
A 2 second data packet arrival rate
W maximum number of transmission repetitions.
The network node has a processing facility for determining a path distance value, which is embodied such that it determines a path distance value assigned thereto for one path, with the path distance value being determined based on a first probability that a data packet is successfully transmitted along the path during a transmission, with
a) a maximum number of transmission repetitions entering into the first probability for a data packet during an individual connection between two network nodes of the network and b) at least one data packet arrival rate entering into the first probability for one or several individual connections of the path.
The network has at least one such network node.
The method can be used for instance in a routing method, such as AODV for instance.
The use of an embodiment of the routing metrics is to be shown below in a routing method. The ad-hoc network shown in FIG. 1 forms the basis here. This ad-hoc network contains a first to seventh node K 1 . . . 7 and a gateway G.
In this example, the first node K 1 would like to send a message to the gateway G. It is assumed for this example that none of the nodes K 1 . . . 7 identifies a path to the gateway G and such a path does not therefore have to be completely determined.
The routing protocol AODV (Ad-hoc On-demand Distance Vector) is used to determine the path. AODV provides that the first node K 1 sends a so-called route request message, in short RREQ, per broadcast to further nodes in its environment. These in turn forward the route request message. A route is determined if the RREQ reaches the destination. This route is sent by a so-called route reply message per Unicast back to the origin of the route request message, i.e. to the first node K 1 . To this end, each node K 1 . . . 7 , which has received and forwarded the request, has stored the nodes K 1 . . . 7 , from which it has received the route-request message.
Three path candidates P 1 . . . 3 are produced in this way in this example, along which the message can be transmitted from the first node K 1 to the gateway G. The first path candidate P 1 leads here from the first node K 1 via the second, third and fourth nodes K 2 , 3 , 4 to the gateway G. The second path candidate P 2 leads from the first node K 1 via the second and fifth nodes K 2 , 5 to the gateway G. The third path candidate P 3 leads from the first node K 1 via the second and seventh nodes K 2 , 6 to the gateway G. The seventh node K 7 does not appear in any of the path candidates P 1 . . . 3 in this example.
To transmit the path candidates P 1 . . . 3 to the first node K 1 , route reply messages are now sent along the path candidates back to the first nodes K 1 . The gateway G therefore sends a route-reply message for the first path candidate P 1 to the fourth node K 4 . This sends a route reply message to the third node K 3 , which in turn sends a route reply message to the second node K 2 , which sends a route reply message to the first node K 1 .
When receiving a route reply message, the receiving node K 1 . . . 7 determines a route metric for the respective path candidate P 1 . . . 3 in each instance. This relates here to the part of the path candidate P 1 . . . 3 from the destination, i.e. in this example the gateway G to the respective receiving nodes K 1 . . . 7 . The route metric is then forwarded in the route reply message so that the first node K 1 can finally determine the overall route metric for each of the path candidates P 1 . . . 3 .
As a routing metrics, i.e. as a specification for determining the quality of a path candidate P 1 . . . 3 , a route metric is used here, in which a data arrival rate is used as the link metrics. The link metrics is determined in this exemplary embodiment on the basis of the following formula:
LM = 1 - ( bp * nbp * m mttmtt ) rtm + 1
where
LM link metrics bp time period for metric messages mtt metric time interval rtm maximum number of retransmissions m,n number of received metric messages in the last metric time interval for one of the nodes of the link in each instance
The link metrics LM is calculated from the afore-cited formula for a link comprising two nodes K 1 . . . 7 of the network in each instance. The nodes K 1 . . . 7 here transmit metric messages such as hello messages for instance with the temporal distance bp, for instance 1 second. For each of the two nodes K 1 . . . 7 of a link, account is taken of how many (m, n) of the metrics messages it has received in the last metrics time interval mtt, for instance 30 seconds, from other nodes K 1 . . . 7 in each instance. The value rtm specifies how many retransmissions, i.e. renewed packet transmissions, are allowed. rtm=4 is assumed here as an example, other values such as 7 for instance are also possible.
If in the case of the given exemplary values for the time intervals the third node K 3 and fourth node K 4 has received 10 and 20 metrics messages within the last 30 seconds respectively, i.e. each third and/or each second metrics message, the following results for the links metrics:
LM
=
1
-
(
1
-
1
s
·
15
30
s
·
1
s
·
10
30
s
)
4
+
1
=
1
-
(
1
-
1
6
)
5
≈
0.6
It is also conceivable to determine the data packet arrival rate differently to metrics messages.
The route metric results from the product of the link metrics of a respective path candidate P 1 . . . 3 :
R
=
∏
Links
LM
R—route metric
LM—link metrics
Links—all of the links of a path candidate P 1 . . . 3
Here the term
bp · n mtt bp · m mtt
can be considered as the probability that a transmission with a possible renewed transmission, i.e. retransmissions, is successful via a given link. The term
R = ∏ Links LM
in turn specifies the probability that a transmission with possible renewed transmissions, i.e. retransmissions, is successful via an overall path candidate.
The criterion
1 - bp · n mtt bp · m mtt
is used advantageously as a metrics component, since it is clear herefrom whether a VoIP transmission actually makes sense. The route metric according to various embodiments can also be used to implement a so-called admission control. A VoIP connection is completely prevented here, if all existing path candidates P 1 . . . 3 are not able to have an adequate route metric, since in this case, a VoIP connection with adequate quality is not easily possible.
During the further course of the afore-cited example, each node K 1 . . . 7 , which receives a route reply message, compares the route metric of the respective path candidate P 1 . . . 3 with a threshold value. The threshold value is to amount here to 0.95. If the route metric of the respective path candidate P 1 . . . 3 , which is determined with a node K 1 . . . 7 , exceeds the threshold value, the respective path candidate P 1 . . . 3 is rejected. This means that the node K 1 . . . 7 does not send any more route reply message in respect of the respective path candidates P 1 . . . 3 . The rejected path candidate P 1 . . . 3 does not reach the first node K 1 and can thus also not be used to transmit the message to the gateway G. The first node K 1 itself also compares the route metric of a path candidate P 1 . . . 3 transmitted thereto per route reply message with the threshold value and rejects the path candidate P 1 . . . 3 if its route metric reaches or fails to reach the threshold value.
The first node K 1 firstly selects the path candidate with the best, i.e. highest route metric, from the path candidate P 1 . . . 3 which was not rejected.
The course described below results from the specified diagram for the individual path candidates P 1 . . . 3 . Exemplary values are assumed here for the link metrics, which are combined in the following table:
Link between:
Link metrics:
Gateway G, fourth node K4
0.98
Gateway G, fifth node K5
1.00
Gateway G, sixth node K6
0.99
Fourth node K4, third node K3
0.99
Third node K3, second node K2
1.00
Second node K2, first node K1
0.97
Fifth node K5, second node K2
0.98
Sixth node K6, second node K2
0.89
In the case of the first path candidate P 1 , a route reply message is sent from the gateway G to the fourth node K 4 . This calculates the route metric for the previous first path to the link metrics for this link, in other words 0.98. The path candidate P 1 is thereupon not rejected since its route metric is greater than 0.95. A route reply message subsequently moves from the fourth node K 4 to the third node K 3 . This calculates the route metric from the product of the previous route metric and the link metrics for the link between itself and the fourth node K 4 , in other words 0.98*0.99=0.97. After a route reply message to the second node K 2 , this calculates the route metric in an unchanged fashion to be 0.97*1=0.97. The first node K 1 calculates the route metric to be 0.97*0.97=0.94 after the last route reply message. The first path candidate P 1 is therefore rejected in the case of the first node K 1 , since its route metric is smaller there than 0.95.
With the same procedure, a route metric of 1.00 and/or 0.98 and/or 0.95 results with the second path candidate P 2 in the case of the fifth, second and first node K 5 , 2 , 1 . In the case of the third path candidate P 3 , route metric of 0.99 and 0.88 result in the case of the sixth node K 6 and/or in the case of the second node K 2 . The third path candidate P 3 is therefore already rejected in the case of the second node K 2 , since its route metric is already smaller there than the threshold value of 0.95. The third path candidate P 3 therefore does not reach the first node K 1 .
In this example, the first node will therefore select the second path candidate P 2 , which is the only one to have a suitable route metric, in order to transmit the message to the gateway G.
One alternative embodiment of the routing method results such that the link metrics are already transmitted with the route request messages. This embodiment of the routing method already enables the gateway G to make a decision on the path.
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In a method for determining link and route metrics, in order to determine an optimal path for time-critical transmission such as video telephony or VoIP, for use in routing protocols, the route metric is calculated as the product of the link metrics, wherein the link metrics in turn are calculated from the formula L=1−(1−A 1* A 2 )^(W+1), wherein L is the link metric, A 1 and A 2 are the data packet arrival rates in the outgoing and incoming directions of a link, and W is the maximum number of retransmissions per link. The route metric is optimal for the route which has the lowest number of lost packets.
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BACKGROUND OF THE INVENTION
The present invention relates to a magnetic tape cassette, particularly to a magnetic tape cassette generally referred to as digital audio tape (DAT) cassette.
Recently, the size and weight of cassette tape recorders have been reduced, and magnetic tape cassettes for such recorders made compact. For such applications, audio magnetic tapes capable of recording and playback with good quality and at a high density and having a long recording/playing time have been strongly desired. A digital audio tape, for which an input signal is subjected to digital processing such as pulse code modulation prior to recording, is well known as a tape which meets the above requirement.
In a digital audio tape cassette, the range of recorded signal frequencies is about five times as wide as that of a conventional compact audio tape cassette. The digital audio tape cassette has a mechanism which enables the cassette to be used together with a rotary head. This mechanism includes a guard panel which closes over the front opening of the cassette and opens upward therefrom. The guard panel is provided to protect the tape from dust which, were it to enter the cassette and cling to the tape, would degrade the performance of the tape since the wavelength of the recorded signals on a digital audio tape is much shorter than for the conventional compact audio tape cassette.
Also, because the size of the digital audio tape cassette is much smaller than that of the conventional compact audio tape cassette, the digital audio tape cassette is likely to be carried outdoors more often than a conventional compact audio tape cassette. For this and other reasons, the digital audio tape cassette requires some means for preventing the tape from unwinding due to vibration of the cassette during transport. For this purpose, the digital audio tape cassette is provided with a hub brake to check the rotation of the hubs on which the tape is wound when the tape is not in use. The hub brake is urged toward the hubs by a spring so that sharp-edged lugs of the hub brake contact the hubs when the cassette is not in use. The lugs are moved out of contact with the hubs when the tape is to be recorded on or reproduced.
A digital audio tape cassette as discussed above is disclosed in Japanese Unexamined Published Utility Model Application No. 84787/88.
However, since such cassettes are small in size, it is not easy to assemble the components thereof. The hub brake is especially difficult to assemble due to the spring, and it often falls out of the cassette during assembly. Therefore, the assembly efficiency of the cassette is low.
Digital audio tape cassettes in which an engagement device is provided between the upper half portion of the casing body of the cassette and the hub brake to improve the ease of assembly of the cassette have been proposed in Japanese Unexamined Published Utility Model Applications Nos. 67374/87 and 69879/87 and Japanese Unexamined Published Patent Application No. 134874/87. However, such an engagement device, which is provided between the upper half portion of the casing body of the cassette and a flat portion of the hub brake, can readily contact the side edge of the wound magnetic tape, causing damage to the tape or placing an undesirable load on the tape. If such loading occurs, the tape cannot be run at the prescribed speed to properly perform recording and playback.
The present invention was achieved in order to solve the above-mentioned problems.
Accordingly, it is an object of the present device to provide a magnetic tape cassette having a hub brake for preventing the hubs of the cassette from moving which can be easily assembled and which does not interfere with the normal running of the tape.
SUMMARY OF THE INVENTION
A magnetic tape cassette provided in accordance with the present invention includes a window member which is secured to the upper half portion of the casing body of the cassette and by which a pair of hubs on which the magnetic tape is wound are rotatably supported, and a hub brake urged toward the upper half portion of the casing body of the cassette by a spring so that the hub brake can be selectively engaged with the hubs to prevent their rotation and disengaged therefrom to release them. The inventive magnetic tape cassette is characterized in that the engaging portions of the hub brake, which are formed at the top thereof, are engaged with the support portions of the window member so that the engaging portions are slidably supported between the upper half portion of the casing body of the cassette and the support portions, and the engaging portions are disengaged from the support portions when the hub brake is located at the front half part of the cassette, out of the range of operation of the hub brake, which corresponds in position to the support portions.
When the magnetic tape cassette is to be assembled, the hub brake is placed at the front half part of the inside surface of the upper half portion of the casing body of the cassette and then horizontally moved toward the rear of the cassette so that the engaging portions of the hub brake are easily engaged with the support portions of the window member. After the cassette is assembled, the hub brake cannot be moved up and down relative to the casing body of the cassette and can only slide toward the front and rear of the cassette within the range of operation of the hub brake.
In accordance with another embodiment of the invention, there is provided a magnetic tape cassette which includes a window member secured to the upper half portion of the casing body of the cassette and by which a pair of hubs on which the magnetic tape is wound are rotatably supported, and a hub brake urged toward the upper half portion of the casing body of the cassette by a spring so that the hub brake can be engaged with the hubs to prevent them from rotating and disengaged therefrom to release them. This magnetic tape cassette is characterized in that the engaging portions of the hub brake, which are formed at the top thereof, are slidably supported between the upper half portion of the casing body of the cassette and the support portions of the window member, which are formed near both ends thereof, and the inside surface of the upper half portion of the casing body is provided with a lug for arching the central portion of the hub brake toward the inner portion of the interior of the cassette at the front half part thereof when the hub brake is out of the range of operation thereof.
To assemble the magnetic tape cassette, the hub brake is first placed at the front half part of the inside surface of the upper half portion of the casing body and then urged toward the inside surface near both ends of the hub brake so that the central portion of the brake is elastically deformed toward the inner part of the interior of the cassette by the lug. At that time, the side edges of the engaging portions of the hub brake are oriented toward the top of the cassette so that the engaging portions can be easily engaged with the support portions of the window member. After the cassette is assembled, the hub brake cannot be moved up and down relative to the casing body of the cassette and can only be slid toward the front and rear of the cassette within the range of operation of the hub brake.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial perspective view of a magnetic tape cassette constructed according to the present invention;
FIG. 2 is a perspective view of a window member of the cassette of FIG. 1;
FIG. 3 is a sectional view of the window member taken along a line X--X in FIG. 2;
FIG. 4 is a perspective view of the hub brake of the cassette;
FIG. 5 is a partial sectional view of the cassette taken along a line Y--Y in FIG. 1;
FIG. 6 is a partial perspective view of a magnetic tape cassette of another embodiment of the present invention;
FIG. 7 is a perspective view of the window member of the cassette of FIG. 6; and
FIG. 8 is a partial sectional view of the hub brake being set in the cassette of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present device are hereafter described in detail with reference to the attached drawings.
FIG. 1 is a partial perspective view of a magnetic tape cassette constructed according to a first embodiment of the invention. A hub brake 11 and a window member 2 are provided on the upper half portion 1 of the casing body of the cassette as shown in FIG. 1. The window member 2 is secured in a prescribed position to the inside surface of the upper half portion 1 by ultrasonic fuse-bonding, for example.
As shown in FIG. 2, the window member 2 is formed with a pair of bearing portions 3 by which a pair of hubs (not shown) are supported at the upper edges of the hubs. The window member 2 has right and left arms 4 and 5 extending toward the front of the cassette, which have respective support portions 6 and 7 for slidably supporting the hub brake 11.
As shown in FIG. 3, each of the support portions 6 and 7 has a wedge shape in cross section so that the top of each of the support portions extends obliquely downward to the side edge of the bottom of the support portion and also appropriately toward the front of the cassette. Accordingly, a wedge-shaped opening is defined between the inside surface of the upper half portion 1 of the casing body of the cassette and each of the support portions 6 and 7.
As shown in FIG. 2, the arms 4 and 5 have notches 16 and 17 for receiving the hub brake 11. The notches 16 and 17 are located at the side edges of the arms 4 and 5 next to the support portions 6 and 7 of the window member 2, and extend from the support portions toward both the right and left ends of the cassette.
As shown in FIG. 4, the hub brake 11 has a pair of sharp-edged lugs 12 and 13 at the rear of the brake which can be moved into contact with the outer circumferential projecting edges of the hubs to prevent them from rotating. The hub brake 11 has engaging portions 14 and 15 extending at the top of the hub brake and corresponding to the support portions 6 and 7. The engaging portions 14 and 15 are engaged with the support portions 6 and 7 so that the hub brake 11 is slidable backward and forward relative to the window member 2. The cross sections of the engaging portions 14 and 15 are shaped correspondingly to those of the wedge-shaped openings between the inside surface of the upper half portion 1 of the casing body of the cassette and the support portions 6 and 7 of the window member 2 so that the engaging portions can be fitted in the openings.
As shown in FIGS. 1 and 4, a spring 21 is fitted on a fixed boss 23 on the central part of the front half area of the inside surface of the upper half portion 1 and engaged at both ends of the spring in the notch 22 of the front of the hub brake 11 so that the spring urges the brake toward the rear of the cassette. The bottom of the central portion of the hub brake 11 is flat and flush with the bottoms of the sharp-edged lugs 12 and 13 thereof.
When the magnetic tape cassette is to be assembled, the window member 2 is first secured to the upper half portion of the casing body of the cassette by ultrasonic fuse-bonding, for example. The hub brake 11 is then placed in the upper half portion 1 so that the engaging portions 14 and 15 of the hub brake are located over the notches 16 and 17. The hub brake 11 is thereafter moved toward the rear of the cassette so that the engaging portions 14 and 15 of the brake hub are inserted in between the inside surface of the upper half portion 1 and the support portions 6 and 7 of the window member 2. The hub brake 11 is thus set in the upper half portion 1 of the cassette casing body, as shown in FIG. 5. The ends of the spring 21 fitted on the fixed boss 23 provided on the central part of the front half area of the inside surface of the upper half portion 1 are engaged in the notch 22 of the hub brake 11 to urge the brake toward the rear of the cassette. After the hubs with a magnetic tape wound thereon, a friction sheet, and other required members have been arranged in the upper half portion 1 of the cassette casing body, the lower half portion is coupled to the upper half portion. The assembly of the magnetic tape cassette is thus completed.
During the assembly of the cassette, the hub brake 11 is located at the front half of the inside surface of the upper half portion 1 of the cassette casing body, and is then moved horizontally toward the rear of the cassette. Accordingly, the engaging portions 14 and 15 of the hub brake 11 are easily engaged with the support portions 6 and 7 of the window member 2 so that the hub brake is slidably supported in the upper half portion 1. Therefore, the ease of assembly of the cassette is good.
After the cassette has been assembled, the hub brake 11 cannot be moved up and down relative to the casing body of the cassette, but can only be slid toward the front and rear of the cassette within the prescribed range of operation of the hub brake. Thus, the hub brake 11 is prevented from being elastically deformed. As a result, the sharp-edged lugs 12 and 13 of the hub brake 11 can be surely engaged with the hubs to prevent them from rotating and disengaged from the hubs to release them and allow them to rotate.
The engaging portions 14 and 15 of the hub brake 11 and the support portions 6 and 7 of the window member 2 constitute an engagement structure which engages the inside surface of the upper half portion 1 of the casing body of the cassette and the flat top of the hub brake. This engagement structure cannot come into contact with the side edge of the wound magnetic tape in the cassette to damage the tape or place an unnecessary load upon the running of the tape.
Although the cross sections of the engaging portions 14 and 15 and those of the support portions 6 and 7 are wedge-shaped, the present invention is not limited to this shape as the cross sections of these members may have various forms, for example, an oblong shape, as far as the engaging portions are slidably supported between the inside surface of the upper half portion 1 of the cassette casing body and the support portions.
Moreover, the notches 16 and 17 of the window member 2 are not limited to the above-described forms, but may have other various forms as far as the engaging portions 14 and 15 of the hub brake 11 can be disengaged from the support portions 6 and 7 of the window member when the hub brake is at the front half part of the cassette out of the range of operation of the hub brake, which corresponds to the support portions.
A magnetic tape cassette provided in accordance with the present invention includes a window member secured to the upper half portion of the casing body of the cassette, and a hub brake which can be engaged with the hubs to prevent the latter from rotating and disengaged from the hubs to allow them to rotate. The engaging portions of the hub brake, which are formed thereon at the top thereof, are engaged with the support portions of the window member so that the engaging portions are slidably supported between the upper half portion of the casing body of the cassette and the support portions of the window member. The engaging portions of the hub brake are disengaged from the support portions of the window member when the hub brake is located at the front half part of the cassette out of the range of operation of the hub brake, which corresponds in position to the support portions.
When the cassette is to be assembled, the hub brake is placed in the front half part of the inside surface of the upper half portion of the casing body of the cassette, and then horizontally moved toward the rear of the cassette so that the engaging portions of the hub brake are easily engaged with the support portions of the window member to support the hub brake slidably in the upper half portion of the cassette body. With this arrangement, the cassette is easy to assemble. Moreover, after the cassette is assembled, the hub brake cannot be moved up and down relative to the casing body of the cassette but can only be slid toward the front and rear of the cassette within the range of operation of the hub brake. Thus, the hub brake is prevented from being elastically deformed. As a result, the hub brake can be surely engaged with the hubs to prevent them from rotating and disengaged to release the hubs and allow them to rotate.
Since the engaging portions of the hub brake and the support portions of the window member constitute an engagement structure to engage the inside surface of the upper half portion of the cassette casing body and the top of the hub brake, the bottom of the central portion of the hub brake can be made flat and the engagement structure cannot contact the side edge of the magnetic tape in the cassette. Thus, damage to the tape is prevented and no unnecessary load is placed on the running of the tape.
Accordingly, it is very easy to position the window member and the hub brake relative to each other and to assemble them in the upper half portion of the casing body of the cassette. As a result, the cassette is easy to assemble and the tape runs smoothly.
A further embodiment of the invention will be explained with reference to FIGS. 6-8. In these figures, elements the same or similar to those of the above-described embodiment are identified by like reference numbers.
As shown in FIG. 6, a lug 25 shaped substantially as a rectangular parallelepiped is provided on the inside surface of the upper half portion 1 of the cassette casing body, located near the rear of the fixed boss 23, and projecting from the inside surface of the upper half portion 1 toward the inner part of the interior of the cassette. The rear of the lug 25 is sloped. The length of the lug 25, which extends in the front-to-rear direction of the cassette, is appropriately preset so that the hub brake 11 will not be hindered from moving within a prescribed range of operation thereof after being set in a prescribed position. Otherwise, the cassette is the same in construction as the first-described embodiment.
To assemble the magnetic tape cassette, the window member 2 is first secured to the upper half portion 1 of the casing body of the cassette by ultrasonic fuse-bonding, for example, and the hub brake 11 is then placed in the upper half portion 1 so that the hub brake is located over the lug 25. The hub brake 11 is urged toward the inside surface of the upper half portion 1 by pushers 27 and 28 provided at an appropriate distance from each other near the ends of the hub brake, as shown in FIG. 8. At that time, the central portion of the hub brake 11 comes into contact with the bottom of the lug 25 so that the central portion of the hub brake is elastically deformed toward the inner portion of the interior of the cassette As a result, the side edges of the engaging portions 14 and 15 formed on the hub brake 11 at the top thereof near its two ends are oriented obliquely toward the top of the cassette so that the side edges can be inserted in between the upper half portion 1 of the casing body of the cassette and the support portions 6' and 7' of the window member 2. As shown in FIG. 7, the support portions 6' and 7' in this embodiment may be longer than the support portions 6 and 7 in the first embodiment. The hub brake 11 is then moved toward the rear of the cassette while being urged by the pushers 27 and 28 so that the central portion of the hub brake departs from the lug 25 and is then horizontally extended again. At that time, the engaging portions 14 and 15 of the hub brake 11 are inserted between the inside surface of the upper half portion 1 of the cassette casing body and the support portions 6' and 7' of the window member 2 so that the hub brake is set in the prescribed position in the upper half portion 1, as shown in FIG. 5. The bottom of the hub brake 11 has dimples 24 in which the pushers 27 and 28 are fitted to urge the hub brake toward the inside surface of the upper half portion 1, as mentioned above. The ends of the spring 21 fitted on the fixed boss 23 provided on the central part of the front half area of the inside surface of the upper half portion 1 are engaged in the notch 22 at the front of the hub brake 11 to urge the brake toward the rear of the cassette. After the hubs with the magnetic tape wound thereon, a friction sheet, and other elements are assembled in the upper half portion 1 of the casing body of the cassette, the lower half portion thereof is coupled to the upper half portion. The assembly of the magnetic tape cassette is thus completed.
During the assembly of the cassette, the hub brake 11 is located at the front half of the inside surface of the upper half portion 1 of the casing body of the cassette, and is then moved horizontally toward the rear of the cassette while being urged near both the ends of the hub brake by the pushers 27 and 28. Thus, the engaging portions 14 and 15 of the hub brake 11 are easily engaged with the support portions 6 and 7 of the window member 2 so that the hub brake is slidably supported in the upper half portion.
Hence, it can be appreciated that the cassette can be easily assembled.
The shape of the lug 25 provided on the inside surface of the upper half portion 1 of the cassette casing body is not confined to that mentioned above as the lug 25 may have various forms and be coupled to the boss 23 integrally therewith as far as the lug functions to arch the central portion of the hub brake 11 toward the inner portion of the interior of the cassette at the front half part thereof while the hub brake is out of the prescribed range of operation.
A magnetic tape cassette provided in accordance with this embodiment of the invention includes a window member secured to the upper half portion of the casing body of the cassette and supporting a pair of hubs rotatably, and a hub brake whose engaging portions are slidably supported between the upper half portion of the casing body of the cassette and the support portions of the window member so that the hub brake can be engaged with the hubs to prevent them from rotating and disengaged therefrom to release the hubs to allow them to rotate. The inside surface of the upper half portion of the cassette casing body is provided with a lug for arching the central portion of the hub brake toward the inner portion of the interior of the cassette at the front half part thereof when the hub brake is out of the range of operation thereof.
To assemble the cassette, the hub brake is first placed at the front half area of the inside surface of the upper half portion of the casing body and then horizontally moved toward the rear of the cassette while being urged near both ends of the cassette so that the engaging portions of the hub brake can be easily engaged with the support portions of the window member to support the hub brake slidably in the upper half portion of the casing body of the cassette. With this structure, the cassette can be easily assembled. After the cassette is assembled, the hub brake cannot be moved up and down relative to the casing body of the cassette but only slid toward the front and rear of the cassette within the range of operation of the hub brake. Hence, as in the first-described embodiment, the hub brake is prevented from being elastically deformed, and as a result, the hub brake can be surely engaged with the hubs to prevent them from rotating and disengaged to release them.
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A magnetic tape cassette, particularly, a digital audio tape cassette, having an improved hub brake structure. The cassette includes upper and lower casing body half portions, and a window member secured to the upper casing body half portion. The window portion rotatably supports the pair of hubs on which a tape is wound. The hub brake includes a pair of lugs engageable with the hubs to prevent their rotation when the cassette is not in use. The hub brake is provided with a pair of engaging portions slidably received between respective support portions of the window member and the upper casing body half portion of slidably mounting the hub brake thereon. A spring urges the hub brake into engagement with the hubs.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of Ser. No. 13/935,679, filed Jul. 5, 2013, which is a divisional application of Ser. No. 13/332,950, filed Dec. 21, 2011, now issued as U.S. Pat. No. 8,509,270, filed Aug. 13, 2013, which is a continuation application of Ser. No. 12/816,105, filed Jun. 15, 2010, now issued as U.S. Pat. No. 8,094,691 on Jan. 10, 2012, which is a divisional of U.S. application Ser. No. 12/340,036, filed Dec. 19, 2008, now issued as U.S. Pat. No. 7,782,912 on Aug. 24, 2010, which is a divisional of U.S. application Ser. No. 11/005,218 filed Dec. 7, 2004, now issued as U.S. Pat. No. 7,508,853 on Mar. 24, 2009, the disclosures of which are incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] Regenerative amplifiers utilizing chirped pulse amplification (CPA) have been the dominant means for obtaining pulse energies greater than a microjoule with pulse durations in the femtosecond to picosecond range. Microjoule to millijoule pulse energies with pulse durations below 10 picoseconds have been found to be particularly useful for micromachining and for medical applications such as Lasik. However, a big stumbling block in the utilization of ultrafast sources for these applications has been that the regenerative amplifier is more of a piece of laboratory equipment and not conducive to the industrial setting.
[0003] Alternative sources for microjoule level, ultrafast pulses are emerging; utilizing all fiber chirped pulse amplification designs. Such systems are inherently more stable since they are based on technology similar to that utilized in Telecomm systems. During the past decade, there has been intensive work and success in making such systems practical. However, for higher pulse energies in the millijoule range, regenerative amplifiers will continue to dominate for some time since pulse energies above a millijoule have not been demonstrated in an all fiber system.
[0004] For micromachining applications, more industrially compatible regenerative amplifiers are now being developed based on Nd: or Yb: doped materials, rather than the Ti:sapphire that has dominated the scientific market. There are two basic reasons for this change. Commercial markets typically do not require the shorter pulses that can only be obtained from the Ti:sapphire regenerative amplifier, and the Nd: and Yb: based materials can be directly diode pumped, which makes these systems more robust and less expensive. An unresolved technical issue for Nd: or Yb: based regenerative amplifiers is the need for an equally robust seed source for femtosecond or picosecond pulses. The present seed lasers are mode-locked solid-state lasers with questionable reliability. It would be preferable to have a robust fiber seed source similar to that which has been developed for the Ti:sapphire regenerative amplifier, and used where Ti:sapphire regenerative amplifiers are applied to more commercial applications.
[0005] In a copending U.S. application Ser. No. 10/960,923, filed which is assigned to the common assignee and the disclosure of which is incorporated by reference in its entirety, the design changes needed for a mode-locked Yb:doped fiber oscillator and amplifier to be utilized as a seed source for a Yb: or Nd: based solid-state regenerative amplifier are described. The purpose of this application is to modify and apply many of the improvements in all fiber chirped pulse amplification systems for application to the seed source of a regenerative amplifier.
SUMMARY OF THE INVENTION
[0006] The purpose of this invention is to incorporate the many recent improvements in femtosecond mode-locked fiber lasers and femtosecond fiber chirped pulse amplification systems to regenerative amplifier systems that incorporate femtosecond or picosecond pulse sources based on fiber seed-sources and/or fiber amplifiers.
[0007] Yb: and Nd: mode-locked oscillators with fiber amplifiers can be utilized as sources of ultrafast pulses for regenerative amplifiers in order to obtain higher pulse energies than can be realized at this time from all fiber short pulse systems. A8827 (incorporated by reference herein) describes specifically how the sources can be configured to be implemented in such fiber based seed sources for solid state regenerative amplifiers. The femtosecond source and fiber amplifier need to be carefully configured in order to obtain optimum, reliable performance when incorporated into such a system. Recently there have been many improvements in mode-locked fiber sources implemented with fiber amplifiers in chirped pulse amplifier systems that can be utilized in a regenerative amplifier system that typically is based on chirped pulse amplification. Applicable improvements to fiber mode-locked sources are disclosed in Ser. Nos. 09/576,772, 09/809,248, 10/627,069, 10/814,502 and 10/814,319 (all incorporated by reference herein). Alternative suitable femtosecond sources that utilize fiber amplification for pulse conditioning and shortening are described in Ser. No. 10/437,057. One of the difficulties with chirped pulse amplification systems has been in producing reliable and compact pulse stretchers that can be dispersion matched to pulse compressors suitable for high pulse energies.
[0008] Significant improvements for dispersion matched fiber stretchers for fiber based chirped pulse amplification are disclosed in Attorney Docket No. A8717, filed Nov. 22, 2004 (incorporated by reference herein). These improvements are also applicable to chirped pulse amplification systems even when solid state bulk mode-locked lasers are utilized as the seed source. Significant improvements have been made in packaging, electronic controls, fabrication processes and optical parameter controls in order to make fiber based femtosecond sources reliable. These engineering improvements can also be utilized in these regenerative amplifier systems and are disclosed in Ser. Nos. 10/606,829, 10/813,163, 10/813,173 and Attorney Docket No. A8828 (all incorporated by reference herein).
[0009] Previously, Yb: and Nd: mode-locked oscillators and fiber amplifiers have been utilized as pulse sources for narrow bandwidth, bulk, solid-state amplifiers including regenerative amplifiers that can produce pulses 20 picoseconds or greater. In general, the configuration solutions for these longer pulse sources as described, for example in Ser. No. 10/927,374 (incorporated by reference herein) are different than those described here for sub-picosecond systems. However, the engineering improvements described here will also be applicable for the longer pulse systems, and the bulk amplifier operated as a regenerative amplifier has increased flexibility.
[0010] The first important element for a short pulse regenerative amplifier system is the source of short pulses. Femtosecond mode-locked fiber lasers are a good source of such pulses. Typically the fiber oscillator is low power and needs additional amplification for application as a seed source. Other important needs are pulse compression, wavelength flexibility, dispersion control and fiber delivery.
[0011] Therefore, it is an object of the present invention to introduce a modular, compact, widely-tunable, high peak and high average power, low noise ultrafast fiber amplification laser system suitable for a seed source for a regenerative amplifier.
[0012] It is a further object of the invention to ensure modularity of the system by employing a variety of easily interchangeable optical systems, such as 1) short pulse seed sources, 2) wide bandwidth fiber amplifiers, 3) dispersive pulse stretching elements, 4) dispersive pulse compression elements, 5) nonlinear frequency conversion elements and 6) optical components for fiber delivery. In addition, any of the suggested modules can be comprised of a subset of interchangeable optical systems.
[0013] It is a further object of the invention to ensure system compactness by employing efficient fiber amplifiers, directly or indirectly pumped by diode lasers as well as highly integrated dispersive delay lines. The high peak power capability of the fiber amplifiers is greatly expanded by using parabolic or other optimized pulse shapes. In conjunction with self-phase modulation, parabolic pulses allow for the generation of large-bandwidth high-peak power pulses, as well as for well-controlled dispersive pulse stretching. High power parabolic pulses are generated in high-gain single or multi-mode fiber amplifiers operating at wavelengths where the fiber material dispersion is positive.
[0014] Parabolic pulses can be delivered or transmitted along substantial fiber lengths even in the presence of self-phase modulation or general Kerr-effect type optical nonlinearities, while incurring only a substantially linear pulse chirp. At the end of such fiber delivery or fiber transmission lines, the pulses can be compressed to approximately their bandwidth limit.
[0015] Further, the high energy capability of fiber amplifiers is greatly expanded by using chirped pulse amplification in conjunction with parabolic pulses or other optimized pulse shapes, which allow the toleration of large amounts of self-phase modulation without a degradation of pulse quality. Highly integrated chirped pulse amplification systems are constructed without compromising the high-energy capabilities of optical fibers by using fiber-based pulse stretchers in conjunction with bulk-optic pulse compressors (or low nonlinearity Bragg gratings) or periodically poled nonlinear crystals, which combine pulse compression with frequency-conversion.
[0016] The dispersion in the fiber pulse stretcher and bulk optic compressor is matched to quartic order in phase by implementing fiber pulse stretchers with adjustable 2nd, 3rd and 4th order dispersion. Adjustable higher-order dispersion can be obtained by using high numerical aperture single-mode fibers with optimized refractive index profiles by itself or by using standard step-index high numerical aperture fibers in conjunction with linearly chirped fiber gratings. Alternatively, higher-order dispersion can be controlled by using the dispersive properties of the higher-order mode in a high numerical aperture few-moded fiber, by using nonlinearly chirped fiber gratings or by using linearly chirped fiber gratings in conjunction with transmissive fiber gratings. Adjustable 4th order dispersion can be obtained by controlling the chirp in fiber Bragg gratings, transmissive fiber gratings and by using fibers with different ratios of 2 nd , 3 rd and 4 th order dispersion. Equally, higher-order dispersion control can be obtained by using periodically poled nonlinear crystals.
[0017] The fiber amplifiers are seeded by short pulse laser sources, preferably in the form of short pulse fiber sources. For the case of Yb fiber amplifiers, Raman-shifted and frequency doubled short pulse Er fiber laser sources can be implemented as widely tunable seed sources. To minimize the noise of frequency conversion from the 1.5 μm to the 1.0 μm regime, self-limiting Raman-shifting of the Er fiber laser pulse source can be used. Alternatively, the noise of the nonlinear frequency conversion process can be minimized by implementing self-limiting frequency-doubling, where the center wavelength of the tuning curve of the doubling crystal is shorter than the center wavelength of the Raman-shifted pulses.
[0018] The process of Raman-shifting and frequency-doubling can also be inverted, where an Er fiber laser is first frequency-doubled and subsequently Raman-shifted in an optimized fiber providing soliton-supporting dispersion for wavelengths around 800 nm and higher to produce a seed source for the 1 μm wavelength regime.
[0019] As an alternative low-complexity seed source for an Yb amplifier, a modelocked Yb fiber laser can be used. The fiber laser can be designed to produce strongly chirped pulses and an optical filter can be incorporated to select near bandwidth-limited seed pulses for the Yb amplifier.
[0020] Presently the mode-locked Yb: doped fiber laser is the preferred oscillator. The preferred source is described Ser. No. 10/627,069 (incorporated herein).
[0021] The present invention is similarly directed to a mass-producible passively modelocked fiber laser. By incorporating apodized fiber Bragg gratings, integrated fiber polarizers and concatenated sections of polarization-maintaining and non-polarization-maintaining fibers, a fiber pig-tailed, linearly polarized output can be readily obtained from the laser. By further matching the dispersion value of the fiber Bragg grating to the inverse, or negative, of the dispersion of the intra-cavity fiber, the generation of optimally short pulses with a large optical bandwidth can be induced. In this regard, either positive dispersion in conjunction with negative dispersion fiber gratings or negative dispersion in conjunction with positive dispersion fiber gratings can be implemented. Preferably, the dispersion characteristics of the fiber Bragg grating and the dispersion characteristics of the rest of the intra-cavity elements are matched to within a factor of three. Even more preferably, these characteristics are matched within a factor of two, or within a factor in the range of 1.0 to 2.0. Also preferably, the Bragg grating has a chirp rate greater than 80 nm/cm. More preferably, the Bragg grating has a chirp rate greater than 160 nm/cm. Most preferably, the Bragg grating has a chirp rater greater than 300 nm/cm. To maximize the output power and the pulse repetition rate, the use of wide-bandwidth fiber Bragg gratings with low absolute dispersion is preferable. These fiber Bragg gratings are also used as end-mirrors for the cavity and allow the transmission of pump light to the intra-cavity gain fiber. The fiber Bragg gratings are conveniently produced using phase masks.
[0022] Alternatively, fiber couplers can be used inside the fiber cavity. Generally, sections of polarization-maintaining and non-polarization-maintaining fiber can be concatenated inside the fiber cavity. The non-polarization-maintaining section should then be short enough so as not to excessively perturb the polarization state. Intra-cavity sections of non-polarization-maintaining fiber preferably comprise all-fiber polarizers to lead to preferential oscillation of one linear polarization state inside the cavity. Similarly, when directly concatenating polarization-maintaining fiber sections, the length of the individual section should be long enough to prevent coherent interactions of pulses propagating along the two polarization axes of the polarization-maintaining fibers, thereby ensuring a maximum in pulse stability.
[0023] Saturable absorber mirrors (SAMs) placed inside the cavity enable passive modelocking. The saturable absorbers (SA) can be made from multiple quantum wells (MQW) or bulk semiconductor films. These saturable absorbers have preferably a bi-temporal life-time with a slow component (>>100 ps) and a fast component (<<20 ps). The realization of the bi-temporal dynamics of the optical nonlinearity is achieved by tailoring the depth profile of the ion-implantation in combination with the implantation dose and energy. The result is that the carriers trap at distinctively different rates in different depth regions of the SAM.
[0024] Saturating semiconductor films can for example be grown from aluminum-containing material such as AlGaInAs, the exact composition can be selected depending on the sought band-gap (typically selected to be in the vicinity of the desired operating wavelength of the laser system) and it is also governed by the requirement of lattice-match between the saturating semiconductor film and an underlying Bragg mirror or any other adjacent semiconductor material. Compositional requirements enabling lattice match between semiconductors and/or a certain band gap are well known in the state of the art and are not further explained here.
[0025] In aluminum containing semiconductors the surface area can induce a low optical damage threshold triggered by oxidization of the surface. In order to prevent optical damage of aluminum containing surface areas a passivation layer, e.g., InP, InGaAs or GaAs, is incorporated. SA degradation is further minimized by optimizing the optical beam diameter that impinges on the SAM. In one implementation the SAM and an intra-cavity fiber end can be either butt-coupled or brought into close contact to induce modelocking. Here, the incorporation of a precision AR-coating on the intra-cavity fiber end minimizes any bandwidth restrictions from etalon formation between the SAM and the fiber end. Etalons can also be minimized by appropriate wedging of the fiber ends. The beam diameter inside the SAM can be adjusted by implementing fiber ends with thermally expanded cores. Alternatively, focusing lenses can be directly fused to the fiber end. Moreover, graded-index lenses can be used for optimization of the focal size and working distance between the fiber tip and SA surface.
[0026] Wavelength tuning of the fiber lasers can be obtained by heating, compression or stretching of fiber Bragg gratings or by the incorporation of bulk optic tuning elements.
[0027] The use of bi- or multi-temporal saturable absorbers allows the design of dispersion compensated fiber laser operating in a single-polarization state, producing pulses at the bandwidth limit of the fiber gain medium.
[0028] Further improvement of the femtosecond Yb doped fiber oscillator can include an integral mass produced master oscillator, power amplifier design (MOPA) which is describe in Ser. No. 10/814,502 (incorporated by reference herein).
[0029] One embodiment of the present invention comprises a master oscillator power amplifier comprising a mode-locked fiber oscillator and a fiber amplifier. The mode-locked fiber oscillator comprises a pair of reflective optical elements that form an optical resonator. At least one of the reflective optical elements is partially transmissive and has a reflection coefficient that is less than about 60%. The mode-locked fiber oscillator outputs a plurality of optical pulses. The fiber amplifier is optically connected to the mode-locked fiber oscillator through a bi-directional optical connection such that light from the mode-locked fiber oscillator can propagate to the fiber amplifier and light from the fiber amplifier can propagate to the mode-locked fiber oscillator.
[0030] Another embodiment of the present invention comprises a method of producing laser pulses. In this method, optical energy is propagated back and forth through a gain fiber by reflecting light from a pair of reflective elements on opposite ends of the gain fiber. Less than about 60% of the light in the gain fiber is reflected back into the gain fiber by one of the reflectors. The pair of reflective elements together form a resonant cavity that supports a plurality of resonant optical modes. The resonant optical modes are substantially mode-locking to produce a train of pulses. The train of optical pulses is propagated from the laser cavity through one of the reflectors to a fiber amplifier along a bi-directional optical path from the laser cavity to the fiber amplifier where the laser pulses are amplified.
[0031] Another embodiment of the present invention comprises a fiber-based master oscillator power amplifier comprising a mode-locked fiber oscillator, a fiber amplifier comprising a gain fiber, and bi-directional optical path between the mode-locked fiber oscillator and the fiber amplifier. The mode-locked fiber oscillator comprises a resonant cavity and a gain medium. The mode-locked fiber oscillator produces a plurality of optical pulses. The bi-directional optical path between the mode-locked fiber oscillator and the fiber amplifier permits light from the mode-locked fiber oscillator to propagate to the fiber amplifier and light from the fiber amplifier to propagate to the mode-locked fiber oscillator. The mode-locked fiber oscillator comprises a first segment of fiber and the fiber amplifier comprises a second segment of optical fiber. The first and second segments form a substantially continuous length of optical fiber. In some embodiments, the first and second segments are spliced together. The first and second segments may be fusion spliced. The first and second segments may also be butt coupled together with or without a small gap, such as a small air gap, between the first and second segments.
[0032] Another embodiment of the present invention comprises a method of producing laser pulses comprising substantially mode-locking longitudinal modes of a laser cavity to produce laser pulses and propagating the laser pulses from the laser cavity to a fiber amplifier. The laser pulses are amplified in the fiber amplifier. Amplified spontaneous emission emitted from the fiber amplifier is received at the laser cavity. A first portion of the spontaneous emission enters the laser cavity. A second portion of the amplified spontaneous emission from the laser cavity is retro-reflected back to the fiber amplifier to cause the second portion to be directed away from the cavity toward the fiber amplifier.
[0033] Another embodiment of the present invention comprises a fiber master oscillator power amplifier comprising a mode-locked fiber oscillator and a fiber amplifier. The mode-locked fiber oscillator comprises a first portion of optical fiber and a pair of reflectors spaced apart to form a fiber optic resonator in the first fiber portion. At least one of the fiber reflectors comprises a partially transmissive fiber reflector. The mode-locked fiber oscillator outputs a plurality of optical pulses. The fiber amplifier comprises a second portion of optical fiber optically connected to the partially transmissive fiber reflector to receive the optical pulses from the mode-locked oscillator. The second portion of optical fiber has gain to amplify the optical pulses. The first portion of optical fiber, the partially transmissive fiber reflector, and the second portion of optical fiber comprise a continuous path formed by optical fiber uninterrupted by non-fiber optical components.
[0034] Another embodiment of the present invention comprises a master oscillator power amplifier comprising a mode-locked fiber oscillator and a fiber amplifier. The mode-locked fiber oscillator comprises a pair of reflective optical elements that form an optical resonator. At least one of the reflective optical elements comprises a partially transmissive Bragg fiber grating having a reflection coefficient that is less than about 60%. The mode-locked fiber oscillator outputs a plurality of optical pulses. A fiber amplifier is optically connected to the oscillator through an optical connection to the partially transmissive Bragg fiber grating.
[0035] Another embodiment of the present invention comprises a master oscillator power amplifier comprising a mode-locked fiber oscillator, a fiber amplifier, and a pump source. The mode-locked fiber oscillator comprises a pair of reflective optical elements that form an optical resonator. At least one of the reflective optical elements is partially transmissive and has a reflection coefficient that is less than about 60%. The mode-locked fiber oscillator outputs a plurality of optical pulses. A fiber amplifier is optically connected to the oscillator through an optical connection to the at least one partially transmissive reflective optical elements. The pump source is optically connected to the mode-locked fiber oscillator and the fiber amplifier to pump the mode-locked fiber oscillator and the fiber amplifier.
[0036] However, for most embodiments for a source for a regenerative amplifier the pulses need to be conditioned before amplification. Ser. No. 10/814,319 (incorporated by reference herein) addresses the utilization of modules so that the correct performance can be obtained from the femtosecond source for the seeder or a portion of the seeder for the regenerative amplifier system. Parameter controls available through these modules can be utilized for the optimization of the output from the regenerative amplifier.
[0037] One embodiment of the invention thus comprises a pulsed fiber laser outputting pulses having a duration and corresponding pulse width. The pulsed laser comprises a modelocked fiber oscillator, an amplifier, a variable attenuator, and a compressor. The modelocked fiber oscillator outputs optical pulses. The amplifier is optically connected to the modelocked fiber oscillator to receive the optical pulses. The amplifier comprises a gain medium that imparts gain to the optical pulse. The variable attenuator is disposed between the modelocked fiber oscillator and the amplifier. The variable attenuator has an adjustable transmission such that the optical energy that is coupled from the mode-locked fiber oscillator to the amplifier can be reduced. The compressor compresses the pulse thereby reducing the width of the pulse. Preferably a minimum pulse width is obtained.
[0038] Another embodiment of the invention comprises a method of producing compressed high power short laser pulses having an optical power of at least about 200 mW and a pulse duration of about 200 femtoseconds or less. In this method, longitudinal modes of a laser cavity are substantially mode-locked to repetitively produce a laser pulse. The laser pulse is amplified. The laser pulse is also chirped thereby changing the optical frequency of the optical pulse over time. The laser pulse is also compressed by propagating different optical frequency components of the laser pulse differently to produce compressed laser pulses having a shortened temporal duration. In addition, the laser pulse is selectively attenuated prior to the amplifying of the laser pulse to further shorten the duration of the compressed laser pulses.
[0039] Another embodiment of the invention comprises a method of manufacturing a high power short pulse fiber laser. This method comprises mode-locking a fiber-based oscillator that outputs optical pulses. This method further comprises optically coupling an amplifier to the fiber-based oscillator through a variable attenuator so as to feed the optical pulses from the fiber-based oscillator through the variable attenuator and to the amplifier. The variable attenuator is adjusted based on a measurement of the optical pulses to reduce the intensity of the optical pulses delivered to the amplifier and to shorten the pulse.
[0040] Another embodiment of the invention comprises a pulsed fiber laser outputting pulses having a pulse width. The pulsed fiber laser comprises a modelocked fiber oscillator, an amplifier, and a spectral filter. The modelocked fiber oscillator produces an optical output comprising a plurality of optical pulses having a pulse width and a spectral power distribution having a bandwidth. The amplifier is optically connected to the modelocked fiber amplifier for amplifying the optical pulses. The spectral filter is disposed to receive the optical output of the modelocked fiber oscillator prior to reaching the amplifier. The spectral filter has a spectral transmission with a band edge that overlaps the spectral power distribution of the optical output of the modelocked fiber oscillator to attenuate a portion of the spectral power distribution and thereby reduce the spectral bandwidth. The pulse width of the optical pulses coupled from the mode locked fiber oscillator to the fiber amplifier is thereby reduced.
[0041] Another embodiment of the invention comprises a method of producing compressed optical pulses. In this method, longitudinal modes of a fiber resonant cavity are substantially mode-locked so as to produce a train of optical pulses having a corresponding spectral power distribution with a spectral bandwidth. The optical pulses are amplified and compressed to produce compressed optical pulses. The spectral bandwidth of the spectral power distribution is reduced such that the compressed optical pulses have a shorter duration.
[0042] Another embodiment of the invention comprises a pulsed fiber laser comprising a modelocked fiber oscillator, an amplifier, one or more optical pump sources, a pulse compressor, and a pre-compressor. The modelocked fiber oscillator comprises a gain fiber and a pair of reflective optical elements disposed with respect to the gain fiber to form a resonant cavity. The modelocked fiber oscillator produces a train of optical pulses having an average pulse width. The amplifier is optically connected to the modelocked fiber amplifier such that the optical pulses can propagate through the amplifier. The fiber amplifier amplifies the optical pulses. The one or more optical pump sources are optically connected to the modelocked fiber oscillator and the fiber amplifier to pump the fiber oscillator and fiber amplifier. The pulse compressor is optically coupled to receive the amplified optical pulses output from fiber amplifier. The pulse compressor shortens the pulse width of the optical pulses output by the fiber amplifier. The pre-compressor is disposed in an optical path between the modelocked fiber oscillator and the fiber amplifier. The pre-compressor shortens the duration of the optical pulses introduced into the fiber amplifier such that the pulse duration of the optical pulses output by the compressor can be further shortened.
[0043] Another embodiment of the invention comprises a method of generating short high power optical pulses. The method comprises substantially mode-locking optical modes of a laser cavity to produce an optical signal comprising a plurality of laser pulses having an average pulse width. The optical signal comprises a distribution of frequency components. The method further comprises compressing the optical pulses and amplifying the compressed optical pulses to produce amplified compressed optical pulses. The amplified compressed optical pulses are further compressed subsequent to the amplifying using a dispersive optical element to differentiate between spectral components and introducing different phase shifts to the different spectral components.
[0044] Another embodiment of the invention comprises a pulsed fiber laser comprising a modelocked fiber oscillator, a fiber amplifier, an optical pump source, and a pulse compressor. The modelocked fiber oscillator outputs optical pulses. The fiber amplifier is optically connected to the modelocked fiber oscillator and amplifies the optical pulses. The optical pump source is optically connected to the fiber amplifier. The pulse compressor is optically coupled to receive the amplified optical pulses output from the fiber amplifier. The pulsed fiber laser further comprises at least one of (i) a first optical tap in the optical path between the modelocked fiber oscillator and the fiber amplifier and a first feedback loop from the first tap to control the modelocked fiber oscillator based on measurement of output from the first optical tap, and (ii) a second optical tap in the optical path between the fiber amplifier and the compressor and a second feedback loop from the second tap to control the fiber amplifier based on measurement of output from the first optical tap.
[0045] Another embodiment of the invention comprises a pulsed light source comprising a light source module, an isolator module, an amplifier module, and a compressor module. The light source module comprises an optical fiber and outputs optical pulses. The isolator module comprises an optical isolator in a housing having input and output fibers. The input fiber is optically coupled to the optical fiber of the light source module. The optical isolator is disposed in an optical path connecting the input and output fibers such that the optical pulses introduced into the input fiber are received by the isolator and permitted to continue along the optical path to the output coupler. The amplifier module comprises an amplifying medium and has an optical input optically connected to the output fiber of the isolator module to amplify the optical pulses. The compressor module is optically coupled to the amplifier module to compress the optical pulses.
[0046] Up to this point a mode-locked fiber laser or a bulk solid state mode-locked laser as the seed source for the fiber amplifier and regenerative amplifier has been disclosed. Other sources can also be utilized such a laser-diodes or microchip lasers. In Ser. No. 10/437,057 (incorporated by reference herein), it is disclosed how to modify these sources to give higher energy and shorter pulses through amplification and pulse compression in fiber amplifiers. An advantage of these sources that is mentioned in Ser. No. 10/437,057 is the repetition rate can be variable. It is a true advantage to match the repetition rate of the source to that of the regenerative amplifier.
[0047] Thus, one object of this invention is to convert relatively long pulses from rep-rate variable ultrafast optical sources to shorter, high-energy pulses suitable for seed sources in high-energy ultrafast lasers including a regenerative amplifier. Another object of this invention is to take advantage of the need for higher pulse energies at lower repetition rates so that such sources can be cost effective.
[0048] A gain switched laser diode as is used in telecom systems can be used as the initial source of pulses. In this case, the diode is operated at a much lower repetition rate. The pulses are still amplified in fiber amplifiers. Fiber amplifiers can be used as constant output power devices. The upper-state lifetime in typical doped amplifier fibers such as Ytterbium and Erbium is in the millisecond range so that these amplifiers can amplify pulse trains with the same efficiency at repetition rates from 10's of kHz to 100's of GHz and beyond. If the amplifier is amplifying pulses at 10 kHz rather than at 10 GHz at constant power, then the pulse energy will be six orders of magnitude higher. Again, with such high peak powers, pulse compression methods need to be different and unique. One first embodiment uses conventional compression by spectral broadening the pulses in an optical fiber with positive group velocity dispersion (GVD) and then compressing the pulse with diffraction gratings. The object of the pulse compression is to convert the 3-25 picosecond pulses from the gain switched laser diode to pulses that are subpicosecond.
[0049] Another source starts with pulses from a low cost Q-switched microchip laser. These lasers give pulses as short as 50 picoseconds but typically 250 picoseconds to 1.0 nanosecond. The pulse peak powers are typically 1-10 kW with pulse energies 6 orders of magnitude higher than from telecom laser diodes. Microchip lasers could be a very cost effective source for pulses less than 10 picoseconds with suitable pulse compression methods. Single mode fiber compression has thus far been limited to pulses shorter than 150 ps and peak powers less than 1 kW. Before compression the pulse can be further amplified in a regenerative amplifier.
[0050] Once a suitable femtosecond source has been identified further improvements have been made in the incorporation of these lasers in chirped pulse amplification systems where the amplifier has been a fiber amplifier. In Ser. No. 10/813,163, many improvements to the fiber chirped pulse amplification (FCPA) configuration have been made for a configuration that is more robust and suitable to an industrial environment. Here it has been realized that these improvements can be also utilized for fiber lasers seeding solid state amplifiers and particular solid state regenerative amplifiers. Specifically, the improvements for the FCPA configuration that are disclosed in Ser. No. 10/813,163 can be utilized in a regenerative amplifier seeded with a fiber laser configuration. The simplest embodiments are for the replacement of the power amplifier in FIGS. 1 and 11 of this application with a regenerative amplifier.
[0051] The following topics that are covered in Ser. No. 10/813,163 are relevant to this configuration.
1) Functional segmentation of opto-mechanical components into modular devices to produce manufacturable industrial laser systems with Telcordia-grade quality and reliability. 2) Polarization fidelity within and between modules 3) Provision for tap units for test, monitoring or feedback 4) Spectral matching of oscillator to amplifier 5) Selection of the length of an amplifier to cut ASE at the lasing wavelength 6) Active stabilization of the optical performance of gain fiber in a laser or amplifier. The stabilization is realized by actively adjusting the pump source wavelength by changing the source temperature in order to match pump wavelength with the absorption spectrum of the gain medium. The temperature dependent spectrum in the gain fiber is cloned in the same type of fiber, and thus used as a monitor. Accurate control of the gain performance over a wide range of operating temperatures is possible implementing this method. 7) Extraction of one or more chirped pulses from a series of such pulses using an acousto-optic deflector, and compensation for detrimental effects on the spatial characteristics of the extracted chirped pulse, caused by dispersion in that deflector.
[0059] The invention thus relates to the technologies necessary to overcome the above problems and limitations of the prior art, to build a hybrid fiber and solid-state based chirped pulse amplification laser system suitable for industrial applications, with the fiber in a modular and compact laser design with all modules replaceable. The modules are designed and manufactured to telecom standards and quality.
[0060] Environmentally stable laser design is crucial for industrial application. An industrial laser system can be, for example, characterized by an output power variation below 0.5 dB over an environmental temperature range from 0 to 50 degrees Celsius, and by compliance with the vibration, thermal shock, high temperature storage and thermal cycling test criteria in Telcordia GR-468-CORE and GR-1221-CORE. This target can be achieved by functional segmentation of the components and packaging the modular device with Telcordia-qualified packaging technology. Before the modules are assembled into a system, they are tested and assembled separately.
[0061] Included in the modules are tap units that allow taking out signals along the propagation path in an integrated design. This is necessary for the optimization of each module as it is assembled, and important in the spectral matching along the chain of modules.
[0062] Polarization units are provided to prevent the buildup of side-pulses from orthogonal polarization light.
[0063] The acousto-optical down counter module can be designed to operate as a bandwidth filter. For further modulation of the signal an additional pulse extractor can be included near the end of the output. This unit suffers from dispersion due to the large bandwidth of the pulse. The compressor can be used to correct for this dispersion as disclosed hereafter.
[0064] The invention also relates to a means to extract one or more chirped pulses from a series of such pulses using an acousto-optic deflector, and to compensate for the detrimental effects on the spatial characteristics of the extracted chirped pulse caused by dispersion in that deflector. An important aspect of this system is to manage the spectrum of the pulse in the system while maintaining the ability to correct for dispersion and compress the pulse back to the femtosecond regime. Two principal embodiments of this type will be described. The first is the case where the spectral content of the seed pulse is small. In this case a nonlinear amplifier may be employed for the generation of additional spectrum while spectral filtering is employed to obtain a compressible pulse. The second case is where the spectrum from the source is larger than necessary. Nonlinear affects can be limited in the amplifier chain in this case, while spectral filtering is again employed to obtain a compressible pulse. An additional attribute that is necessary for many applications is the reduction of the ASE at the output. Specific amplifier designs are used to cut the ASE at the output wavelength. The compressor can be used as an optical spectral filter to this end.
[0065] Once gain performance is attained, a method for active stabilization of the optical performance of the gain fiber in a laser or amplifier is disclosed to maintain this performance. The present invention stabilizes the temperature dependent absorption of a gain fiber over a wide environmental temperature variation by an active feedback loop. A piece of fiber, optically identical with the gain fiber itself, is used as a spectral filter for monitoring the emission spectrum of the pump diode. The absorption spectrum of the filter fiber follows that of the gain fiber if both fibers are packaged so that the fibers are in proximity to each other. The transmission of the pump light through the filter fiber clones exactly the absorption characteristics of the gain fiber at a given package temperature. The temperature of the pump diode is controlled by a feedback loop such that the transmission through the filter fiber is maintained at the minimum. Importantly, the filter fiber functions as an active temperature sensor of the gain fiber. Precise spectral control of the gain at any fiber or package temperature can thus be realized.
[0066] As mentioned above, an important field of use for this system is in micromachining. An additional feature needed for this application field is the capability to start and stop the pulse stream while moving the targeted material in place. One method to do this is to control the down counter. However, this leads to problems with gain stabilization in the amplifier and excessive ASE on target. These problems have been addressed in Ser. No. 10/813,173 “Method and Apparatus for Controlling and Protecting Pulsed High Power Fiber Amplifier Systems” (incorporated by reference herein). However, another means to stop the pulse stream is to utilize an optical switch at the output.
[0067] The invention extracts one or more chirped pulses from a series of such pulses using an acousto-optic deflector, and compensates for the detrimental effects on the spatial characteristics of the extracted chirped pulse caused by dispersion in that deflector. The instant invention has the additional advantage that the means to compensate for dispersion in the acousto-optic deflector can be used to compress the duration of the chirped pulse. This is accomplished by placing the AOM in proximity to a grating compressor.
[0068] Further improvements for correction of higher order dispersion terms in fiber chirped pulse amplification systems are disclosed in Attorney Docket No. A8717 (incorporated by reference herein). These can be applied to chirped pulse amplification systems with regenerative amplifiers.
[0069] Here, an ultra-compact high energy chirped pulse amplification systems based on linearly or nonlinearly chirped fiber grating pulse stretchers and photonic crystal fiber pulse compressors. Alternatively, photonic crystal fiber pulse stretchers and photonic crystal fiber compressors can also be implemented. For industrial applications the use of all-fiber chirped pulse amplification systems is preferred, relying on fiber-based pulse compressors and stretchers as well as fiber-based amplifiers.
[0070] Fiber-based high energy chirped pulse amplification systems of high utility can also be constructed from conventional optical components such as pulse stretchers based on long lengths of conventional fiber as well as bulk grating compressors. The performance of such ‘conventional’ chirped pulse amplification systems can be greatly enhanced by exploiting nonlinear cubicon pulse formation, i.e. by minimization of higher-order dispersion via control of self-phase modulation inside the amplifiers.
[0071] Finally, a particularly compact seed source for an Yb fiber-based chirped pulse amplification system can be constructed from an anti-Stokes frequency shifted modelocked Er fiber laser amplifier system, where a wavelength tunable output is obtained by filtering of the anti-Stokes frequency shifted output. The noise of such an anti-Stokes frequency shifted source is minimized by the amplification of positively chirped pulses in a negative dispersion fiber amplifier.
[0072] The preceding improvements have been focused on systems operating close to 1 μm. These systems appear to be the most suitable for industrial applications. However, Ti:sapphire regenerative amplifiers are presently the dominant design. Frequency doubled erbium fiber lasers are utilized for the more industrial Ti:sapphire systems. FCPA front ends are suitable for higher repetition rates utilizing an electro-optic pulse selector as is disclosed in Ser. No. 10/960,923. FCPA systems operating in the 1.5 telecomm wavelength which are then frequency doubled would be suitable for a Ti:sapphire amplifier or regenerative amplifier system.
[0073] The invention in Ser. No. 10/606,829 (incorporated by reference herein) provides an erbium fiber (or erbium-ytterbium) based chirped pulse amplification system operating at a wavelength of approximately 1550 nanometers. The use of fiber amplifiers operating in the telecommunications window enables telecommunications components and telecommunications compatible assembly procedures to be used, with superior mechanical stability
[0074] It is found that electronic controls are needed for reliable operation for these complex systems. In Ser. No. 10/813,173 (incorporated by reference herein), the implementation of electronic controls are described which prevent catastrophic damage in a short pulse amplifier system as well as maintaining constant output power over the life of the system. These systems are very applicable in a regenerative amplifier system seeded by a fiber laser. The damage issues will also be a concern in a regenerative amplifier system. However, more importantly these front end systems normally will encompass nonlinear optical processes in the fiber amplifiers. These nonlinear optical processes are very dependent on laser intensity. Thus, to maintain the desired results over the life of the system, careful control of the optical powers is needed particularly in the nonlinear optical components in the system.
[0075] It is thus an object of the present invention to provide a high power fiber amplifier system with means for controlling the pump diode current and the gain of the fiber amplifier such that the output pulse energy is constant as the pulse width and repetition rate are adjusted during operation. This includes keeping the pulse energy constant during turn-on of the pulse train.
[0076] It is a further object of the invention to provide means for controlling the temperature of the fiber amplifier pump diode such that the pump diode wavelength is maintained at a fixed value with changes in diode current.
[0077] It is also an object of the invention to provide means for protecting the high power amplifier from damage due to gain buildup in excess of the damage threshold of the amplifier by monitoring the repetition rate of the injected oscillator pulses or external signal, and shutting off or reducing the pump diode current if the repetition rate falls below this threshold.
[0078] It is also an object of the invention to provide for monitoring of the amplitude of the seed pulses and to protect the high power fiber amplifier from damage by shutting off the pump diode if the amplitude of the injected pulses falls outside a safe threshold.
[0079] It is also an object of the invention to provide a high power amplifier system with means for controlling the amplitude of the seed pulse such that the output energy of the power amplifier is constant.
[0080] The above and other objects of the invention are met by providing a device and method for controlling the diode current of the pump diode in a high power fiber amplifier, the device comprising a means for setting the pump diode current or power, monitoring such current or power, and maintaining the diode current or power at a constant value. Typically the current of the diode is controlled to correct for long term decrease on its output due to aging. In contrast, in accordance with an embodiment of the present invention, the pump diode current is controlled to dynamically control the gain of the power amplifier to maintain uniform pulse energy as the repetition rate and the pulse temporal width is changed. This includes turning the pump diode on sufficiently in advance and ramping up the current to produce equal power for the first pulses when the unit is turned on.
[0081] The device also provides a means for calculating and/or storing the desired pump diode current setting as a function of system pulse width and repetition rate, such that the energy of the output pulse is maintained at a desired value as the pulse width and repetition rate are varied.
[0082] A device in accordance with an embodiment of the invention also provides a means for calculating and storing the appropriate pump diode temperature setting as a function of the pump diode current setting, such that the emission wavelength of the pump diode is maintained at a wavelength that provides maximum absorption of the pump diode energy by the fiber amplifier medium as the pump diode current is varied.
[0083] Means are also provided to monitor the repetition rate of the injected pulses into the amplifier system, to compare it to the predetermined repetition rate, and if lower than this repetition rate, to disable or reduce the current to the amplifier pump diode to prevent it from being damaged.
[0084] The exemplary device discussed above also provides a means for comparing the amplitude of the pulse being injected into the fiber amplifier with a predetermined minimum amplitude value and if lower than this predetermined minimum, a means to disable or reduce the current to the amplifier pump diode to prevent it from being damaged. A device in accordance with an embodiment of the invention also provides a means of selecting and attenuating the seed pulses such that the amplified output pulses are of uniform energy.
[0085] It is an even further object of the invention to monitor the repetition rate of the oscillator and to provide a means for calculating the required down counter divide ratio needed to obtain a lower repetition rate.
[0086] It is also an object of the invention to synchronize the oscillator with an external reference signal. It is also an object of the invention to vary this external reference in frequency, and have the oscillator repetition rate vary accordingly.
[0087] It is an even further object of the invention to vary the external reference in frequency, and have the oscillator repetition rate vary accordingly, and also have the down counted repetition rate vary accordingly. However, this variation will be of a limited range compared to an all fiber system due to the operation repetition rate of a regenerative amplifier.
[0088] Finally, these regenerative amplifier systems will be utilized in many cases for micromachining. Improvements for FPCA systems have been developed that are unique for a fiber seed source. Ser. No. 10/813,389 (incorporated by reference herein), describes the benefit for changing the pulse shapes that allow the change of the material processing properties of that laser. These methods include allowing the addition of heat by the addition of longer pulses. The physical means for changing these pulse shapes and building a all fiber chirped pulse amplification system suitable for material processing is described Ser. No. 10/813,269 (incorporated by reference herein). As is mentioned in Ser. No. 10/813,269 some of these changes in the seed source for a fiber chirped pulse amplification systems will also be suitable for regenerative amplifier systems. Herein further methods of obtaining various pulse changes are described.
[0089] The invention thus provides methods of materials processing using bursts of laser light comprised of ultrashort pulses in the femtosecond, picosecond and nanosecond ranges, wherein parameters of the pulses comprising the burst, such as pulse width, pulse separation duration, pulse energy, wavelength and polarization, are manipulated to induce desirable properties in the processed material.
[0090] While a precise and controlled removal of material is achieved using ultrashort pulses, there are situations when having a small amount of thermal effect retained by the material from the previous pulse prior to being irradiated by a subsequent ultrashort pulse is beneficial. In addition, it is well known that the properties of most materials have some dependence on temperature. For example, the absorption of light by silicon is very dependent on temperature. Hence, heating such a target material can help initiate the ablation process at lower threshold fluence and may produce a smoother surface. In general, the thermal and physical effect or any change in structure caused by the prior pulse influences the laser matter interaction with the next pulse.
[0091] The ablation threshold energy density, as a function of pulse width, can vary significantly from the square root of t as pulse widths enter the femtosecond range. These ultrashort pulses can be used to micro-machine cleanly without causing significant heat. These ultrashort pulses also have deterministic thresholds compared to the statistical thresholds of longer pulses.
[0092] The present invention may be used in micro-machining with bursts of pulses having pulse shapes that cannot be quantified by a single pulse width in order to describe their micro-machining properties. For example, a burst comprises a 100 femtosecond pulse and a one nanosecond pulse, where the one nanosecond pulse contains ninety percent of the energy and the 100 femtosecond pulse contains ten percent of the energy. The threshold for ablation of gold is a little over 0.3 J/cm 2 for the 100 femtosecond pulse and 3.0 J/cm 2 for the one nanosecond pulse. Thus, if the burst is focused to output 0.3 J/cm 2 , then ablation will occur during the 100 femtosecond pulse, and not during the one nanosecond pulse. If the one nanosecond pulse impinges upon the surface first, it will have no affect while the 100 femtosecond pulse will ablate. Thus, the one nanosecond predominant pulse will not leave a heat affected zone. However, if the 100 femtosecond pulse is right before the one nanosecond pulse, then the 100 femtosecond pulse will change the absorption properties of the material so the one nanosecond pulse will also interact with the material. In this case, the ablation process would be predominantly heat related. If the one nanosecond pulse is increased to 100 nanoseconds, then the pulse energy content in the long pulse can be increased by ten-fold but the threshold is still determined by the ultrashort pulse and remains fixed even with one percent of the total energy in the ultrafast pulse.
[0093] Thus, in one embodiment of the present invention, the long pulse is before the ultrafast pulse if the pulse repetition rate is substantially greater than or equal 100 kilohertz. In another embodiment of the present invention, a portion of the long pulse follows after the ultrafast pulse, and adding a pedestal on the short pulse can create the long pulse. Micro-machining can be accomplished with an ultrashort pulse, where substantial energy is in a long pulse pedestal (>ten picoseconds) and where the long pulse pedestal adds a thermal machining mechanism.
[0094] The present invention can perform laser machining on material using a burst of ultrashort laser pulses and tailors the pulse width, pulse separation duration, wavelength and polarization to maximize the positive effect of thermal and physical changes achieved by the previous pulse on the laser matter interaction in a burst-machining mode. Better processing results can be achieved by manipulating the pulse width, the pulse separation duration and the pulse energies of pulses within a burst. The wavelength and polarization of a laser beam also strongly affect the absorption of the laser beam, and have to be varied pulse-to-pulse in a burst in order to produce maximum laser-matter interaction.
[0095] Besides the methods of manipulating laser beam parameters described above to achieve desired results, the present invention also includes methods to achieve the thermal and physical enhancement of a material during laser processing. In an embodiment of the present invention, the background light (commonly referred to as Amplified Spontaneous Emission (ASE)) is controlled to provide a constant source of energy for achieving thermal and physical changes to enhance the machining by individual ultrashort pulses. ASE is often emitted simultaneously and co-linearly with the ultrashort pulse from an amplified fiber laser. There are a number of ways to change the ASE ratio in the laser. Examples are changing the ultrashort pulse input energy into the amplifier, changing its center wavelength or changing the diode pump power to the amplifier. Another means more variable is within the compressor of the laser. As disclosed in application Ser. No. 10/813,163 the spectral output of the ASE can be designed to be at a different wavelength then that of the ultrashort pulse. Thus, in the compressor, where the spectral components are physically separated, a component can be placed to block or partially block the ASE, as disclosed in application Ser. No. 10/813,163. The ratio between the ASE and the ultrashort pulse energy can be controlled to vary the amount of preheating applied to the target material. In another embodiment of the invention, a pedestal of an ultrashort pulse is controlled. The pedestal is similar to a superimposed long-pulse with lower amplitude.
[0096] The invention is based on the interaction with a material of laser pulses of different pulse widths, pulse separation duration, energy, wavelength and polarization in a burst mode. The positive aspects of pulses having different pulse widths, pulse separation duration, energies, wavelengths and polarization are utilized, and a negative aspect of one pulse complements a positive aspect of another pulse. The coupling of laser energy during interaction of successive laser pulses with a material induces various thermal, physical and chemical couplings. The induced coupling involves microscopic change of electronic structure, phase transition, structural disintegration and/or other physical changes. For example, pulses with different pulse widths in a burst induce coupling that is different from a burst having pulses with the same pulse width.
[0097] An aspect of the invention provides a method of materials processing using laser light. The method comprises applying bursts of laser light to a target area of a material at a predetermined repetition rate. Preferably, the burst repetition rate is large enough for multipulse pulses generated within the round trip time of the regenerative amplifier, although lower repetition rates can be used. The burst of laser light comprises a first pulse and a second pulse of laser light displaced in time, although more pulses could be used in the burst as necessary. The first pulse has a first pulse width and the second pulse has a second pulse width, and predetermined parameters of the first pulse are selected to induce a change in a selected property of the processed material. The second pulse has a second pulse width, and predetermined parameters of the second pulse are selected based upon the property change induced by the first pulse. The first pulse width is generally in the nanosecond range, and the second pulse width is generally in the picosecond to femtosecond range. However, as stated previously it can be reversed. Predetermined parameters include pulse energy, pulse wavelength, pulse separation duration and pulse polarization vector. These parameters of the first and second pulses are controlled as well to machine the target area of the processed material.
[0098] A still further aspect of the present invention provides a method of materials processing that is similar to the previous aspect, except that the first and second pulses of the burst of laser light are overlapped in time, instead of being displaced in time. More pulses could be used in the burst as necessary. The first pulse has a first pulse width and the second pulse has a second pulse width, and the first pulse width can be greater than the second pulse width. The first pulse has a first pulse width and predetermined parameters of the first pulse are selected to induce a change in a selected property of the processed material. The second pulse has a second pulse width, and predetermined parameters of the second pulse are selected on based upon the property change induced by the first pulse. The first pulse width is generally in the nanosecond range, and the second pulse width is generally in the picosecond to femtosecond range. Predetermined parameters include pulse energy, pulse wavelength, pulse separation duration and pulse polarization vector which are controlled as well to machine the target area of the processed material. In addition, the second pulse may include a pedestal to facilitate thermally heating the processed material.
[0099] In yet another aspect of the present invention, an apparatus for generating optical pulses, wherein each pulse may have individualized characteristics, is provided. The apparatus comprises a laser means for generating the bursts of pulses, a control means that controls the laser means and a beam manipulation means for monitoring the pulse width, wavelength, repetition rate, polarization and/or temporal delay characteristics of the pulses comprising the pulse bursts. The apparatus generates feedback data based on the measured pulse width, wavelength, repetition rate, polarization and/or temporal delay characteristics for the control means. In one embodiment of the present invention, the laser means may comprise a fiber amplifier that uses stretcher gratings and compressor gratings. The beam manipulation means can comprise a variety of devices, e.g., an optical gating device that measures the pulse duration of the laser pulses, a power meter that measures the power of the laser pulses output from the laser means or a photodiode that measures a repetition rate of the laser pulses. Another beam manipulation means optically converts the fundamental frequency of a percentage of the generated laser pulses to one or more other optical frequencies, and includes at least one optical member that converts a portion of the fundamental of the laser pulses into at least one higher order harmonic signal. The optical member device may comprise a non-linear crystal device with a controller that controls the crystal's orientation. Preferably, the means for converting an optical frequency includes a spectrometer that measures predetermined parameters of pulses output from the non-linear crystal device and generates feedback for the control means.
BRIEF DESCRIPTION OF THE DRAWINGS
[0100] The accompanying drawings, which are incorporated in and constitute a part of this specification illustrate embodiments of the invention and, together with the description, serve to explain the aspects, advantages and principles of the invention. In the drawings,
[0101] FIG. 1 is a block diagram showing the basic components of the present invention.
[0102] FIG. 2 is an illustration of a modular, compact, tunable system for generating high peak and high average power ultrashort laser pulses in accordance with the present invention;
[0103] FIG. 3 is an illustration of an embodiment of a Seed Module (SM) for use in the present invention;
[0104] FIG. 4 is a diagram graphically illustrating the relationship between the average frequency-doubled power and wavelength which are output at a given range of input power according to one embodiment of the present invention.
[0105] FIG. 5 is an illustration of an embodiment of a Pulse Compressor Module (PCM) for use with the present invention;
[0106] FIG. 6 is an illustration of an embodiment of a Pulse Stretcher Module (PSM) for use with the present invention;
[0107] FIG. 7 is an illustration of a second embodiment of a Seed Module (SM) for use with the present invention;
[0108] FIG. 8 is an illustration of a third embodiment of a Seed Module (SM) for use with the present invention;
[0109] FIG. 9 is an illustration of a fourth embodiment of a Seed Module (SM) for use with the present invention;
[0110] FIG. 10 is an illustration of a fifth embodiment of a Seed Module (SM) for use with the present invention;
[0111] FIG. 11 is an illustration of an embodiment of the present invention in which a Fiber Delivery Module (FDM) is added to the embodiment of the invention shown in FIG. 1 ;
[0112] FIG. 12 is an illustration of an embodiment of a Fiber Delivery Module (FDM) for use with the present invention;
[0113] FIG. 13 is an illustration of a second embodiment of a Pulse Stretcher Module (PSM) for use with the present invention;
[0114] FIG. 14 is an illustration of a third embodiment of a Pulse Stretcher Module (PSM) for use with the present invention;
[0115] FIG. 15 is an illustration of an embodiment of the present invention in which pulse picking elements and additional amplification stages are added.
[0116] FIG. 16 is an illustration of another embodiment of the present invention where a fiber amplifier is operated with at least one forward and one backward pass, in combination with optical modulators such as pulse picking elements.
[0117] FIG. 17 is a diagram of a cladding pumped fiber cavity design according to a first embodiment of the invention.
[0118] FIG. 18 a is a diagram of a saturable absorber mirror according to an embodiment of the invention.
[0119] FIG. 18 b is a diagram of a saturable absorber mirror according to an alternative embodiment of the invention.
[0120] FIG. 19 is a diagram of the proton concentration as a function of depth obtained after proton implantation into a saturable semiconductor film.
[0121] FIG. 20 is a diagram of the measured bi-temporal reflectivity modulation obtained in a semiconductor saturable mirror produced by ion-implantation with selective depth penetration.
[0122] FIG. 21 a is a diagram of a scheme for coupling a saturable absorber mirror to a fiber end according to an embodiment of the invention.
[0123] FIG. 21 b is a diagram of a scheme for coupling a saturable absorber mirror to a fiber end according to an alternative embodiment of the invention.
[0124] FIG. 22 is a diagram for increasing the optical bandwidth of a fiber laser according to an embodiment of the invention.
[0125] FIG. 23 is a diagram of a core pumped fiber cavity design according to an embodiment of the invention.
[0126] FIG. 24 is a diagram of a core pumped fiber cavity design using intra-cavity wavelength division multiplexers and output couplers according to an embodiment of the invention.
[0127] FIG. 25 is a diagram of a core pumped fiber cavity design using intra-cavity wavelength division multiplexers and a butt-coupled fiber pig-tail for output coupling according to an embodiment of the invention.
[0128] FIG. 26 is a diagram of a cladding pumped fiber cavity design using an intra-cavity output coupler according to an embodiment of the invention.
[0129] FIG. 27 is a diagram of a cladding pumped fiber cavity design using intra-cavity fiber output couplers according to an embodiment of the invention.
[0130] FIG. 28 a is a diagram of a passively modelocked fiber laser based on concatenated sections of polarization maintaining and non-polarization maintaining fiber sections according to an embodiment of this invention.
[0131] FIG. 28 b is a diagram of a passively modelocked fiber laser based on concatenated sections of long polarization maintaining fiber sections according to an embodiment of this invention.
[0132] FIG. 28 c is a diagram of a passively modelocked fiber laser based on short concatenated sections of polarization maintaining fiber and additional sections of all-fiber polarizer according to an embodiment of this invention.
[0133] FIG. 29 is a diagram of a dispersion compensated fiber laser cavity according to an embodiment of this invention.
[0134] FIG. 30 is a diagram of a dispersion compensated fiber laser cavity according to an alternative embodiment of this invention, including means for additional spectral broadening of the fiber laser output.
[0135] FIG. 31 is a diagram of a design based on a fiber based MOPA having the fewest bulk optical components, according to a further embodiment.
[0136] FIG. 32 is an embodiment which includes monitoring electronics and feedback control of a fiber based pulse source.
[0137] FIG. 33 a illustrates a module usable for polarization correction or as variable attenuation in a fiber based laser system.
[0138] FIG. 33 b illustrates a particularly preferred embodiment for a fiber solid-state regenerative amplifier system.
[0139] FIG. 34 shows a source of ultra-fast pulses based upon a microchip laser.
[0140] FIG. 35 illustrates a source based on a DFB laser and a lithium niobate pulse generator.
[0141] FIG. 36 illustrates a system allowing independent control of higher order dispersion and self-phase modulation.
[0142] FIG. 37 illustrates an algorithm for a control system for ensuring mode-locking.
[0143] FIG. 38 illustrates an embodiment enabling the gain bandwidth of the regenerative amplifier to be easily matched to the fiber amplifier system.
[0144] FIG. 39 illustrates a generic scheme for the amplification of the output of a FCPA system in a bulk optical amplifier.
[0145] FIG. 40 illustrates an embodiment employing a series of chirped gratings operating on different portions of the spectrum, for elongating the pulse envelope.
[0146] FIGS. 41 and 42 show a laser diode-based multiple pulse source, and a laser system including this source.
[0147] FIGS. 43 a - 43 c show outputs of the pulse source of FIG. 41 in graphic form.
[0148] FIG. 44 illustrates a wavelength router scheme usable with the embodiment of FIG. 41 ; and
[0149] FIG. 45 illustrates a fiber splitter arrangement useable in the embodiment of FIG. 41 .
DETAILED DESCRIPTION OF THE INVENTION
[0150] A generalized illustration of the system of the invention is shown in FIG. 1 . The pulses are generated in a short pulse source. 11 . These are coupled into a pulse conditioner 12 for spectral narrowing, broadening or shaping, wavelength converting, temporal pulse compression or stretching, pulse attenuation and/or lowering the repetition rate of the pulse train. The pulses are subsequently coupled into an Yb: or Nd: fiber amplifier 13 . Pulse stretcher 14 provides further pulse stretching before the amplification in the regenerative amplifier 15 that is based on an Nd: or Yb: doped solid-state laser material. The compressor 16 compresses the pulse back to near transform limit. The six basic subsystems described here are each subject to various implementations, as is described in the subsequent embodiments.
[0151] A generalized illustration of one embodiment of the short pulse source 11 is shown in FIG. 2 . The pulses generated in a laser seed source 1 (seed module; SM) are coupled into a pulse stretcher module 2 (PSM), where they are dispersively stretched in time. The stretched pulses are subsequently coupled into the fundamental mode of a cladding-pumped Yb fiber amplifier 3 (amplifier module, AM1), where the pulses are amplified by at least a factor of 10. Finally, the pulses are coupled into a pulse compressor module 4 (PCM), where they are temporally compressed back to approximately the bandwidth limit.
[0152] The embodiment shown in FIG. 2 is modular and four sub-systems; the SM 1 , PSM 2 , AM1 3 and PCM 4 . The sub-systems can be used independently as well as in different configurations, as described in the alternative embodiments.
[0153] In the following, discussion is restricted to the SM-PSM-AM1-PCM system. The SM 1 preferably comprises a femtosecond pulse source (seed source 5 ). The PSM preferably comprises a length of fiber 6 , where coupling between the SM and the PSM is preferably obtained by fusion splicing. The output of the PSM is preferably injected into the fundamental mode of the Yb amplifier 7 inside the AM1 module 3 . Coupling can be performed by fusion splicing, a fiber coupler or a bulk-optic imaging system between PSM 2 and the fiber amplifier 7 . All fibers are preferably selected to be polarization maintaining. The PCM 4 is preferably a dispersive delay line constructed from one or two bulk optic diffraction gratings for reasons of compactness. Alternatively, a number of bulk optic prisms and Bragg gratings can be used inside the PCM 4 . Coupling to the PCM 4 can be performed by a bulk optic lens system as represented by the single lens 8 in FIG. 2 . In the case of a PCM that contains fiber Bragg gratings, a fiber pig-tail can be used for coupling to the PCM.
[0154] As an example of a femtosecond laser seed source, a Raman-shifted, frequency-doubled Er fiber laser is shown within an SM 1 b in FIG. 3 . The femtosecond fiber laser 9 can be a commercial high energy soliton source (IMRA America, Inc., Femtolite B-60) delivering ≈200 fs pulses at a wavelength of 1.57 μm and a pulse energy of 1 nJ at a repetition rate of 50 MHz.
[0155] For optimum Raman-shifting from 1.5 μm to the 2.1 μm wavelength region, a reduction in the core diameter (tapering) along the length of the polarization maintaining Raman-shifting fiber 10 is introduced. A reduction of the core diameter is required to keep the 2nd order dispersion in the Raman-shifter close to zero (but negative) in the whole wavelength range from 1.5 to 2.1 μm. By keeping the absolute value of the 2nd order dispersion small, the pulse width inside the Raman shifter is minimized, which leads to a maximization of the Raman frequency shift (J. P. Gordon, “Theory of the Soliton Self-frequency Shift,” Opt. Lett., 11, 662 (1986)). Without tapering, the Raman frequency-shift is typically limited to around 2.00 μm, which even after frequency-doubling is not compatible with the gain bandwidth of Yb fiber amplifiers.
[0156] In this particular example, a two-stage Raman shifter 10 consisting of 30 and 3 m lengths of silica ‘Raman’ fiber (single-mode at 1.56 μm) with core diameters of 6 and 4 μm respectively, was implemented. Due to the onset of the infrared absorption edge of silica at 2.0 μm, it is beneficial to increase the rate of tapering towards the end of the Raman shifter 10 . In the present example, conversion efficiencies up to 25% from 1.57 μm to 2.10 μm were obtained. Even better conversion efficiencies can be obtained by using a larger number of fibers with smoothly varying core diameter, or by implementing a single tapered fiber with smoothly varying core diameter.
[0157] Frequency-conversion of the Raman-shifted pulses to the 1.05 μm region can be performed by a length of periodically poled LiNbO3 (PPLN) crystal 11 with an appropriately selected poling period. (Although throughout this specification, the preferable material for frequency conversion is indicated as PPLN, it should be understood that other periodically-poled ferroelectric optical materials such as PP lithium tantalate, PP MgO:LiNbO 3 , PP KTP, or other periodically poled crystals of the KTP isomorph family can also be advantageously used.) Coupling with the PPLN crystal 11 occurs through the use of a lens system, represented in FIG. 3 by lenses 12 . The output of the PPLN crystal 11 is coupled by lenses 12 into output fiber 13 . Conversion efficiencies as high as 16% can so be obtained for frequency-doubling of 2.1 μm resulting in a pulse energy up to 40 pJ in the 1 μm wavelength region. The spectral width of the frequency-converted pulses can be selected by an appropriate choice of the length of the PPLN crystal 11 ; for example a 13 mm long PPLN crystal produces a bandwidth of 2 nm in the 1.05 μm region corresponding to a pulse width of around 800 fs. The generated pulse width is approximately proportional to the PPLN crystal length, i.e., a frequency converted pulse with a 400 fs pulse width requires a PPLN length of 6.5 mm. This pulse width scaling can be continued until the frequency-converted pulse width reaches around 100 fs, where the limited pulse width of 100 fs of the Raman-shifted pulses limits further pulse width reduction.
[0158] In addition, when the frequency-converted pulse width is substantially longer than the pulse width of the Raman-shifted pulses, the wide bandwidth of the Raman-pulses can be exploited to allow for wavelength-tuning of the frequency-converted pulses, i.e., efficient frequency conversion can be obtained for pulses ranging in frequency from 2(ω 1 −δω) to 2(ω 1 +δω), where 2δω is the spectral width at half maximum of the spectrum of the Raman-shifted pulses. Continuous wavelength tuning here is simply performed by tuning the temperature of the frequency-conversion crystal 11 .
[0159] The amplified noise of the Raman-shifter, PPLN-crystal combination is minimized as follows. Self-limiting Raman-shifting of the Er fiber laser pulse source can be used by extending the Raman shift out to larger than 2 μm in silica-based optical fiber. For wavelengths longer than 2 μm, the infrared absorption edge of silica starts to significantly attenuate the pulses, leading to a limitation of the Raman shift and a reduction in amplitude fluctuations, i.e., any increase in pulse energy at 1.5 μm tends to translate to a larger Raman-shift and thus to a greater absorption in the 2 μm wavelength region, which thus stabilizes the amplitude of the Raman-shifted pulses in this region.
[0160] Alternatively, the noise of the nonlinear frequency conversion process can be minimized by implementing self-limiting frequency-doubling, where the center wavelength of the tuning curve of the doubling crystal is shorter than the center wavelength of the Raman-shifted pulses. Again, any increase in pulse energy in the 1.5 μm region translates into a larger Raman-shift, producing a reduced frequency conversion efficiency, and thus the amplitude of the frequency-doubled pulses is stabilized. Therefore a constant frequency-converted power can be obtained for a large variation in input power.
[0161] This is illustrated in FIG. 4 , where the average frequency-converted power in the 1 μm wavelength region as a function of average input power at 1.56 μm is shown. Self-limiting frequency-doubling also ensures that the frequency-shifted wavelength in the 1 μm wavelength region is independent of average input power in the 1.56 μm wavelength region, as also demonstrated in FIG. 4 .
[0162] Several options exist for the PSM 2 . When a length of fiber 6 (stretching fiber) is used as a PSM as shown in FIG. 2 , an appropriate dispersive delay line can then be used in the PCM 4 to obtain near bandwidth-limited pulses from the system. However, when the dispersive delay line in the PCM 4 consists of bulk diffraction gratings 14 as shown in FIG. 5 , a possible problem arises. The ratio of |3 rd /2 nd |-order order dispersion is typically 1-30 times larger in diffraction grating based dispersive delay lines compared to the ratio of |3 rd /2 nd |-order dispersion in typical step-index optical fibers operating in the 1 μm wavelength region. Moreover, for standard step-index fibers with low numerical apertures operating in the 1 μm wavelength regime, the sign of the third-order dispersion in the fiber is the same as in a grating based dispersive delay line. Thus a fiber stretcher in conjunction with a grating-based stretcher does not typically provide for the compensation of 3 rd - and higher-order dispersion in the system.
[0163] For pulse stretching by more than a factor of 10, the control of third-order and higher-order dispersion becomes important for optimal pulse compression in the PCM 4 . To overcome this problem, the stretcher fiber 6 in the PSM 2 can be replaced with a length of fibers with W-style multi-clad refractive index profiles, i.e., ‘W-fibers’ (B. J. Ainslie et al.) or holey fibers (T. M. Monroe et al., ‘Holey Optical Fibers’ An Efficient Modal Model, J. Lightw. Techn., vol. 17, no. 6, pp. 1093-1102). Both W-fibers and holey fibers allow adjustable values of 2nd, 3rd and higher-order dispersion. Due to the small core size possible in W and holey fibers, larger values of 3rd order dispersion than in standard single-mode fibers can be obtained. The implementation is similar to the one shown in FIG. 1 and is not separately displayed. The advantage of such systems is that the PSM can work purely in transmission, i.e., it avoids the use of dispersive Bragg gratings operating in reflection, and can be spliced into and out of the system for different system configurations.
[0164] An alternative PSM 2 with adjustable values of 2 nd , 3 rd and 4 th order dispersion is shown in FIG. 6 . The PSM 20 a is based on the principle that conventional step-index optical fibers can produce either positive, zero or negative 3rd order dispersion. The highest amount of 3rd order dispersion in a fiber is produced by using its first higher-order mode, the LP 11 mode near cut-off. In FIG. 6 , the 4 th and 3 rd order dispersion of the PSM 20 a is adjusted by using three sections 15 , 16 , 17 of pulse stretching fiber. The 1st stretcher fiber 15 can be a length of fiber with zero 3rd-order and appropriate 4 th -order dispersion. The 1st stretcher fiber 15 is then spliced to the 2 nd stretcher fiber 16 , which is selected to compensate for the 3 rd -order dispersion of the grating compressor as well as the whole chirped-pulse amplification system. To take advantage of the high 3 rd -order dispersion of the LP 11 mode the 1st stretcher fiber 15 is spliced to the 2 nd stretcher fiber 16 with an offset in their respective fiber centers, leading to a predominant excitation of the LP 11 mode in the 2nd stretcher fiber 16 . To maximize the amount of 3rd-order dispersion in the 2nd stretcher fiber 16 , a fiber with a high numerical aperture NA>0.20 is preferred. At the end of the 2nd stretcher fiber 16 , a similar splicing technique is used to transfer the LP 11 mode back to the fundamental mode of the 3 rd stretcher fiber 17 . By an appropriate choice of fibers, the 4th-order dispersion of the whole amplifier compressor can be minimized. The 3 rd stretcher fiber 17 can be short with negligible dispersion.
[0165] The transfer loss of the whole fiber stretcher assembly is at least 25% due to the unavoidable 50% or greater loss incurred by transferring power from the LP 11 mode to the LP 01 mode without the use of optical mode-converters. Any residual energy in the LP 01 mode in the 2nd stretcher fiber can be reflected with an optional reflective fiber grating 18 as shown in FIG. 6 . Due to the large difference in effective index between the fundamental and the next higher-order mode, the grating resonance wavelength varies between 10-40 nm between the two modes, allowing for selective rejection of one mode versus the other for pulses with spectral widths between 10-40 nm.
[0166] The energy loss of the fiber stretcher assembly can be made to be insignificant by turning the 3 rd stretcher fiber 17 into an Yb amplifier. This implementation is not separately shown.
[0167] When 4th-order dispersion is not significant, the 1st stretcher fiber 15 can be omitted. 4 th order dispersion can also be compensated by using a 1st stretcher fiber with non-zero 3 rd order dispersion, as long as the ratio of 3 rd and 4 th order dispersion is different between the 1 st and 2 nd stretcher fiber.
[0168] The Yb-doped fiber inside the AM1 3 can have an Yb doping level of 2.5 mole % and a length of 5 m. Both single-mode and multi-mode Yb-doped fiber can be used, where the core diameter of the fiber can vary between 1-50 μm; though the fundamental mode should be excited in case of a MM fiber to optimize the spatial quality of the output beam. Depending on the amount of required gain, different lengths of Yb-doped fiber can be used. To generate the highest possible pulse energies, Yb fiber lengths as short as 1 m can be implemented.
[0169] Pulse compression is performed in the PCM 4 . The PCM 4 can contain conventional bulk optic components (such as the bulk diffraction grating pair shown in FIG. 5 ), a single grating compressor, or a number of dispersive prisms or grisms or any other dispersive delay line.
[0170] Alternatively, a fiber or bulk Bragg grating can be used, or a chirped periodically poled crystal. The chirped periodically poled crystal combines the functions of pulse compression and frequency doubling (A. Galvanauskas, et al., ‘Use of chirped quasi-phase matched materials in chirped pulse amplification systems,’ U.S. application Ser. No. 08/822,967, the contents of which are hereby incorporated herein by reference) and operates in transmission providing for a uniquely compact system.
[0171] Other modifications and variations to the invention will be apparent to those skilled in the art from the foregoing disclosure and teachings.
[0172] In particular, the SM 1 can be used as a stand-alone unit to produce near bandwidth limited femtosecond pulses in the frequency range from 1.52-2.2 μm, and after frequency conversion in a nonlinear crystal also in the frequency range from 760 nm to 1.1 μm. The frequency range can be further extended by using a fluoride Raman-shifting fiber or other optical fibers with infrared absorption edges longer than silica. Using this technique wavelengths up to around 3-5 μm can be reached. In conjunction with frequency-doubling, continuous tuning from 760 nm to 5000 nm can be achieved. The pulse power in the 2 μm region can be further enhanced by using Tm or Ho-doped fiber. With such amplifiers, near bandwidth-limited Raman-soliton pulses with pulse energies exceeding 10 nJ can be reached in single-mode fibers in the 2 μm wavelength region. After frequency-doubling, femtosecond pulses with energies of several nJ can be obtained in the 1 μm region without the use of any dispersive pulse compressors. Such pulses can be used as high energy seed pulses for large-core multi-mode Yb amplifiers, which require higher seed pulse energies than single-mode Yb amplifiers to suppress amplified spontaneous emission.
[0173] An example of an ultra-wide tunable fiber source combining an Er-fiber laser pulse source 19 with a silica Raman-shifter 20 , a Tm-doped amplifier 21 and a 2 nd fluoride glass based Raman shifter 22 is shown in the SM 1 c of FIG. 7 . An optional frequency-doubler is not shown for converting into the 900 nm to 1050 nm range. This would be a means for obtaining a high power source in this range. For optimum stability all fibers should be polarization maintaining. As another alternative to the Er-fiber laser pulse source a combination of a diode-laser pulse source with an Er-amplifier can be used; this is not separately shown.
[0174] As yet another alternative for a SM, SM 1 d is shown in FIG. 8 , and contains a frequency-doubled high-power passively mode-locked Er or Er/Yb-fiber oscillator 23 in conjunction with a length of Raman-shifting holey fiber 24 . Here the pulses from the oscillator 23 operating in the 1.55 μm wavelength region are first frequency-doubled using frequency doubler 25 and lens system 26 , and subsequently the frequency-doubled pulses are Raman-shifted in a length of holey fiber 24 that provides soliton supporting dispersion for wavelengths longer than 750 nm or at least longer than 810 nm. By amplifying the Raman-shifted pulses in the 1 μm wavelength regime or in the 1.3, 1.5, or 2 μm wavelength regime and by selecting different designs of Raman-shifting fibers, a continuously tunable source operating in the wavelength region from around 750 nm to 5000 nm can be constructed. The design of such a source with a number of attached amplifiers 27 is also shown in FIG. 8 .
[0175] For optimum Raman self-frequency shift, the holey fiber dispersion should be optimized as a function of wavelength. The absolute value of the 3rd order dispersion of the holey fiber should be less than or equal to the absolute value of the 3rd order material dispersion of silica. This will help ensure that the absolute value of the 2nd order dispersion remains small over a substantial portion of the wavelength tuning range. Moreover the value of the 2nd order dispersion should be negative, and a 2nd order dispersion zero should be within 300 nm in wavelength to the seed input wavelength.
[0176] As yet another alternative for a seed source for an Yb amplifier, anti-Stokes generation in a length of anti-Stokes fiber can be used. After anti-Stokes generation, additional lengths of fiber amplifiers and Raman-shifters can be used to construct a widely wavelength-tunable source. A generic configuration is similar to the one shown in FIG. 8 , where the frequency-doubling means 25 are omitted and the Raman-shifter means 24 are replaced with an anti-Stokes generation means. For example, to effectively generate light in the 1.05 μm wavelength regime in an anti-Stokes generation means using an Er fiber laser seed source operating at 1.55 μm, an anti-Stokes generation means in the form of an optical fiber with small core diameter and a low value of 3 rd order dispersion is optimum. A low value of 3 rd order dispersion is here defined as a value of 3 rd order dispersion smaller in comparison to the value of 3 rd order dispersion in a standard telecommunication fiber for the 1.55 wavelength region. Moreover, the value of the 2 nd order dispersion in the anti-Stokes fiber should be negative.
[0177] As yet another alternative seed-source for an Yb amplifier, a passively modelocked Yb or Nd fiber laser can be used inside the SM. Preferably an Yb soliton oscillator operating in the negative dispersion regime can be used. To construct an Yb soliton oscillator, negative cavity dispersion can be introduced into the cavity by an appropriately chirped fiber grating 29 , which is connected to output fiber 36 as shown in FIG. 9 ; alternatively, negative dispersion fiber such as holey fiber (T. Monroe et al.) can be used in the Yb soliton laser cavity. A SM incorporating such an arrangement is shown as SM 1 e in FIG. 9 . Here the Yb fiber 30 can be polarization maintaining and a polarizer 31 can be incorporated to select oscillation along one axis of the fiber (coupling being accomplished with lenses 32 ). For simplicity, the Yb fiber 30 can be cladding pumped from the side as shown in FIG. 9 . However, a passively modelocked Yb fiber laser incorporating conventional single-mode fiber with conventional pumping through a WDM can also be used. Such an arrangement is not separately shown. In FIG. 9 , SA 28 is used to induce the formation of short optical pulses. The grating 35 is used for dispersive control, and as an intra-cavity mirror. The pump diode 33 delivers pump light through V-groove 34 .
[0178] An arrangement incorporating a holey fiber can be nearly identical to the system displayed in FIG. 9 , where an additional length of holey fiber is spliced anywhere into the cavity. In the case of incorporating a holey fiber, the fiber Bragg grating does not need to have negative dispersion; equally the Bragg grating can be replaced with a dielectric mirror.
[0179] Most straight-forward to implement, however, is an Yb oscillator operating in the positive dispersion regime, which does not require any special cavity components such as negative dispersion fiber Bragg gratings or holey fiber to control the cavity dispersion. In conjunction with a ‘parabolic’ Yb amplifier (or ordinary Yb amplifier), a very compact seed source for a high-power Yb amplifier system can be obtained. Such a Yb oscillator with an Yb amplifier 40 is shown in FIG. 10 , where preferably the Yb amplifier 40 is a ‘parabolic’ Yb amplifier as discussed below. Elements which are identical to those in FIG. 9 are identically numbered.
[0180] The SM 1 f in FIG. 10 comprises a side-pumped Yb amplifier 40 as described with respect to FIG. 9 , though any other pumping arrangement could also be implemented. The Yb fiber 44 is assumed to be polarization maintaining and a polarizer 31 is inserted to select a single polarization state. The fiber Bragg grating 37 has a reflection bandwidth small compared to the gain bandwidth of Yb and ensures the oscillation of pulses with a bandwidth small compared to the gain bandwidth of Yb. The Bragg grating 37 can be chirped or unchirped. In the case of an unchirped Bragg grating, the pulses oscillating inside the Yb oscillator are positively chirped. Pulse generation or passive modelocking inside the Yb oscillator is initiated by the saturable absorber 28 . The optical filter 39 is optional and further restricts the bandwidth of the pulses launched into the Yb amplifier 40 .
[0181] To optimize the formation of parabolic pulses inside the Yb amplifier 40 inside the SM 1 f , the input pulses should have a bandwidth small compared to the gain bandwidth of Yb; also the input pulse width to the Yb amplifier 40 should be small compared to the output pulse width and the gain of the Yb amplifier 40 should be as high as possible, i.e., larger than 10. Also, gain saturation inside the Yb amplifier 40 should be small.
[0182] As an example of a parabolic amplifier a Yb amplifier of 5 m in length can be used. Parabolic pulse formation is ensured by using a seed source with a pulse width of around 0.2-1 ps and a spectral bandwidth on the order of 3-8 nm. Parabolic pulse formation broadens the bandwidth of the seed source to around 20-30 nm inside the Yb amplifier 40 , whereas the output pulses are broadened to around 2-3 ps. Since the chirp inside parabolic pulses is highly linear, after-compression pulse widths on the order of 100 fs can be obtained. Whereas standard ultrafast solid state amplifiers can tolerate a nonlinear phase shift from self-phase modulation only as large as pi (as well known in the state of the art), a parabolic pulse fiber amplifier can tolerate a nonlinear phase shift as large as 10*pi and higher. For simplicity, we thus refer to a large gain Yb amplifier as a parabolic amplifier. Parabolic amplifiers obey simple scaling laws and allow for the generation of parabolic pulses with spectral bandwidths as small as 1 nm or smaller by an appropriate increase of the amplifier length. For example, a parabolic pulse with a spectral bandwidth of around 2 nm can be generated using a parabolic amplifier length of around 100 m.
[0183] Since a parabolic pulse can tolerate large values of self-modulation and a large amount of spectral broadening without incurring any pulse break up, the peak power capability of a parabolic amplifier can be greatly enhanced compared to a standard amplifier. This may be explained as follows. The time dependent phase delay Φ nl (t) incurred by self-phase modulation in an optical fiber of length L is proportional to peak power, i.e.
[0000] Φ nl ( t )=γ P ( t ) L,
[0184] where P(t) is the time dependent peak power inside the optical pulse. The frequency modulation is given by the derivative of the phase modulation, i.e., δω=γL[∂P(t)/∂t]. For a pulse with a parabolic pulse profile P(t)=P 0 [1−(t/t 0 ) 2 ], where (−t 0 <t<t 0 ), the frequency modulation is linear. It may then be shown that indeed the pulse profile also stays parabolic, thus allowing the propagation of large peak powers with only a resultant linear frequency modulation and the generation of a linear pulse chirp.
[0185] The chirped pulses generated with the Yb amplifier 40 can be compressed using a diffraction grating compressor as shown in FIG. 5 . Alternatively, the pulses can be left chirped and compensated with the compressor after the regenerative amplifier.
[0186] In addition to the passively modelocked Yb fiber laser 44 shown in FIG. 10 , alternative sources could also be used to seed the Yb amplifier. These alternative sources can comprise Raman-shifted Er or Er/Yb fiber lasers, frequency-shifted Tm or Ho fiber lasers and also diode laser pulse sources. These alternative implementations are not separately shown.
[0187] In FIG. 11 a fiber delivery module (FDM) 45 is added to the basic system shown in FIG. 2 . The PSM 2 is omitted in this case; however, to expand the peak power capability of the amplifier module a PSM 2 can be included when required. The Yb amplifier 7 shown in FIG. 11 can be operated both in the non-parabolic or the parabolic regime.
[0188] In its simplest configuration, the FDM 45 consists of a length of optical fiber 46 (the delivery fiber). For a parabolic amplifier, the delivery fiber 46 can be directly spliced to the Yb amplifier 7 without incurring any loss in pulse quality. Rather, due to the parabolic pulse profile, even for large amounts of self-phase modulation, an approximately linear chirp is added to the pulse allowing for further pulse compression with the PCM 4 . The PCM 4 can be integrated with the FDM 45 by using a small-size version of the bulk diffraction grating compressor 14 shown in FIG. 5 in conjunction with a delivery fiber. In this case the delivery fiber in conjunction with an appropriate collimating lens would replace the input shown in FIG. 5 . A separate drawing of such an implementation is not shown. However, the use of the PCM 4 is optional and can for example be omitted, if chirped output pulses are required from the system. In conjunction with a PCM 4 , the system described in FIG. 11 constitutes a derivative of a chirped pulse amplification system, where self-phase modulation as well as gain is added while the pulse is dispersively broadened in time. The addition of self-phase modulation in conventional chirped pulse amplification systems typically leads to significant pulse distortions after pulse compression. The use of parabolic pulses overcomes this limitation.
[0189] To obtain pulse widths shorter than 50 fs, the control of third order and higher-order dispersion in a FDM module or in an optional PSM becomes significant. The control of higher-order dispersion with a PSM was already discussed with reference to FIGS. 2 and 6 ; the control of higher-order dispersion in a FDM is very similar and discussed with an exemplary embodiment of the FDM 45 a shown in FIG. 12 . Just as in FIG. 2 , the large third-order dispersion of a W-fiber can be used to compensate for the third-order dispersion of a bulk PCM 4 . Just as in FIG. 6 , by using fibers 15 , 16 , 17 with different values for higher-order dispersion in the FDM, the higher order dispersion of the whole system including a PCM 4 consisting of bulk diffraction gratings may be compensated.
[0190] Alternative embodiments of PSMs are shown in FIGS. 13 and 14 , which are also of practical value as they allow the use of commercially available linearly chirped fiber Bragg gratings in the PSM, while compensating for higher-order dispersion of a whole chirped-pulse amplification system comprising PSM as well as PCM. As another alternative, nonlinearly chirped fiber Bragg gratings can also be used in the PSM to compensate for the dispersion of the PCM. Such an arrangement is not separately shown.
[0191] Alternatively, the pulses can be left chirped and compensated with the compressor after the regenerative amplifier. This would mean not utilizing the PCM. This design would place additional design challenges on the dispersion correction in the PSM.
[0192] To avoid the use of W-fibers or the LP 11 mode in the PSM, an alternative embodiment of a PSM as shown in FIG. 13 is shown as PSM 2 b . Here a negatively linearly chirped Bragg grating 47 is used in conjunction with a single-mode stretcher fiber 48 with negative third-order dispersion and circulator 49 . The introduction of the negative linearly chirped Bragg grating increases the ratio of (3 rd /2 nd )-order dispersion in the PSM 2 b , allowing for the compensation of the high value of 3 rd order dispersion in the PCM 4 , when a bulk diffraction grating compressor is used. The PSM 2 b can also contain W-fibers in conjunction with a linearly chirped fiber Bragg grating to further improve the flexibility of the PSM.
[0193] As yet another alternative embodiment of a PSM for the compensation of higher-order dispersion the arrangement in FIG. 14 is shown as PSM 2 c , comprising a positively linearly chirped fiber Bragg grating 50 , circulator 49 and another fiber transmission grating 51 . Here the positively linearly chirped fiber Bragg grating 50 produces positive 2nd order dispersion and the other fiber transmission grating 51 produces an appropriate amount of additional 2 nd 3 rd and 4 th order dispersion, to compensate for the linear and higher order dispersion inside the PCM module. More than one fiber transmission grating or fiber Bragg grating can be used to obtain the appropriate value of 3 rd and 4 th and possibly even higher-order dispersion.
[0194] To increase the amplified pulse energy from an Yb amplifier to higher pulse energies, pulse picking elements and further amplification stages can be implemented as shown in FIG. 15 . In this case, pulse pickers 52 are inserted in between the PSM 2 and the 1 st amplifier module AM1 3 a , as well as between the 1st amplifier stage AM3 3 a and 2 nd amplifier stage AM2 3 b . Any number of amplifiers and pulse pickers can be used to obtain the highest possible output powers, where the final amplifier stages preferably consist of multi-mode fibers. To obtain a diffraction limited output the fundamental mode in these multi-mode amplifiers is selectively excited and guided using well-known techniques (M. E. Fermann et al., U.S. Pat. No. 5,818,630 and U.S. application Ser. No. 10/424,220) (both incorporated by reference herein). The pulse pickers 52 are typically chosen to consist of optical modulators such as acousto-optic or electro-optic modulators. The pulse pickers 52 down-count the repetition rate of the pulses emerging from the SM 1 by a given value (e.g. from 50 MHz to 5 KHz), and thus allow the generation of very high pulse energies while the average power remains small. Alternatively, directly switchable semiconductor lasers could also be used to fix the repetition rate of the system at an arbitrary value. Further, the pulse pickers 52 inserted in later amplifier stages also suppress the build up of amplified spontaneous emission in the amplifiers allowing for a concentration of the output power in high-energy ultra-short pulses. The amplification stages are compatible with PSMs and PCMs as discussed before; where the dispersion of the whole system can be minimized to obtain the shortest possible pulses at the output of the system.
[0195] Amplifier module AM1 3 a can be designed as a parabolic amplifier producing pulses with a parabolic spectrum. Equally, the parabolic pulses from AM1 3 a can be transformed into pulses with a parabolic pulse spectrum in a subsequent length of pulse-shaping or pulse stretching fiber 53 as also shown in FIG. 15 , where the interaction of self-phase modulation and positive dispersion performs this transformation. This may be understood, since a chirped pulse with a parabolic pulse profile can evolve asymptotically into a parabolic pulse with a parabolic spectrum in a length of fiber. The parabolic pulse shape maximizes the amount of tolerable self-phase modulation in the subsequent amplification stages, which in turn minimizes the amount of dispersive pulse stretching and compression required in the PSM 2 and PCM 4 . Equally, parabolic pulse shapes allow the toleration of significant amounts of self-phase modulation in the PSM 2 without significant pulse distortions.
[0196] Once the pulses are stretched, the detrimental influence of self-phase modulation in subsequent amplifiers can be minimized by using flat-top pulse shapes. A flat-top pulse shape can be produced by inserting an optional amplitude filter 54 as shown in FIG. 15 in front of the last amplifier module to produce a flat-top pulse spectrum. A flat-top spectrum is indeed transformed into a flat-top pulse after sufficient pulse stretching, because there is a direct relation between spectral content and time delay after sufficient pulse stretching. It can be shown that even values of self-phase modulation as large as 10*π can be tolerated for flat-top pulses without incurring significant pulse distortions.
[0197] An amplitude filter as shown in FIG. 15 may in turn also be used to control the amount of higher-order dispersion in the amplifier chain for strongly chirped pulses in the presence of self-phase modulation when reshaping of the pulse spectrum in the amplifier can be neglected, i.e., outside the regime where parabolic pulses are generated. In this case self-phase modulation produces an effective amount of higher-order dispersion of:
[0000]
β
n
SPM
=
γ
P
0
L
eff
n
S
(
ω
)
ω
n
|
ω
=
0
,
[0000] where P 0 is the peak power of the pulse and S(ω) is the normalized pulse spectrum. L eff is the effective nonlinear length L eff =[exp(gL)−1]/g, where L is the amplifier length and g is the amplifier gain per unit length. Thus by accurately controlling the spectrum of strongly chirped pulses with an amplitude filter as shown in FIG. 15 , any amount of higher-order dispersion can be introduced to compensate for the values of higher-order dispersion in a chirped pulse amplification system. It can indeed be shown for 500 fs pulses stretched to around 1 ns, a phase shift of ≈10 π is sufficient to compensate for the third-order dispersion of a bulk grating compressor (as shown in FIG. 5 ) consisting of bulk gratings with 1800 grooves/mm. Attractive well-controllable amplitude filters are for example fiber transmission gratings, though any amplitude filter may be used to control the pulse spectrum in front of such a higher-order dispersion inducing amplifier.
[0198] As another embodiment for the combination of an amplifier module with a pulse picker, the configuration displayed in FIG. 16 can be used. Since very high energy pulses require large core multi-mode fibers for their amplification, the control of the fundamental mode in a single-pass polarization maintaining fiber amplifier may be difficult to accomplish. In this case, it may be preferred to use a highly centro-symmetric non-polarization maintaining amplifier to minimize mode-coupling and to obtain a high-quality output beam. To obtain a deterministic environmentally stable polarization output from such an amplifier, a double-pass configuration as shown in FIG. 16 may be required. Here a single-mode fiber 55 is used as a spatial mode filter after the first pass through the amplifier 56 ; alternatively, an aperture could be used here. The spatial mode filter 55 cleans up the mode after the first pass through the multi-mode amplifier 56 , and also suppresses amplified spontaneous emission in higher-order modes that tends to limit the achievable gain in a multi-mode amplifier. Lenses 60 can be used for coupling into and out of amplifier 56 , spatial mode filter 55 , and pulse pickers 52 a and 52 b . The Faraday rotator 57 ensures that the backward propagating light is polarized orthogonal to the forward propagating light; the backward propagating light is coupled out of the system at the shown polarization beam splitter 58 . To optimize the efficiency of the system, a near-diffraction limited source is coupled into the fundamental mode of the multi-mode fiber 56 at the input of the system, where gain-guiding can also be used to further improve the spatial quality of the beam amplified in the multi-mode fiber. To count-down the repetition rate of the pulse train delivered from a SM and to suppress amplified spontaneous emission in the multi-mode amplifier, a 1st optical modulator 52 a can be inserted after the first pass through the multi-mode amplifier. An ideal location is just in front of the reflecting mirror 59 as shown. As a result a double-pass gain as large as 60-70 dB could be obtained in such a configuration, minimizing the number of amplification stages required from amplifying seed pulses with pJ energies up to the mJ energy level. This type of amplifier is fully compatible with the SMs, PSMs and PCMs as discussed before, allowing for the generation of femtosecond pulses with energies in the mJ regime. As another alternative for the construction of a high-gain amplifier module, a count-down of the repetition rate from a pulse train delivered by a SM can also be performed with an additional 2nd modulator 52 b prior to injection into the present amplifier module as also shown in FIG. 16 . The repetition rate of transmission windows of the 1st modulator 52 a should then be either lower or equal to the repetition rate of the transmission window of the 2nd modulator 52 b . Such a configuration is not separately shown. FIG. 16 shares some similarities with FIG. 5 of U.S. Pat. No. 5,400,350, which is hereby incorporated by reference.
[0199] FIG. 17 represents an embodiment of the femtosecond fiber oscillator embodied in a fiber laser cavity 100 . A polarization-maintaining gain fiber 101 has a core 102 and cladding region 103 . The fiber core 102 is doped with rare-earth ions, such as Yb, Nd, Er, Er/Yb, Tm or Pr, to produce gain at a signal wavelength when the laser is pumped with diode laser 104 . The fiber core can be single-mode or multi-mode. The fiber laser cavity 100 further contains an integrated fiber polarizer 105 and a chirped fiber Bragg grating 106 . Both of these elements, 105 and 106 , are generally constructed of short fiber pigtails (e.g., 0.001-1 m in length), which are preferably fusion-spliced to fiber 101 using splices 107 , 108 and 109 . Alternatively, fiber polarizer 105 can be spliced in front of beam expander 110 . When using multi-mode fiber, splice 107 is selected to match the fundamental mode in the gain fiber 101 .
[0200] An exemplary integrated fiber polarizer in accordance with the invention comprises a polarization-maintaining undoped polarizer fiber (PF), with two orthogonal polarization axes, where the loss along one polarization axis is significantly higher than the loss along the other polarization axis. Alternatively, a very short section (less than 1 cm) of non-birefringent fiber (i.e., non-polarization-maintaining fiber) can be sandwiched between two sections of polarization-maintaining fiber, where the polarization axes of the polarization-maintaining fibers are aligned with respect to each other. By side-polishing the non-birefringent fiber, e.g., down to the evanescent field of the fiber core, along one of the axes of the birefringent fiber, and coating the polished region with metal, high extinction polarization action can be obtained along one of the axes of the birefringent fiber. The design of side-polished fiber polarizers is well known in the field and not discussed further here.
[0201] For optimum laser operation, the fiber polarization axes of the PF are aligned parallel to the polarization axes of the gain fiber 101 . To ensure stable modelocked operation, the polarizer preferably effectively eliminates satellite pulses generated by any misalignment between the polarization axes of the PF and the gain fiber 101 .
[0202] Neglecting any depolarization in the all-fiber polarizer itself, it can be shown by applying a Jones matrix calculation method that for a misalignment of the polarization axes of gain fiber 101 and fiber polarizer 105 by cc degrees, the linear reflectivity R from the right-hand side of the cavity varies approximately between R=1−0.5 sin 2 2α and R=1 depending on the linear phase in the gain fiber 101 . If the group delay along the two polarization axes of the gain fiber is larger than the intra-cavity pulse width, any satellite pulse is suppressed by sin 4 α after transmission through the polarizer. Typical fiber splicing machines can align polarization-maintaining fibers with an angular accuracy of less than ±2°; hence any reflectivity variation due to drifts in the linear phase between the two polarization eigenmodes of fiber 101 can be kept down to less than 3×10 −3 , whereas (for sufficiently long fibers) any satellite pulses obtained after transmission through the polarizer can be kept down to less than 6×10 −6 when using an integrated polarizer.
[0203] The chirped fiber Bragg grating 106 is preferably spliced to the PF 105 at splice position 108 and written in non-polarization-maintaining fiber. In order to avoid depolarization in the fiber Bragg grating, the Bragg grating pig-tails are preferably kept very short, e.g., a length smaller than 2.5 cm is preferable between splice locations 108 and 109 . To obtain a linear polarization output, a polarization-maintaining fiber pig-tail is spliced to the left-side of the fiber Bragg grating at splice location 109 . The laser output is obtained at a first fiber (or cavity) end 111 , which is preferably angle-cleaved to avoid back-reflections into the cavity. An alternative preferred design is with the fiber grating written in polarization-maintaining fiber.
[0204] Fiber Bragg grating 106 serves two functions. First, it is used as an output mirror (i.e., it feeds part of the signal back to the cavity) and, second, it controls the amount of cavity dispersion. In the present implementation, the chirped fiber Bragg grating has a negative (soliton-supporting) dispersion at the emission wavelength in the wavelength region near 1060 nm and it counter-balances the positive material dispersion of the intra-cavity fiber. To produce the shortest possible pulses (with an optical bandwidth comparable to or larger than the bandwidth of the gain medium), the absolute value of the grating dispersion is selected to be within the range of 0.5-10 times the absolute value of the intra-cavity fiber dispersion. Moreover, the fiber Bragg grating is apodized in order to minimize any ripple in the reflection spectrum of the grating. Accordingly, the oscillation of chirped pulses is enabled in the cavity, minimizing the nonlinearity of the cavity and maximizing the pulse energy. Chirped pulses are characterized in having a pulse width which is longer than the pulse width that corresponds to the bandwidth limit of the corresponding pulse spectrum. For example the pulse width can be 50%, 100%, 200% or more than 1000% longer than the bandwidth limit.
[0205] Alternatively, the oscillation of chirped pulses is also enabled by using negative dispersion fiber in conjunction with positive dispersion chirped fiber Bragg gratings. Pulses with optical bandwidth comparable to the bandwidth of the gain medium can also be obtained with this alternative design.
[0206] A SAM 112 at a second distal fiber end 113 completes the cavity. In an exemplary implementation a thermally expanded core (TEC) 110 is implemented at cavity end 113 to optimize the modelocking performance and to allow close coupling of the SAM 112 to the second fiber end 113 with large longitudinal alignment tolerances. Etalon formation between the fiber end 113 and the SAM 112 is prevented by an anti-reflection coating deposited on fiber end 113 (not separately shown). In the vicinity of the second fiber end 113 , fiber 101 is further inserted into ferrule 114 and brought into close contact with SAM 112 . Fiber 101 is subsequently fixed to ferrule 114 using, for example, epoxy and the ferrule itself is also glued to the SAM 112 .
[0207] The pump laser 104 is coupled into the gain fiber 101 via a lens system comprising, for example, two lenses 115 and 116 and a V-groove 117 cut into fiber 101 . Such side-coupling arrangements are described in, for example, U.S. Pat. No. 5,854,865 ('865) to L. Goldberg et al. Alternatively, fiber couplers can be used for pump light coupling.
[0208] An exemplary design for a SAM in accordance with the present invention is shown in FIG. 18 a . For example, SAM 200 includes an InGaAsP layer 201 with a thickness of 50-2000 nm. Further, layer 201 is grown with a band edge in the 1 μm wavelength region; the exact wavelength is defined by the sought emission wavelength of the fiber laser and can vary between 1.0-1.6 μm. The InGaAsP layer 201 is further coated or processed with a reflective material such as Au or Ag. A dielectric mirror or semiconductor Bragg reflector 202 is located beneath layer 201 and the entire structure is attached to heat sink 203 , based on, for example, metal, diamond or sapphire.
[0209] In order to cover a broad spectral range (e.g., greater than 100 nm) metallic mirrors are preferred. When using a metallic mirror it is advantageous to remove the substrate (InP) by means of etching. When using HCl as an etching solvent the etching selectivity between InGaAsP and InP can be low, depending on the compound composition of InGaAsP. An etch-stop layer is beneficial between the substrate and the InGaAsP layer. InGaAs can be a proper etch-stop layer. When adding an InGaAs layer with a band-gap wavelength shorter than 1.03 μm, lattice relaxations can be avoided by keeping the thickness below 10 nm.
[0210] The InGaAsP layer can further be anti-reflection coated with layer 204 on its upper surface to optimize the performance of the SAM. Because of the saturable absorption by InGaAsP, the reflectivity of the SAM increases as a function of light intensity, which in turn favors the growth of short pulses inside the laser cavity. The absence of Al in the saturable absorber layer prevents oxidization of the semiconductor surfaces in ambient air and thus maximizes the life-time and power handling capability of the structure.
[0211] Instead of InGaAsP, any other Al-free saturable semiconductor can also be used in the construction of the SAM. Alternatively, Al-containing semiconductors can be used in the SAM with appropriately passivated surface areas. Surface passivation can, for example, be accomplished by sulfidization of the semiconductor surface, encapsulating it with an appropriate dielectric or with an Al-free semiconductor cap layer. An AlGaInAs absorber layer grown lattice-matched on InP can be surface-passivated with a thin (about 10 nm range) cap layer of InP. AlGaInAs with a higher band gap energy than the absorber layer can also be used for a semiconductor Bragg reflector in combination with InP. Among concepts for semiconductor Bragg mirrors lattice-matched to InP, an AlGaInAs/InP combination has an advantage over an InGaAsP/InP Bragg reflector due to its high refractive index contrast.
[0212] Instead of a bulk semiconductor saturable absorber, a MQW saturable absorber structure as shown in FIG. 18 b may also be used. In this case, the SAM 205 conveniently comprises MQW structures 206 , 207 and 208 separated by passive spacer layers 209 - 212 in order to increase the saturation fluence and depth-selective ion-implantation concentration of each MQW section. Additional MQW structures can further be used, similarly separated by additional passive spacer layers. To reduce the wavelength and location sensitivity of the MQW saturable absorbers, the width of the spacer layers varies from spacer layer to spacer layer. Furthermore, multiple bulk layers with thicknesses larger than 500 Å can replace the MQW structure. The MQW layers, in turn, can contain several layers of quantum wells and barriers such as, for example, InGaAs and GaAs, respectively. Top surface 209 can further be anti-reflection coated (not shown); a reflective structure is obtained by including mirror structure 213. The entire structure can be mounted on heat sink 214 .
[0213] The control of the response time of the saturable absorption for concomitant existence of fast and slow time constants is realized by introducing carrier trap centers with depth controlled H+ (or other ions) implantation. The implantation energy and dose are adjusted such that part of the absorbing semiconductor film contains a minimal number of trap centers. For example the semiconductor layer with the minimal number of trap centers can be selected to be at the edge of the optical penetration range of exciting laser radiation. Such a design serves only as an example and alternatively any semiconductor area within the optical penetration range can be selected to contain a minimal number of trap centers. Hence distinctive bi-temporal carrier relaxation is obtained in the presence of optical excitation. As an illustration of depth selective ion implantation, FIG. 19 shows the measurement of the depth profile of H+ ion implantation of an InGaAsP absorber film taken from secondary ion mass spectroscopy (SIMS).
[0214] The obtained bi-temporal carrier life-time obtained with the semiconductor film with a proton concentration as shown in FIG. 19 , is further illustrated in FIG. 20 . Here the reflectivity modulation (dR/R0) of a semiconductor saturable mirror due to excitation of the saturable mirror with a high energy short pulse at time t=0 is shown as a function of time delay. The measurement was obtained with a pump-probe technique, as well known in the art. FIG. 20 clearly displays the bi-temporal response time due to fast (<1 ps) and slow (>>100 ps) recovery. The distinctive fast response originates from the depth region with high trap concentration, while the slow component results from the rear depth region with a much lower trap center concentration.
[0215] When employing this absorber in the laser system described with respect to FIG. 17 , Q-switched mode-locking is obtained at intracavity power levels of a few mW. At the operating pump power level, stable cw mode-locking evolving from Q-switch mode-locking is observed. In contrast, no Q-switching and no mode-locking operation is obtained with the same semiconductor material implanted uniformly with protons without bi-temporal carrier relaxation (exhibiting only fast carrier relaxation).
[0216] We emphasize that the description for FIG. 19 and FIG. 20 is to serve as an example in controlling 1) the fast time constant, 2) the slow time constant, 3) the ratio of the fast and slow time constants, 4) the amplitude of the fast response, 5) the amplitude of the slow response, and finally 6) the combination of all of the above by ion implantation in a saturable absorber. Thus, the concept depicted hereby can be applicable for any type of laser modelocked with a saturable absorber. Specifically, in the presence of un-avoidable large spurious intra-cavity reflections such as in fiber lasers or thin disk lasers (F. Brunner et al., Sub-50 fs pulses with 24 W average power from a passively modelocked thin disk Yb:YAG laser with nonlinear fiber compression, Conf. on Advanced Solid State Photonics, ASSP, 2003, paper No.: TuA1), the disclosed engineerable bi-temporal saturable absorbers can greatly simplify and stabilize short pulse formation.
[0217] The preferred implantation parameters for H+ ions in GaAs or InP related materials including MQW absorbers are as follows: The doses and the implantation energies can be selected from 10 12 cm −2 to 10 17 cm −2 and from 5 keV to 200 keV, respectively, for an optically absorbing layer thickness between 50 nm and 2000 nm. For MQW absorbers, the selective ion-implantation depth is rather difficult to measure because the shallow MQW falls into the implantation peak in FIG. 19 . However, with the separation of MQW sections with spacers 209 - 212 (as shown in FIG. 18 ) it is feasible to employ depth selective ion implantation. For arsenic implantation, the implantation parameters for 50-2000 nm absorbing layer spans from 10 12 cm −2 to 10 17 cm −2 for the dosage and an implantation energy range of 100 keV to 1000 keV. In case of MQW saturable absorbers, the implantation range is preferably selected within the total thickness of the semiconductor layer structure containing MQW sections and spacers. In addition to H + and arsenic, any other ions such as for example Be can be implanted with controlled penetration depth by adjusting the above recipes according to the stability requirements of the desired laser.
[0218] FIG. 21 a illustrates an alternative implementation of the fiber end and SAM coupling in FIG. 17 . Here cavity 300 comprises an angle-polished thermal-diffusion expanded core (TEC) 301 . Fiber end 302 is brought into close contact with SAM 303 and fiber 304 is rotated inside ferrule 305 to maximize the back reflection from SAM 303 . Ferrule 305 is further angle-polished and SAM 303 is attached to the angle-polished surface of ferrule 305 . As shown in FIG. 21 a , fiber 304 is conveniently glued to the left-hand side of ferrule 305 . A wedge-shaped area between the fiber surface 302 and SAM 303 greatly reduces the finesse of the etalon between the two surfaces, which is required for optimum modelocked laser operation.
[0219] Instead of TEC cores, more conventional lenses or graded index lenses can be incorporated between the fiber end and the SAM to optimize the beam diameter on the SAM. Generally, two lenses are required. A first lens collimates the beam emerging from the fiber end, and a second lens focuses the beam onto the SAM. According to present technology, even conventional lenses allow the construction of a very compact package for the second fiber end. An implementation with two separate collimation and focusing lenses is not separately shown. To minimize unwanted back reflections into the fiber cavity and to minimize the number of components, a single lens can be directly fused to the fiber end as depicted in FIG. 21 b . As shown in FIG. 21 b , assembly 306 contains SAM 303 and fiber 304 as well as lens 307 , which focuses the optical beam onto the SAM. Lens 307 can also include a graded index lens.
[0220] To minimize aberrations in assembly 306 , an additional lens can also be incorporated between lens 307 and SAM 303 . Such an assembly is not separately shown. Alternatively, a lens can be directly polished onto fiber 304 ; however, such an arrangement has the disadvantage that it only allows a beam size on the SAM which is smaller than the beam size inside the optical fiber, thereby somewhat restricting the design parameters of the laser. To circumvent this problem, a lens surface can be directly polished onto the surface of a TEC; such an implementation is not separately shown. Another alternative is to exploit a graded-index lens design attached directly onto the fiber tip to vary the beam size on the SAM. In the presence of air-gaps inside the oscillator a bandpass filter 308 can be incorporated into the cavity, allowing for wavelength tuning by angular rotation as shown, for example, in FIG. 21 b.
[0221] Passive modelocking of laser cavity 100 ( FIG. 17 ) is obtained when the pump power exceeds a certain threshold power. In a specific, exemplary, implementation, polarization-maintaining fiber 101 was doped with Yb with a doping level of 2 weight %; the doped fiber had a length of 1.0 m; the core diameter was 8 um and the cladding diameter was 125 um. An additional 1.0 m length of undoped polarization-maintaining fiber was also present in the cavity. The overall (summed) dispersion of the two intra-cavity fibers was approximately +0.09 ps 2 . In contrast, the fiber grating 106 had a dispersion of −0.5 ps 2 , a spectral bandwidth of 10 nm and a reflectivity of 50%. The grating was manufactured with a phase mask with a chirp rate of 80 nm/cm.
[0222] When pumping with an optical power of 1.0 W at a wavelength of 910 nm, the laser produced short chirped optical pulses with a full width half maximum width of 1.5 ps at a repetition rate of 50 MHz. The average output power was as high as 10 mW. The pulse bandwidth was around 2 nm and hence the pulses were more than two times longer than the bandwidth-limit which corresponds to around 800 fs.
[0223] Alternatively, a fiber grating 106 with a dispersion of −0.1 ps 2 , closely matching the dispersion of the intra-cavity fiber, was implemented. The fiber grating had a reflectivity of 9% and a spectral bandwidth of 22 nm centered at 1050 nm. The grating was manufactured with a phase mask with a chirp rate of 320 nm/cm. The laser then produced chirped optical pulses with a full-width half maximum width of 1.0 ps at a repetition rate of 50 MHz with an average power of 25 mW. The pulse spectral bandwidth was around 20 nm and thus the pulses were around 10 times longer than the bandwidth limit, which corresponds to around 100 fs. The generation of pulses with a pulse width corresponding to the bandwidth limit was enabled by the insertion of a pulse compressing element; such elements are well known in the state of the art and are not further discussed here. The generation of even shorter pulses can be generated with fiber gratings with a bandwidth of 40 nm (and more) corresponding to (or exceeding) the spectral gain bandwidth of Yb fibers.
[0224] Shorter pulses or pulses with a larger bandwidth can be conveniently obtained by coupling the fiber output into another length of nonlinear fiber as shown in FIG. 22 . Here, assembly 400 contains the integrated fiber laser 401 with pig-tail 402 . Pig-tail 402 is spliced (or connected) to the nonlinear fiber 403 via fiber splice (or connector) 404 . Any type of nonlinear fiber can be implemented. Moreover, fiber 403 can also comprise a fiber amplifier to further increase the overall output power.
[0225] In addition to cladding pumped fiber lasers, core-pumped fiber lasers can be constructed in an integrated fashion. Such an assembly is shown in FIG. 23 . The construction of cavity 500 is very similar to the cavity shown in FIG. 17 . Cavity 500 contains polarization-maintaining fiber 501 and integrated fiber polarizer 502 . Fiber 501 is preferably single-clad, though double-clad fiber can also be implemented. The chirped fiber grating 503 again controls the dispersion inside the cavity and is also used as the output coupler. Fiber 501 , fiber polarizer 502 , fiber grating 503 and the polarization-maintaining output fiber are connected via splices 504 - 506 . The output from the cavity is extracted at angle-cleaved fiber end 507 . SAM 508 contains anti-reflection coated fiber end 509 , located at the output of the TEC 510 . Fiber 501 and SAM 508 are fixed to each other using ferrule 511 . The fiber laser is pumped with pump laser 512 , which is injected into the fiber via wavelength-division multiplexing coupler 513 .
[0226] In addition to chirped fiber gratings, unchirped fiber gratings can also be used as output couplers. Such cavity designs are particularly interesting for the construction of compact Er fiber lasers. Cavity designs as discussed with respect to FIGS. 17 and 23 can be implemented and are not separately shown. In the presence of fiber gratings as shown in FIGS. 17 and 23 , the fiber gratings can also be used as wavelength tuning elements. In this, the fiber gratings can be heated, compressed or stretched to change their resonance condition, leading to a change in center wavelength of the laser output. Techniques for heating, compressing and stretching the fiber gratings are well known. Accordingly, separate cavity implementations for wavelength tuning via a manipulation of the fiber grating resonance wavelength are not separately shown.
[0227] In the absence of a fiber grating, a mirror can be deposited or attached to one end of the fiber cavity. The corresponding cavity design 600 is shown in FIG. 24 . Here, it is assumed that the fiber 601 is core pumped. The cavity comprises an intra-cavity all-fiber polarizer 602 spliced to fiber 601 via splice 603 . Another splice 604 is used to couple WDM 605 to polarizer 602 . Polarization maintaining WDM 605 is connected to pump laser 606 , which is used to pump the fiber laser assembly. Saturable absorber mirror assembly 607 , as described previously with respect to FIGS. 17 and 23 , terminates one cavity end and is also used as the passive modelocking element.
[0228] A second fiber polarizer 608 is spliced between WDM 605 and polarization-maintaining output coupler 609 to minimize the formation of satellite pulses, which can occur when splicing sections of polarization maintaining fiber together without perfect alignment of their respective polarization axes, as discussed in U.S. patent application Ser. No. 09/809,248. Typically, coupler 609 has a coupling ratio of 90/10 to 50/50, i.e., coupler 609 couples about 90-50% of the intra-cavity signal out to fiber pig-tail 610 . Pig-tail 610 can be spliced to a fiber isolator or additional fiber amplifiers to increase the pulse power. The second cavity end is terminated by mirror 611 . Mirror 611 can be directly coated onto the fiber end face or, alternatively, mirror 611 can be butt-coupled to the adjacent fiber end.
[0229] The increase in stability of cavity 600 compared to a cavity where the output coupler fiber, the WDM fiber and gain fiber 601 are directly concatenated without intra-fiber polarizing stages, can be calculated using a Jones matrix formalism even when coherent interaction between the polarization axes of each fiber section occurs.
[0230] Briefly, due to the environmental sensitivity of the phase delay between the polarization eigenmodes of each fiber section, for N directly concatenated polarization-maintaining fibers the reflectivity of a fiber Fabry-Perot cavity can vary between R=1 and R=1−(N×α) 2 , where α is the angular misalignment between each fiber section. Further, it is assumed that α is small (i.e., α<<10°) and identical between each pair of fiber sections. Also, any cavity losses are neglected. In fact, it is advantageous to analyze the possible leakage L into the unwanted polarization state at the output of the fiber cavity. L is simply given by L=1−R. For the case of N concatenated fiber sections, the maximum leakage is thus (N×α) 2 .
[0231] In contrast, a cavity containing N−1 polarizers in-between N sections of polarization-maintaining fiber is more stable, and the maximum leakage is L=2×(N−1)α 2 . Here, any depolarization in the fiber polarizers itself is neglected. For instance, in a case where N=3, as in cavity 600 , the leakage L into the wrong polarization axis is 2×(3−1)/3 3 =4/9 times smaller compared to a cavity with three directly concatenated fiber sections. This increase in stability is very important in manufacturing yield as well as in more reproducible modelocked operation in general.
[0232] In constructing a stable laser, it is also important to consider the construction of WDM 605 as well as output coupler 609 . Various vendors offer different implementations. An adequate optical representation of such general polarization-maintaining fiber elements is shown in FIG. 25 . It is sufficient to assume that a general coupler 700 comprises two polarization-maintaining fiber sections (pig-tails) 701 , 702 with a coupling point 703 in the middle, where the two polarization axes of the fiber are approximately aligned with respect to each other.
[0233] In order to ensure pulse stability inside a passively modelocked laser, the group-velocity walk-off along the two polarization axes of fiber sections 701 , 702 should then be longer than the full-width half maximum (FWHM) pulse width of the pulses generated in the cavity. For example, assuming a birefringent fiber operating at a wavelength of 1550 nm with a birefringence of 3×10 −4 corresponding to a polarization beat length of 5 mm at 1550 nm, the stable oscillation of soliton pulses with a FWHM width of 300 fs requires pig-tails with a length greater than 29 cm. For 500 fs pulses, the pig-tail length should be increased to around 50 cm.
[0234] Referring back to FIG. 24 , if a fiber pig-tailed output is not required, mirror 611 as well as output coupler 609 can be omitted, and the 4% reflection from the fiber end adjacent to mirror 611 can be used as an effective output mirror. Such an implementation is not separately shown.
[0235] Alternatively, a fiber-pig-tail can be butt-coupled to mirror 611 and also be used as an output fiber pigtail. Such an implementation is shown in FIG. 26 . Here, cavity 800 comprises core-pumped fiber 801 , fiber polarizer 802 and SAM assembly 803 . The laser is pumped via WDM 804 connected to pump laser 805 . An appropriate mirror (or mirror coating) 806 is attached to one end of the cavity to reflect a part of the intra-cavity light back to the cavity and to also serve as an output mirror element. Fiber pig-tail 807 is butt-coupled to the fiber laser output mirror 806 and an additional ferrule 808 can be used to stabilize the whole assembly. The polarization axes of fiber 807 and 801 can be aligned to provide a linearly polarized output polarization. Again, applying a Jones matrix analysis, cavity 800 is more stable than cavity 600 , because it comprises only one intra-fiber polarizing section. The maximum leakage in cavity 800 compared to a cavity comprising directly concatenated WDM and gain fiber sections is 50% smaller.
[0236] Similarly, a cladding pumped version of cavity 600 can be constructed. Cavity 900 shown in FIG. 27 displays such a cavity design. Fiber 901 is pumped via pump laser 902 , which is coupled to fiber 901 via lens assembly 903 and 904 as well as V-groove 905 . Alternatively, polarization-maintaining multi-mode fiber couplers or star-couplers could be used for pump power coupling. Such implementations are not separately shown. One end of the laser cavity is terminated with SAM assembly 906 (as discussed in regard to FIGS. 17 , 23 and 24 , which is also used as the modelocking element. A single-polarization inside the laser is selected via all-fiber polarizer 907 , which is spliced into the cavity via splices 908 and 909 . Polarization-maintaining output coupler 910 is used for output coupling. The laser output is extracted via fiber end 911 , which can further be spliced to additional amplifiers. Cavity mirror 912 terminates the second cavity end. Output coupler 910 can further be omitted and the laser output can be obtained via a butt-coupled fiber pig-tail as explained with reference to FIG. 30 .
[0237] The cavity designs discussed with respect to FIGS. 17 , 23 , 24 , 26 and 27 follow general design principles as explained with reference to FIGS. 28 a - 28 c.
[0238] FIG. 28 a shows a representative modelocked Fabry-Perot fiber laser cavity 1000 , producing a linear polarization state oscillating inside the cavity containing one (or more) sections of non-polarization maintaining fiber 1001 and one (or more) sections of polarization maintaining fiber 1002 , where the length of fiber section 1001 is sufficiently short so as not to degrade the linear polarization state inside the fiber laser cavity, more generally a predominantly linear polarization state is oscillating everywhere within the intracavity fiber. The fiber laser output can be obtained from cavity end mirrors 1003 or 1004 on either side of the cavity. To suppress the oscillation of one over the other linear polarization state inside the cavity, either fiber 1001 or 1002 has a polarization dependent loss at the emission wavelength.
[0239] FIG. 28 b shows a representative modelocked Fabry-Perot fiber laser cavity 1005 , producing a linear polarization state oscillating inside the cavity containing two (or more) sections of polarization maintaining fibers 1006 , 1007 , where the length of fiber sections 1006 , 1007 is sufficiently long so as to prevent coherent interaction of short optical pulses oscillating inside the cavity and propagating along the birefringent axes of fibers 1006 , 1007 . Specifically, for an oscillating pulse with a FWHM width of τ, the group delay of the oscillating pulses along the two polarization axes of each fiber should be larger than τ. For oscillating chirped pulses τ represents the bandwidth-limited pulse width that corresponds to the oscillating pulse spectrum. Cavity 1005 also contains end mirrors 1008 and 1009 and can further contain sufficiently short sections of non-polarization maintaining fiber as discussed with reference to FIG. 28 a.
[0240] FIG. 28 c shows a representative modelocked Fabry-Perot fiber laser cavity 1010 , producing a linear polarization state oscillating inside the cavity containing one (or more) sections of polarization maintaining fiber 1011 , 1012 and one (or more) sections of polarizing fiber (or all-fiber polarizer) 1013 , where the length of fiber sections 1011 , 1013 is not sufficient to prevent coherent interaction of short optical pulses oscillating inside the cavity and propagating along the birefringent axes of fibers 1011 , 1013 , where the polarizing fiber is sandwiched between the sections of short polarization maintaining fiber. Cavity 1010 further contains cavity end mirror 1014 and 1015 and can further contain short sections of non-polarization maintaining fiber as discussed with reference to FIG. 28 a . Moreover, cavity 1010 (as well as 1000 and 1005 ) can contain bulk optic elements 1016 , 1017 (or any larger number) randomly positioned inside the cavity to provide additional pulse control such as wavelength tuning or dispersion compensation. Note that the fibers discussed here can be single-clad, double-clad; the fibers can comprise also holey fibers or multi-mode fibers according to the system requirement. For example polarization maintaining holey fibers can be used for dispersion compensation, whereas multi-mode fibers can be used for maximizing the output pulse energy. Cavity mirrors 1014 , 1015 , 1003 , 1004 and 1008 , 1009 can further comprise bulk mirrors, bulk gratings or fiber gratings, where the fiber gratings can be written in short sections of non-polarization maintaining fiber that is short enough so as not to perturb the linear polarization state oscillating inside the cavity.
[0241] FIG. 29 serves as an example of a passively modelocked linear polarization cavity containing holey fiber for dispersion compensation. Cavity 1100 contains fiber 1101 , side-pumping assembly 1102 (directing the pump light either into the cladding or the core of fiber 1101 as explained before), saturable absorber mirror assembly 1103 , all fiber polarizer 1104 and fiber output coupler 1105 providing an output at fiber end 1106 . All the above components were already discussed. In addition, a length of polarization maintaining holey fiber 1006 is spliced to the cavity for dispersion compensation and the cavity is terminated on the left hand side by mirror 1107 .
[0242] FIG. 30 serves as another example of a passively modelocked linear polarization cavity containing a fiber grating for dispersion compensation as applied to the generation of ultra-stable spectral continua. System 1400 comprises a small modification of the cavity explained with respect to FIG. 23 . System 1400 contains a fiber laser 1401 generating pulses with a bandwidth comparable to the spectral bandwidth of the fiber gain medium 1402 . Fiber laser 1401 further comprises saturable absorber mirror assembly 1403 , wide bandwidth fiber grating 1404 , polarization maintaining wavelength division multiplexing (WDM) coupler 1405 , which is used to direct pump laser 1406 into fiber gain medium 1402 . Pump laser 1406 is preferably single-mode to generate the least amount of noise.
[0243] To enable the oscillation of short pulses with a bandwidth comparable to the bandwidth of the gain medium 1402 , saturable absorber mirror 1403 contains a bi-temporal saturable absorber, constructed with a bi-temporal life-time comprising a 1 st short life-time of <5 ps and a 2 nd long life-time of >50 ps. More preferable is a first life-time of <1 ps, to allow pulse shaping of pulses as short as 100 fs and shorter. By selecting the penetration depth of the implanted ions into the saturable absorber, even tri-temporal saturable absorbers can be constructed.
[0244] The wide-bandwidth grating is preferably selected to approximately match the dispersion of the intra-cavity fibers. The wide-bandwidth grating can be made in short non-polarization maintaining fibers and it can be made also in polarization maintaining fibers. In order to suppress detrimental effects from cross coupling between the two polarization axes of the fiber grating, coupling to cladding modes in such large bandwidth fiber gratings should be suppressed. Gratings with suppressed coupling to cladding modes can be made in optical fibers with photosensitive core and cladding area, where the photosensitive cladding area is index-matched to the rest of the cladding. Such fiber designs are well known in the state of the art and can for example be manufactured with an appropriate selection of germania and fluorine doping in the core and cladding regions and such fiber designs are not further discussed here. Because of the large generated bandwidth, splicing of such polarization maintaining gratings to the rest of the cavity without coherent coupling between the linear polarization eigenmodes is no problem. Alternatively, the fiber gratings can be written directly into the photosensitive gain fiber, with an index and dopant profile that suppresses coupling to cladding modes in the fiber grating.
[0245] To sustain large spectral bandwidth, fiber grating 1404 has preferably a spectral bandwidth >20 nm. A splice 1407 (or an equivalent bulk optic lens assembly) is used to connect the output of fiber laser 1401 to nonlinear fiber 1408 to be used for additional spectral broadening of the output of the fiber laser. For example fiber 1408 can comprise a highly nonlinear dispersion-flattened holy fiber. In conjunction with such fiber, smooth broad-bandwidth spectral profiles with bandwidths exceeding 100 nm can be generated. These spectral outputs can be used directly in high precision optical coherence tomography.
[0246] The pulses at the output of fiber 1408 are generally chirped and a dispersion compensation module 1409 can be inserted after the output from fiber 1408 for additional pulse compression. The dispersion compensation module can be spliced directly to fiber end 1408 when optical fiber is used for dispersion compensation. Alternatively, the dispersion compensation module can comprise two (or one) bulk grating (or prism) pair(s). Such bulk optic elements for dispersion compensation are well known in the state of the art and are not further discussed here. Coupling into and out of a bulk dispersion compensating module is obtained via lenses 1410 and 1411 . The output can also be from the other end of the cavity. The pulses generated after pulse compression can be as short as 20-200 fs. As mentioned previously this pulse compression module is optional and the dispersion compensation needed for this oscillator can be compensated by the pulse stretcher before and pulse compressor after the regenerative amplifier.
[0247] A fiber amplifier 1412 can also be added if further pulse energy is necessary.
[0248] Note that the discussion with respect to FIG. 30 serves only as an example of the use of bi- or multi-temporal saturable absorbers in the generation of mass producible ultra-broad band, low noise spectral sources. Other modifications are obvious to anyone skilled in the art. These modifications can comprise for example the construction of an integrated all-fiber assembly substituting elements 1408 , 1409 - 1411 and 1412 .
[0249] Though the discussion of the laser system with respect to FIG. 30 was based on the use of polarization maintaining fiber, non polarization maintaining fiber can also be used to produce pulses with bandwidth comparable to the bandwidth of the gain medium. In this case, saturable absorbers with depth controlled ion implantation are also of great value. Essentially, any of the prior art modelocked fiber laser systems described above (that were using saturable absorbers) can be improved with engineered bi- and multi-temporal saturable absorbers. Specifically, any of the cavity designs described in U.S. Pat. Nos. 5,450,427 and 5,627,848 to Fermann et al. can be used for the generation of ultra broadband optical pulses in conjunction with bi- or multi-temporal saturable absorbers and wide-bandwidth fiber Bragg gratings.
[0250] An embodiment with the fewest bulk optic components in the optical path is shown in FIG. 31 . The source of ultrashort pulses is a fiber-based MOPA 100 . This source is described in detail in Ser. No. 10/814,502 which is incorporated herein. A polarization-maintaining gain fiber 101 has a core 102 and cladding region 103 . The fiber core 102 is doped with rare-earth ions, preferably Yb, to produce gain at a signal wavelength when the laser is pumped with diode laser 104 . The pump diode is coupled into the cladding region 103 of fiber 101 using for example two lenses 105 and 106 and V-groove 107 , though coupling systems comprising more than two lenses can be used. Alternatively a WDM and a single mode laser diode can be used for in core optical pumping. The fiber core can be single-mode or multi-mode. The multi-mode fiber is designed to propagate single mode as is described in U.S. application Ser. No. 09/785,944 (incorporated by reference herein). The multi-mode fiber can also be multi-mode photonic crystal fiber as is described in Ser. No. 10/844,943 (incorporated herein). The fiber laser cavity 100 further contains a fiber Bragg grating 108 , written in polarization maintaining fiber, an optional polarizer (fiber or bulk) 109 and a saturable absorber assembly 110 . A bulk polarizer such as a cube polarizer is preferred. Fiber grating 108 can be chirped or un-chirped, where the polarization cross talk between the two polarization axes of the polarization maintaining fiber containing the fiber gratings is preferably less than 15 dB. Fiber end face 111 completes the basic MOPA system. The fiber Bragg grating can be written directly into fiber 101 or it can be spliced into the MOPA system at splice positions 112 and 113 , where the polarization axes of all involved fibers are aligned with respect to each other. The MOPA comprises an oscillator assembly 114 and an amplifier assembly 115 . The oscillator assembly 114 is bounded on the left hand side by fiber grating 108 and on the right hand side by saturable absorber assembly 110 . The amplifier assembly 115 is bounded by fiber grating 108 and fiber end 111 on the two opposite distal ends. In the present example fiber 101 is used both in the amplifier section and in the amplifier section. In general, however, different fibers can be used in the oscillator and amplifier, though to avoid feedback from the amplifier into the oscillator, the refractive index of both oscillator and amplifier fiber should be closely matched. The chirp of the output pulses can be conveniently compensated with the delivery fiber 118 , where lenses 116 and 117 are used to couple the output from the MOPA into the delivery fiber. Other pulse modification elements can be placed between the lenses such as an isolator, tunable filter or fiber gratings. The delivery fiber can comprise standard silica step-index fiber, holey fiber or photonic crystal fiber. The use of photonic crystal for dispersion compensation and pulse delivery was previously disclosed in Ser. No. 10/608,233. The delivery fiber 118 can also be spliced directly to fiber end face 111 , enabling a further integration of the laser assembly. The delivery fiber can also be sufficiently long to stretch the pulse sufficiently for amplification in the regenerative amplifier. The need for a compressor depends on the exact design of the regenerative amplifier.
[0251] The embodiment in FIG. 31 may be the simplest design, however the pulse conditioning shown in FIG. 1 and described in Ser. No. 10/960,923 are often necessary to obtain the needed specifications from the ultrafast source. Ser. No. 10/814,319 (incorporated by reference herein) teaches how to utilize various modules for pulse conditioning for a fiber laser source. Ser. No. 10/813,163 (incorporated by reference herein) describes utilizing some of these methods in a fiber chirped pulse amplification system. These pulse conditioning methods can be utilized in a regenerative amplifier system. FIG. 32 illustrates one embodiment of a laser system 550 having a monitoring and feedback control capability. In one embodiment of the laser system, monitoring the performance such as output power at some point(s) of the system and providing feedback to the diode pump drivers for active control can achieve a stable operation. FIG. 10 illustrates one embodiment of a laser system 550 having such a monitoring and feedback feature. The exemplary laser system 550 comprises an oscillator 552 coupled to an attenuator 556 via an isolator 554 . The output from the attenuator 556 is fed into a bandpass filter 558 whose output is then directed to a stretcher 561 and then an amplifier 560 . The output from the amplifier 560 is fed into the regenerative amplifier 563 and then a compressor 564 via an isolator 562 . It should be noted that the use of the attenuator 556 and the bandpass filter 558 are exemplary, and that either of these components may be excluded and any other modular components, including those disclosed herein, may be used in the laser system having feedback.
[0252] As shown in FIG. 32 , the laser system 550 further comprises a first monitor component 570 that monitors a performance parameter of the system after the oscillator 552 . The monitor 570 may comprise a sensor and controller. The monitor 570 may issue adjustment commands to a first driver 572 that implements those adjustment commands at the oscillator 552 .
[0253] The exemplary laser system 550 is shown to further comprise a second monitor component 574 that monitors a performance parameter of the system after the amplifier 560 . The monitor 574 may similarly comprise a sensor and controller. The monitor 574 can then issue adjustment commands to a second driver 576 that implements those adjustment commands at the amplifier 560 .
[0254] The monitoring of the system performed by the exemplary monitors 570 and/or 574 may comprise for example an optical detector and electronics that monitors optical intensity or power or other relevant parameter such as, e.g., frequency and spectrum. In response to such measurement, the monitor and the driver may induce changes in the oscillator and/or the amplifier by for example adjusting the pump intensity and/or rate, or adjusting the operating temperature. Temperature control of the oscillator can stabilize the gain dynamics as well as frequency fluctuations. Temperature control of the amplifier can also be used to stabilize the gain dynamics.
[0255] Other configurations for providing feedback to control the operation of the laser system may also be employed. For example, more or less feedback loops may be included. The electronics associated with these feedback loops are further described in Ser. No. 10/813,173 (incorporated by reference herein). A particularly important electronic control is to control the gain of the fiber amplifier. At 1 KHz repetition rate and lower, the gain of the fiber amplifier could be reduced between pulses to conserve the lifetime of the laser diode. Also the gain needs to be reduced on the fiber amplifier if a signal is lost from the short pulse source to protect from optical damage to the fiber amplifier or subsequent optical elements. The loops may involve electronics that perform operations such as calculations to determine suitable adjustments to be introduced. Examples are the mode-lock start-up and search algorithms that are disclosed in Attorney Docket No. A8828 (incorporated by reference herein). The start-up algorithm is shown in FIG. 37 . The feedback may be obtained from other locations in the system and may be used to adjust other components as well. The embodiments described in connection with FIG. 32 should not be construed to limit the possibilities.
[0256] A good Polarization Extinction Ratio (PER) is an important factor in maintaining good temporal pulse quality in a fiber-based ultrafast source for a regenerative amplifier. Poor polarization extinction creates ripple on the spectrum and on the chirped pulse. In various preferred embodiments, the light in the laser is linearly polarized. The degree of the linear polarization may be expressed by the polarization extinction ratio (PER), which corresponds to a measure of the maximum intensity ratio between two orthogonal polarization component. In certain embodiments, the polarization state of the source light may be maintained by using polarization-maintaining single-mode fiber. For example, the pigtail of the individual modular device may be fabricated with a polarization-maintaining fiber pigtail. In such cases, the PER of each modular stage may be higher than about 23 dB. Ensuring a high polarization extinction ratio throughout a series of modules is challenging despite the use of single mode polarization maintaining fiber. Degradation of the PER can occur at the fiber ferrule, fiber holder, or fusion splice in the series of modules.
[0257] Levels of PER above 23 dB may be obtained in a system by utilizing linear-polarizing optical components in the modules. Use of linear-polarizing components in the modules within systems that contain polarization degrading elements such as a fiber ferrule, fiber holder, or fusion splice is advantageous. The linear polarizers counter the superposition of the phase shift from each polarization degrading element. A superposed phase shift of 10 degrees may reduce the PER to about 15 dB in which case intensity fluctuation through a linear polarizer might be more than about 4%. In contrast, by embedding linear polarizers throughout the series of modules, the PER of the aggregate system can be substantially controlled such that the intensity fluctuation is below about 1%, provided that the PER of the individual module and splice is above about 20 dB.
[0258] FIG. 33 a illustrates one embodiment of a module that can be utilized for polarization correction or as variable attenuation. It is a variable attenuator module 730 comprising a housing 732 that contains optical components for providing a controllable amount of optical attenuation. The housing 732 may be sealed and thermally insulated as well. A first optical fiber connector 734 comprising an optical fiber 736 having an angle polished or cleaved end face passes through one sidewall of the housing 732 into an inner region of the housing containing the plurality of optical components. These optical components include a first lens 738 for collecting and preferably collimating light output from the optical fiber 736 , a variable wave plate 740 and a polarization selective optical element 742 . A second optical fiber connector 744 comprising an optical fiber 745 having an angle polished or cleaved end face passes through another sidewall of the housing 732 into the inner region containing the optical components. The variable waveplate 740 comprises a rotatable waveplate mounted on a rotatable wheel 746 and the polarization selective optical element 742 comprises a polarization beamsplitter such as a MacNeille prism. A second lens 748 disposed between the polarization selective optical element 742 couples light between the polarization beamsplitter 742 and the second optical fiber 745 . An optical path is formed from the first optical fiber 736 through the waveplate 740 and prism 742 to the second optical fiber connector 744 .
[0259] The waveplate 740 can be rotated to vary the distribution of light into orthogonal polarizations. The polarization beamsplitter 742 can be used to direct a portion of the light out of the optical path between the first and second fiber connectors 734 , 744 , depending on the state of the waveplate 740 . Accordingly, a user, by rotating the waveplate 740 and altering the polarization of light can control the amount of light coupled between the first and second optical fiber connectors 734 , 744 and thereby adjust the level of attenuation.
[0260] Preferably, the optical elements such as the first and second lenses 738 , 748 , the rotatable waveplate 740 and the MacNeille polarizer 742 comprise micro-optics or are sufficiently small to provide for a compact module. The elements in the housing 732 may be laser welded or otherwise securely fastened to a base of the housing. The housing 732 may be sealed and thermally insulated as well. In various preferred embodiments, these modules conform to Telcordia standards and specifications.
[0261] A particularly preferred embodiment for a fiber solid-state regenerative amplifier system ( 2000 ) is shown in FIG. 33 b . The mode-locked Yb oscillator ( 2100 ) operates at near 50 MHz with a chirped pulse width after the fiber stretcher ( 2200 ) between 2-100 ps. The mode-locking means is a saturable absorber mirror ( 2001 ). The gain is provided by a Yb: doped fiber ( 2002 ). The other output coupler is a chirped fiber grating ( 2003 ) that also provides for dispersion compensation. The center wavelength is between 1030-1040 nm with a bandwidth between 5-20 nm. The pulse is compressible to 100-300 fs. It is pumped in core by a conventional laser diode ( 2005 ) through a polarization maintaining WDM ( 2004 ). Side pumping the cladding is also suitable. The pulse energy is nearly 1 nJ after amplification. The fiber amplifier ( 2300 ) is slightly nonlinear. The spectral broadening is negligible but is dependent on the input power to the fiber amplifier. The Yb: fiber ( 2011 ) is approximately 3 meters long. It is also polarization preserving fiber. The Yb: fiber amplifier gain shapes and frequency shifts slightly the output. It is pumped co propagating by a conventional single mode laser diode ( 2009 ) through a polarization maintaining WDM ( 2010 ). Counterpropagating pumping and cladding pumping are also suitable. The output from the fiber amplifier is through a bulk collimator ( 2012 ) and a bulk isolator ( 2013 ). More than one isolator may be necessary at this point. Alternatively, an AOM pulse selector can be added to the end of the amplifier for isolation. A Faraday rotator and polarizer can be used at this point to separate the input of the regenerative amplifier ( 2400 ) from the output to the bulk grating compressor ( 2500 ). In addition there is an isolator ( 2007 ) between the fiber stretcher and fiber amplifier that includes an optical tap. The tap ( 2007 ) provides an optical sync output ( 2008 ) that is converted to an electrical signal by means of a photodiode. This signal is used to synchronize the regenerative amplifier pulse selector to the mode-locked fiber laser.
[0262] In this next embodiment an alternative source of the ultrafast pulses is a laser-diode or microchip laser. This embodiment is shown in FIGS. 34 and 35 . In FIG. 34 , the microchip laser is a single longitudinal Nd:vanadate source that provides a smooth temporal profile. The pulse width is 250 picoseconds. One solution for the compression fiber 62 is a standard single mode fiber with a mode field diameter of 5.9 μm and a NA of 0.12. The length of this compression fiber would be about 2 meters to create sufficient spectrum for a compression ratio of around 50. The output energy from microchip lasers can be 10 microjoules. In this case, the light intensity at the entrance face of the fiber will be near the damage threshold. A coreless end cap (not shown) can be used on the fiber so the mode can expand before the surface of the fiber. Otherwise, an amplifier with a larger mode field diameter can be used, such as a multimode fiber that propagates a single mode or a holey fiber amplifier as was used in (Furusawa et al “Cladding pumped Ytterbium-doped fiber laser with holey inner and outer cladding”, Optics Express 9, pp. 714-720, (2001)). If a fiber with an order of magnitude higher mode area (mode field diameter of 19.5 μm) is used, then the parameters in the fiber will be the same as in the case with 1 microjoule input. So the fiber length would again be 2 meters.
[0263] Since there is no interplay between dispersion and self-phase modulation in this design, the pulse width stays the same as the original pulse width. The nearly linear chirp is created by the shape of the pulse. Such a fiber is normally called a “compression fiber”. We propose to replace this “compression fiber” with an amplifier fiber. The output of the amplifier will be a chirped pulse that can be compressed in a compressor. This saves the need of a stretcher.
[0264] For pulse energies significantly greater than 1 microjoule, the single mode beam should be further amplified in a multimode fiber. This chirped pulse source is ideal for amplification of ultrashort pulses by chirped pulse amplification in a regenerative amplifier. The pulse is then compressed after amplification. In this case the microchip 71 was operated at 0.5 μJ, and produced 250 ps, pulses and operating at the repetition rate of the regenerative amplifier. The compression fiber 62 is now a multimode amplifier fiber that amplified a single mode with a mode-field diameter of 17 μm. The pulse was then amplified to 30 microjoules where Raman limited the amplification. This pulse is now a chirped 250 ps pulse. It is further amplified in a solid state regenerative amplifier and compressed in a bulk grating compressor to typically less than 1 ps. FIG. 35 illustrates the source generally described in FIG. 3 of US Published Application 20040240037A1, incorporated by reference herein, with modification made to the chirped fiber grating at the end of the source to further stretch the pulses prior to amplification in the regenerative amplifier.
[0265] FIG. 36 illustrates a chirped pulse amplification system that utilizes conventional fiber stretchers, fiber amplifiers, bulk regenerative amplifiers and bulk grating compressors. In order to obtain high quality pulses from such systems, the control of higher-order dispersion and self-phase modulation is critical. A chirped pulse amplification system allowing for independent control of second- and third order dispersion is shown in FIG. 36 . In an exemplary embodiment, a seed source 101 based on a passively modelocked Yb fiber laser was used. Such passively modelocked Yb fiber lasers were previously described in application Ser. No. 10/627,069 and are not further described here. The seed source 101 produces positively chirped optical pulses with a bandwidth of 16 nanometers at a repetition rate of 43 megahertz with an average power of 16 milliwatts. The peak emission wavelength of the oscillator was 1053 nanometers. The pulses from the seed source were compressible to a pulse width of less than 150 femtoseconds, demonstrating that the chirp from the seed source was approximately linear. The output from the seed laser passed through an isolator (not shown) and a tunable bandpass filter 119 with a 15 nanometer bandwidth.
[0266] After the bandpass filter 119 , an output power of 5 milliwatts was obtained and a fiber stretcher 120 was used to stretch the pulses to a width of approximately 100 picoseconds. The fiber stretcher employed for producing stretched pulses had a length of approximately 200 meters and was based on conventional polarization maintaining single-mode step-index fiber. In FIG. 36 , the tunable bandpass filter 119 is shown inserted before the fiber stretcher 120 ; alternatively, the tunable bandpass filter 119 can also be inserted after the fiber stretcher 120 (system implementation is not separately shown).
[0267] A subsequent Yb-based polarization maintaining pre-amplifier 121 amplifies the stretched pulses to an average power of 500 milliwatts. A pulse picker 122 , based on an acousto-optic modulator and pig-tailed with polarization maintaining fiber, reduces the repetition rate of the pulses to 200 kilohertz, resulting in an average power of 1 milliwatt. The pulses from the pulse picker 122 were subsequently injected into a large-mode polarization maintaining Yb fiber power amplifier 123 and amplified to an average power of 950 milliwatts. The Yb power amplifier had a length of 3 meters and the fundamental mode spot size in the Yb power amplifier was around 25 micrometers. All fibers were either spliced together with their polarization axes aligned or connected to each other (with their polarization axes aligned) with appropriate mode-matching optics (not shown). The power amplifier 123 was cladding pumped via a lens 124 with a pump source 125 , delivering a pump power of about 10 watts at a wavelength of 980 nanometers. A beam splitting mirror 126 was implemented to separate the pump light from the amplified signal light. The amplified and stretched pulses from the power amplifier 123 are further amplified in a bulk solid state regenerative amplifier 129 . The output pulses from the regenerative amplifier 129 were compressed in a conventional bulk optics compressor 127 based on a single diffraction grating with a groove density of 1200 lines/mm, operating near the Littrow angle. Such bulk optics compressors are well known in the state of the art and are not further explained here. After the bulk optics compressor 127 , the output 128 will contain pulses with a full-width half-maximum (FWHM) width of around 330 femtoseconds and pulse energies around 1 millijoule. Alternative designs should be feasible including a system without the power amplifier. However, in this case the power amplifier is operating as the nonlinear fiber amplifier that is able to correct for higher order dispersion mismatch between the fiber stretcher and the bulk compressor.
[0268] Because stretched pulses can accumulate significant levels of third-order dispersion in the presence of self-phase modulation, gain-narrowing, gain-pulling and gain depletion, we refer to such pulses as cubicons. More generally, we can define a cubicon as a pulse that produces controllable levels of at least linear and quadratic pulse chirp in the presence of at least substantial levels of self-phase modulation (corresponding to a nonlinear phase delay>1) that can be at least partially compensated by dispersive delay lines that produce significant levels of second and third-order dispersion as well as higher-order dispersion. (Please note that for the compensation of linear pulse chirp, a dispersive delay line with second order dispersion is required, whereas for the compensation of quadratic pulse chirp, a dispersive delay line with third order dispersion is required and so on for higher orders of pulse chirp.) For a dispersive delay line to produce a significant level of 2 nd and 3 rd as well as possibly higher-order dispersion, the stretched pulses are typically compressed by more than a factor of 30. In addition cubicons can also be formed in the presence of resonant amplifier dispersion, gain narrowing, gain pulling as well as gain depletion, where we refer to gain depletion as an appreciable reduction in gain due to a single pulse. If a high power mode-locked oscillator an undoped fiber can be utilized to create the self-phase modulation. Spectral filtering will most likely be necessary to obtain the appropriate pulse shape to the chirped pulse. The chirped pulse width will need to be further expanded before amplification in the regenerative amplifier.
[0269] The importance of the pulse picker 122 has been described in Ser. No. 10/960,923 in that it alleviates the specifications on the optical switch in the regenerative amplifier. A further advantage is that it can be utilized as a variable attenuator for controlling the buildup time in the regenerative amplifier. An AO switch can be used here, however EO switches and EA switches are available in modules that conform to Telcordia standards and specifications. As pointed out in Ser. Nos. 10/437,057 and 10/606,829, it often takes two switches since the standard on off discrimination is 30 db while for lowering the rep rate from 30 MHz to 1 KHz requires an on off discrimination of more than 50 db for the majority of the energy to be in the one pulse operating at the lower repetition rate. Another use of the pulse picker is as a variable attenuator to control the nonlinearities in the fiber for dispersion correction. In cubicon amplification the nonlinearities are critical for dispersion control and the variable attenuation feature of the pulse pickers is a means for controlling the nonlinear affects in the fibers. Other variable attenuators can be used such as described in Ser. No. 10/814,319. Other means of controlling the nonlinearities of the fiber amplifier are utilizing the control of the fiber amplifier output as described above. These include varying the gain or temperature of the fiber amplifier by measuring the spectrum and or the output intensity from the fiber amplifier. Controlling the spectrum and the intensity accurately for cubicon amplification can be implemented.
[0270] The embodiment of a short pulse source in the picosecond and nanosecond range amplified in a fiber amplifier and amplified in a bulk amplifier is disclosed in application Ser. No. 10/927,374 (incorporated by reference herein) This system in some cases will have better performance when the bulk amplifier is utilized as a regenerative amplifier. This embodiment is shown in FIG. 38 . Fiber amplifier system 501 is described in detail in Ser. No. 10/927,374. The output pulse of the fiber amplifier system 501 is mode-matched by beam conditioning optics 506 to the fundamental mode of the solid state regenerative amplifier 505 . The regenerative amplifier 505 utilizes a bulk crystal gain material which is preferably directly diode pumped. The embodiment displayed in FIG. 38 has the advantage that the gain bandwidth of the regenerative amplifier can be matched to the fiber amplifier system. For example 1 ns pulses with a spectral bandwidth of 0.6 nm and a pulse energy exceeding 100 μl, centered at a wavelength of 1064 nm can be generated in a fiber amplifier chain in conjunction with a diode seed laser, for injection into a Nd:YVO 4 amplifier, which has a spectral bandwidth of approximately 0.9 nm. As another example a modelocked Yb-fiber oscillator with center wavelength of 1064 nm and a bandwidth of several nm can be amplified and spectrally narrowed and matched to the gain bandwidth of the Nd:YVO 4 solid state amplifier. Thus 100 ps pulses with an energy of around 100 μl and higher can be generated in a fiber amplifier chain and efficiently amplified in the regenerative amplifier. Without exploitation of spectral narrowing, the pulse energies from fiber amplifier chains designed for the amplification of 100 ps pulses in bulk Nd:YVO 4 amplifiers has to be reduced to avoid spectral clipping in the bulk amplifiers. Spectral narrowing is indeed universally applicable to provide high energy seed pulses for narrow line-width solid state amplifiers. For the example of bulk Nd:YVO 4 amplifiers, spectral narrowing is preferably implemented for pulse widths in the range of 20 ps−1000 ps.
[0271] Bulk solid-state regenerative amplifiers are also useful to increase the energy of pulses generated with fiber based chirped pulse amplification systems. Chirped pulse amplification is generally employed to reduce nonlinearities in optical amplifiers. The implementation of chirped pulse amplification is most useful for the generation of pulses with a width <50 ps. Due to the limited amount of pulse stretching and compression that can be achieved with chirped pulse amplification schemes, stretched pulses with an initial pulse width exceeding 1-5 ns are generally not implemented. Hence optical damage limits the achievable pulse energies from state of the art fiber based chirped pulse amplification systems (assuming fiber power amplifiers with a core diameter of 30 μm) to around 1 mJ. Single stage bulk solid state amplifiers can increase the achievable pulse energies normally by a factor of 10 while a regenerative amplifier has a gain of 10 6 . Therefore a regenerative amplifier can be preferable and give flexibility at a cost of complexity. One advantage is significantly lower pulse energies can be utilized from the fiber amplifier. A generic scheme 500 for the amplification of the output of a fiber based chirped pulse amplification system in a bulk optical amplifier is shown in FIG. 39 . Here short fs-ps pulses with pulse energies of a few nJ are generated in fiber oscillator 501 . The pulses from the oscillator are stretched in pulse stretcher 502 to a width of 100 ps-5 ns. The pulse stretcher is preferably constructed from a chirped fiber grating pulse stretcher as discussed with respect to FIG. 1 and can also be constructed from bulk optical gratings as well known in the state of the art. A pulse picker 503 reduces the repetition rate of the oscillator to the 1 kHz-1 MHz range to increase the pulse energy of the amplified pulses. A fiber amplifier chain represented by a single fiber 504 is further used to increase the pulse energy to the μJ-mJ level. Appropriate mode matching optics 506 is then used to couple the output of amplifier chain 504 into the bulk solid state amplifier 505 . Here bulk solid state amplifiers based on rods, slabs as well as thin disk concepts can be implemented. Appropriate bulk amplifier material are based for example on Yb:YAG, Nd:YAG, Nd:YLF or Nd:YVO 4 , Nd:glass, Yb, glass, Nd:KGW and others. Appropriate bulk amplifier materials and designs are well known in the state of the art and not further discussed here. A collimation lens 507 directs the output of the bulk solid state amplifier to the input of the compressor assembly. To minimize the size of a chirped pulse amplification system employing narrow bandwidth Nd-based crystals such as Nd:YAG, Nd:YLF, Nd:YVO 4 or Nd:KGW the use of a grism based compressor is preferred. The optical beam is directed to via mirror 508 to the grism 509 and an additional folding prism 510 is used to minimize the size of the compressor. Mirror 511 completes the compressor assembly. Such compressor assemblies have previously been used to compensate for third-order dispersion in wide-bandwidth chirped pulse amplification systems (i.e. chirped pulse amplification systems with a bandwidth >5 nm); no prior art exists applying grism technology to narrow bandwidth chirped pulse amplification systems (i.e. chirped pulse amplification systems comprising amplifiers with a spectral bandwidth <5 nm).
[0272] In an exemplary embodiment, fiber oscillator 501 generates 5 ps pulses, which are stretched by a chirped fiber grating stretcher to a width of 1 ns. After amplification in the fiber amplifier chain a pulse energy of 50 μJ is obtained at a repetition rate of 10 kHz. Further amplification in a Nd:YVO 4 solid state booster amplifier generates a pulse energy of 2 mJ. After recompression in the bulk grating compressor 10 ps pulses with an energy of 1 mJ are obtained. To ensure a compact design for the bulk grating compressor, preferably grisms with a groove density of 2800 l/mm are implemented. The whole compressor can then fit into an area of about 0.6×0.2 m by folding the optical beam path only once.
[0273] As discussed above, a burst of multiple pulses with different wavelengths, different pulse widths and different temporal delays may be desired. Referring to FIG. 40 , an embodiment of the laser means 51 is illustrated, which increasing the increasing the possible energy and average power from ultrafast fiber lasers. A longer pulse envelope can be obtained by utilizing a series of chirped gratings that reflect at different wavelengths. After amplification, a similar series of gratings can be placed to recombine/compress the pulses. In FIG. 40 , pulses from a femtosecond pulse source are passed through an acousto-optic modulator, a polarized beam-splitter and a Faraday rotator, and are then supplied to a series of chirped fiber stretcher gratings that operate on different portions of the input pulse spectrum. The spacings between the stretcher gratings can be l 1 , l 2 , l 3 . . . . In order to reconstruct the pulses after amplification in the fiber amplifier and the regenerative amplifier the spacings between a series of complementary bulk glass Bragg grating compressors are set to nl 1 , nl 2 , nl 3 , . . . , where n is the refractive index of the fiber between the stretcher fiber gratings, assuming that the bulk Bragg compression gratings are separated by air. The reconstructed pulse is output via a second beam splitter. As previously mentioned, the reconstructed pulse is generally the result of incoherent addition of the separately amplified spectral components of the input pulse.
[0274] If the distances between the compression and stretcher gratings are not equalized as described above, then multiple pulses will appear at the output. If the distances are not equal between the different sections than the temporal delays will not be equal. This can be beneficial for applications such as micro-machining. By varying the stretching and compression ratios, pulses with different pulse widths can be generated. A single broadband compression grating can be used when generating multiple pulses.
[0275] The utilization of the regenerative amplifier is not as flexible as an all fiber amplifier system for modification of the pulse shape. For example, long pulse widths are limited to repetitive features equal to the round trip time of the regenerative amplifier, e.g., approximately 10 nanoseconds. For a regenerative amplifier, the pulse train created by the gratings needs to be less than the round trip time of the regenerative amplifier.
[0276] Another embodiment of a multiple pulse source is shown in FIG. 41 . This source is utilized in the laser system shown in FIG. 42 . The Ytterbium amplifier is normally needed for the pulse intensity to be sufficient for amplification in the regenerative amplifier. The pulse compressor is optional. The multiple pulse source is a laser diode and multiple electronic drivers. In this case there are three sources with a delay generator that allows different delays to each electronic driver. A long pulse is generated by a conventional pulse driver for a laser diode. The shorter pulses are derived from short pulse laser diode drivers such as are available from Avtech. These signals are added through electronic mixers. The output is shown in FIG. 43 a . This is an oscilloscope screen measured with a sufficiently fast photodiode. There are three peaks observable. The output for one of the short pulses is shown in FIG. 43 b . The pulse width is approximately 100 ps. FIG. 43 c illustrates a three peak pulse that is formed by changing the delay between the pulses so the electronic signals overlap. The short pulses can also be chirped and then recompressed to femtosecond pulses by the final compressor as described in Ser. No. 08/312,912 and U.S. Pat. No. 5,400,350 (incorporated by reference herein). By appropriately choosing the chirp rates and frequency ranges a single bulk grating can compress a plurality of pulses.
[0277] Another embodiment of this is to utilize laser diodes at different wavelengths or polarization states and then combine these optically either with wavelength fiber combiners such as the wavelength router utilized in multiple wavelength telecomm systems or by fiber splitters as shown in FIG. 44 . It is also possible to utilize conventional mode-locked sources to give multiple pulses. The methods for utilizing fiber gratings and etalons as disclosed in U.S. Pat. No. 5,627,848 (incorporated by reference herein) as a source of multiple calibration pulses can be utilized here. Another method is to use fiber splitters with different path lengths as shown in FIG. 45 . Four pulses are output for each pulse from the Ultrashort pulse source. The four pulses are sequentially, temporally delayed by:
[0000] c (2 L N +L 1 +L 4 ) 1.
[0000] c (2 L N +L 1 +L 3 ) 2.
[0000] c (2 L N +L 2 +L 4 ) 3.
[0000] c (2 L N +L 2 +L 3 ) 4.
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The invention describes classes of robust fiber laser systems usable as pulse sources for Nd: or Yb: based regenerative amplifiers intended for industrial settings. The invention modifies adapts and incorporates several recent advances in FCPA systems to use as the input source for this new class of regenerative amplifier.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to supersonic aircraft engine exhaust systems which require noise suppression and particularly relates to the provision of ejector chutes permanently mounted within the exhaust stream for mixing ambient air with the exhaust gasses.
2. Description of Prior Development
Aircraft engines designed for supersonic flight at speeds of Mach 2.0 to Mach 4.0 produce high noise levels during take-off. For commercial applications, this noise must be suppressed to meet governmental noise level limits.
One known method of noise suppression places ejector chutes in the hot exhaust gas stream to entrain ambient air and enhance mixing of the air and exhaust gas. This entrainment of air increases the total mass flow exiting the nozzle while decreasing the exit velocity of the exhaust gas. The decreased exit velocity results in lower noise levels while the increased mass flow maintains the required take-off thrust.
Previous supersonic exhaust nozzle designs employing ejector chutes for air entrainment and noise suppression have used movable chutes that were stowed out of the exhaust stream during modes of operation not requiring noise suppression such as during transonic acceleration, subsonic cruise and supersonic cruise. A problem associated with the use of such movable chutes is the limited space available for their stowage. Thus, their size and ambient air entrainment capabilities are limited.
A measure of the air entrainment capabilities of ejector chutes is defined as the blockage ratio. This is the total flow area at the downstream exit of the ejector chutes divided by the core flow throat area at take-off. An increase in the blockage ratio will tend to increase ambient air entrainment and decrease exhaust noise. For chutes stowed during non-noise suppression operation, maximum blockage ratios are approximately 2.25.
One way to increase the blockage ratio of the ejector chutes is to leave the chutes in the hot exhaust gas stream during both suppressed and non-suppressed operation. With this arrangement, a blockage ratio of approximately 3.0 can be achieved thus improving the ambient air entrainment and noise suppression.
Previous designs that have permanently maintained chutes in the hot exhaust gas stream have employed the aft ends of the chutes to vary the exhaust nozzle throat area and exhaust nozzle internal exit areas throughout take-off, acceleration, subsonic and supersonic modes of operation. Such designs have also used a fixed external nozzle exit area. This results in less than optimum performance during all modes of engine operation.
Accordingly, a need exists for an exhaust system for a high speed civil transport aircraft engine having permanently maintained ejector chutes which provide a high blockage ratio yet which also allow for good engine performance during the acceleration, subsonic and supersonic modes of operation.
SUMMARY OF THE INVENTION
The present invention has been developed to fulfill the needs noted above and therefore has as a primary object the provision of an exhaust system for a jet engine having permanently maintained ejector chutes which allow for a high blockage ratio yet which do not detract from engine performance during acceleration, subsonic operation and supersonic operation.
Another object of the invention is to provide an exhaust system for a high speed civil transport aircraft engine having permanently maintained ejector chutes which act in cooperation with movable flaps which define a first convergent-divergent exhaust nozzle.
Yet another object of the invention is to provide an exhaust nozzle which uses ejector chute flaps for defining the nozzle throat area only during noise-suppressed operation and which uses a second separate convergent-divergent flap system for defining the nozzle throat and external nozzle exit areas during other modes of engine operation.
Briefly, the invention is directed to a jet engine exhaust system having a plurality of permanently maintained ejector chutes having movable aft end portions controlling the exhaust nozzle throat area and internal nozzle exit area only during the noise-suppressed mode of engine operation. During other modes of engine operation, conventional convergent and divergent flaps control the area of the exhaust nozzle throat and external exit area for good engine performance.
This arrangement achieves the highest blockage ratios during the noise suppression mode while maintaining good engine performance during the other modes of engine operation. This dual throat nozzle system may be employed in both axisymmetric and two-dimensional convergent-divergent exhaust nozzles as described below.
By definition the throat is where the gas flow cross sectional area converges until the velocity accelerates to Mach 1. After reaching Mach 1, the gas flow expands with an increasing cross sectional area and the velocity of the gas increases during both subsonic and supersonic conditions. In each embodiment, the throat moves from one location at the chute mixing plane to the intersection of the convergent and divergent flaps. At the chute mixing plane, the area in the chutes and between the chutes converge to form the throat. This is only true during suppressed modes of operation. During other modes of operation, the chute flaps close or rotate together. This allows the cross sectional area in that section of the nozzle not to converge. The convergent section is delayed until the convergent flap section where the cross sectional area is converged.
A key to the invention is the location of the fixed chutes. The chutes are located forward of the throat where less vibration exists in a low velocity field in a lower Mach number area which reduces performance losses and fatigue on the chute parts. This is especially important during supersonic cruise when the chutes are located farther from the throat.
The aforementioned objects, features and advantages of the invention will, in part, be pointed out with particularity, and will, in part, become obvious from the following more detailed description of the invention, taken in conjunction with the accompanying drawings, which form an integral part thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
In The Drawings
FIG. 1 is a schematic view in axial section of the upper half of an axisymmetric convergent-divergent exhaust nozzle constructed in accordance with the invention;
FIG. 2 is a schematic view in axial section of the upper half of a two-dimensional, convergent-divergent exhaust nozzle constructed in accordance with the invention;
FIG. 3 is a sectional view taken along line A--A of FIG. 2;
FIG. 4 is an enlarged side elevation view of the noise suppressor chutes of FIG. 1 with the chutes opened in their noise-suppressing position;
FIG. 5 is a schematic top plan view of the noise suppressor chutes of FIG. 4 taken along line B--B thereof;
FIG. 6 is a partial aft view of the noise suppressor chutes of FIG. 5, looking forward along line C--C thereof;
FIG. 7 is a view similar to FIG. 5 showing the noise suppressor chutes in their closed non noise-suppressing forward thrust position;
FIG. 8 is a view similar to FIG. 6 showing the noise suppressor chutes in their closed position;
FIG. 9 is a view similar to FIG. 5 showing the noise suppressor chutes in their thrust reverse position; this position blocks the flow from exiting the convergent-divergent nozzle and thus diverts the flow to the thrust reverser;
FIG. 10 is a view similar to FIG. 6 showing the noise suppressor chutes in their thrust reverse position;
FIG. 11 is an enlarged side elevation view of the noise suppressor chutes of FIG. 2 showing the chutes opened in their noise-suppressing position;
FIG. 12 is a top plan view of the noise suppressor chutes of FIG. 11 showing the chutes opened in their noise-suppressing position in solid lines and showing the chutes in their non-suppressed position phantom; and
FIG. 13 is an aft view looking forward along line D--D of FIG. 11 showing the noise suppressor chutes in their suppressed and non-suppressed positions.
In the various figures of the drawing, like reference characters designate like parts.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in conjunction with the drawings, wherein a high speed civil transport jet engine exhaust nozzle is shown in FIG. 1 as an axisymmetric convergent-divergent nozzle 10 and shown in FIG. 2 as a two-dimensional convergent-divergent nozzle 12. Each nozzle 10,12 contains noise suppressors which include chutes permanently positioned in the exhaust gas stream.
The exhaust nozzles 10,12 can operate with either turbojet engines or, as shown in FIGS. 1 and 2, with bypass turbofan engines. Each exhaust nozzle 10,12 includes a variable bypass injector 14 in the form of a pivoting valve located downstream of the engine turbine frame 16 for mixing the engine core gas stream 18 with the bypass air stream 20.
The variable area bypass injector 14 can be either a confluent flow multiple door mixer as shown in FIG. 1 or a drop chute variable area bypass injector mixer as shown in FIG. 2. A conventional augmenter 26 is typically provided to add heat to the core and bypass streams 18,20 to increase the thrust relative to nonaugmented operation.
In the two-dimensional convergent-divergent nozzle design of FIG. 2, a centerbody 28 is mounted to the turbine frame 16. Centerbody 28 provides a diffusion flowpath for the core and bypass streams 18,20. In the axisymmetric design of FIG. 1, the centerbody 28 is extended aft from the turbine frame 16 to support the converging inner ends 22 of noise suppressor chutes 30, and the forward end 32 of the centerbody 28 is supported through multiple struts 34 by the outer duct casing 36.
Multiple thrust reverser ports 38 are provided in each nozzle configuration of FIGS. 1 and 2 for discharge of the core gas and bypass air streams 18,20 to effect reverse thrust during landing. The thrust reverser ports 38 are composed of multiple vanes 40 that form, in their stowed position, the outer cover of the turbojet engine and provide for efflux directivity during reverse thrust operation. The thrust reverser ports 38 further include multiple inner doors 42 that seal the inner flowpath 24 in their stowed position and provide an opening for reverse exhaust flow during reverse thrust operation.
In each example, each noise suppressor chute 30 includes a fixed chute portion 44 with ambient air flow guides 46 that guide the flow through the chute and also support the fixed chute sidewalls 48. A chute hinge 50 and aft hinged flap 52 are pivotally connected to each aft end portion of the fixed chute portion 44 of each noise suppressor chute 30. Pivotal movement of flaps 52 meters the amount of ambient air entrained within the exhaust gasses flowing through the nozzles and provides the engine exhaust gas throat area and internal area ratio for the noise-suppressed mode of operation.
The noise suppressor chutes 30 are provided with chute inlet cover doors 54 that prevent the core gas stream 18 from escaping the inner flowpath 24 during normal unsuppressed noise operation. Ambient air inlet doors 56 and 58 open to admit ambient air to the noise suppressor chutes 30 during noise-suppressed operation and close to form the outer surface of the engine during non-suppressed operation.
Convergent flaps 62 are actuated to form a variable area nozzle throat 64 during non-suppressed operation. During noise-suppressed operation, such as during take-off, another nozzle throat 64' is formed in and defined by a portion of the aft hinged flaps 52 of the noise suppressor chutes 30. At this time, the divergent flaps 66 are actuated to form the nozzle exit area 68 while outer flaps 70 are actuated to form the outer boat tail surface of the exhaust nozzles 10,12.
As represented by phantom position 63 in FIG. 1, during supersonic cruise operation, the convergent-divergent position of nozzle 10 formed by convergent flaps 62 and divergent flaps 66 defines nozzle throat 64 along the interconnection of flaps 62 and 66 at the trailing edges 76 of convergent flaps 62. The solid line configuration of flaps 62 and 66 in FIG. 1 represents the flap positions during noise-suppressed take-off while phantom position 65 represents the convergent-divergent nozzle position during subsonic flight operation.
The same phantom position references 63,65 represent the same operating conditions in FIG. 2, with the solid line configuration representing the take-off position of nozzle 12. Phantom position 67 in FIG. 2 represents the reverse thrust position of the convergent-divergent flaps 62,66. As further seen in FIGS. 1 and 2, neither exhaust system includes a nozzle plug as is common in many conventional exhaust systems.
FIG. 3 shows a view of the two-dimensional convergent-divergent exhaust nozzle of FIG. 2 from an aft position looking forward with the nozzle 12 in the noise-suppressed mode. The mixed core and bypass gas 72 passes through the first throat 64' formed by the aft hinged flaps 52. Ambient air 74 passes through the noise suppressor chutes 30 and mixes with the core and bypass gas 72 downstream of the noise suppressor chutes to effect noise suppression.
FIGS. 4 through 10 show the axisymmetric nozzle chutes 30 in more detail. In FIGS. 4, 5 and 6, the aft hinged flaps 52 are in their open, noise-suppressed position. The engine core and bypass gas 72 passes through the throat 64' and the ambient air 74 passes through the noise suppressor chutes 30. These two streams mix downstream of the aft hinged flaps 52.
As seen in FIGS. 7 and 8, the mutually engageable and disengageable aft flaps 52 are pivoted into their closed position for a non-suppressed forward thrust mode of operation. During this mode, the Mach number of the maximum flow of engine core and bypass gas 72 through the chutes 30 is about 0.5 as the second nozzle throat 64 is defined at the trailing edge 76 of the convergent flaps 62 (FIG. 1). The aft flaps thus act as flow control members.
In FIGS. 9 and 10, the aft flaps 52 are pivoted into their reverse thrust position where they act as a blocker for the engine core and bypass gas 72 which is discharged through the reverser ports 38 (FIG. 1). The ambient air inlet doors 56,58 and the chute inlet cover doors 54 are closed during thrust reverse operation.
The chutes 30 for the two-dimensional convergent-divergent nozzle of FIG. 2 are shown in further detail in FIGS. 11 through 14. In FIG. 12, the chutes 30 are shown with the aft flaps 52 pivoted into their noise-suppressed position in solid lines and in their non-suppressed position in phantom. In the two-dimensional convergent-divergent nozzle 12, the convergent flaps 62 are used for the thrust reverser blocking function instead of the aft hinged flaps 52 as in the axisymmetric nozzle of FIG. 1 in order to minimize the structural loading on the aft hinged flaps. For the suppressed and non-suppressed modes of operation, the modes of operation of the noise suppressor chutes 30 are similar to those of the axisymmetric nozzle of FIG. 1.
An example of one method of actuation of the aft hinged flaps 52 is shown in FIG. 13 and 14 wherein a distributed load is applied to the aft hinged flaps to allow their thickness and weight to be reduced or minimized. A horizontal actuation bar 78 is linked to a plurality of vertical bars 80 which in turn are connected by multiple position pivot links 82 to the aft hinged flaps 52.
Each pivot link 82 includes pivot joints 84,86 at its interconnection with vertical bar 80 and hinged flap 52. Up and down movement of actuation bar 78 respectively pivots the aft hinged flaps 52 between their open and closed positions. Thus, the hinged flaps serve as an independently actuated exhaust nozzle located upstream from the convergent-divergent exhaust nozzle defined by flaps 62,66.
The coordination of the movement of the aft hinged flaps 52 with the setting or positioning of the convergent-divergent flaps 62,66 may be controlled by an electronic control system such as that presently developed by the assignee of the subject invention and known as a FADAC system. Conventional hydraulic, electric or air driven actuators may be employed with the FADAC system.
Advantages of the exhaust nozzles described above include the attainment of a larger suppressor chute blockage ratio than that available with movable suppressor chutes. The exhaust nozzles 10,12 provide entrainment of large amounts of ambient air which in turn provides adequate sound suppression to meet current government noise level limits. The independently variable exhaust nozzle throat and exit areas provide good performance during the non-noise suppression modes of operation such as transonic acceleration and subsonic and supersonic cruise. There has been disclosed heretofore the best embodiment of the invention presently contemplated. However, it is to be understood that various changes and modifications may be made thereto without departing from the spirit of the invention. For example, the number of suppression chutes can vary. The suppression chutes can also be convergent-divergent in shape and can have straight or wavy trailing edges for increasing their mixing perimeter.
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An array of chutes is permanently mounted within the flowpath of an exhaust nozzle of an aircraft jet engine for entraining and mixing ambient air with the exhaust gas so as to reduce the noise level of aircraft, particularly during take-off. In order to provide good engine performance during all modes of jet engine operation, a convergent-divergent flap assembly is arranged downstream from the chutes for controlling the nozzle throat and exit areas when the chutes are closed.
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TECHNICAL FIELD
[0001] The present invention relates to a method for the preparation of ready-for-use cryoconserved mature dendritic cells, especially for the preparation of a vaccine which contains such dendritic cells, wherein immature dendritic cells are cultured in the presence of suitable maturing stimulants, and the mature dendritic cells thus obtained are frozen. Prior to or after freezing, the dendritic cells may be loaded with antigen. The invention also relates to a vaccine obtainable by the method according to the invention, and to a composition containing frozen mature antigen-loaded dendritic cells.
BACKGROUND OF THE INVENTION
[0002] Dendritic cells (hereinafter briefly referred to as “DC”) are antigen-presenting cells which influence the immune system by interacting with lymphocytes. Most DCs exhibit an immunostimulatory activity. These classical DCs can induce the formation of helper and killer T cells in vivo in different ways (“nature's adjuvant”). In particular, immature DCs which occur in peripheral tissues have the capability of binding antigens and preparing immunogenic MHC peptide complexes therefrom (“antigen processing mode”). Upon the action of maturation-inducing stimulants, such as inflammatory cytokines, these immature DCs develop into potent T-cell stimulants through an increased formation of adhesion and costimulatory molecules (“T-cell stimulatory mode”). At the same time, the cells migrate into secondary lymphatic organs to select and stimulate rare antigen-specific T cells. It could be shown that DCs which were isolated from tissues or blood and loaded with antigen in vitro were immunogenic after back injection as mature DCs in vivo.
[0003] Recently, it could be shown that DCs can induce CD4+ and CD8+ T-cell immunity in both healthy humans and cancer patients. In immunocompetent healthy subjects, a single booster injection with mature DCs could enhance not only the frequency, but also the functional avidity of the CD8+ T-cell response. For these reasons, DCs (especially mature ones) are currently extremely promising adjuvants for induce potent T-cell responses against tumors and infections in humans.
[0004] One precondition for the use of DCs in immunotherapy is the development of techniques which allow to produce a great number of DCs in culture, either from proliferating CD34+ precursor cells or from non-proliferating or little proliferating CD14+ monocytic precursor cells. DCs derived from monocytes are frequently used currently because they are easily prepared without any cytokine pretreatment of the donor, and because the resulting DC population is fairly homogeneous and best characterized. For example, immature DCs can be prepared from adherent monocytes in the absence of fetal calf serum (FCS) during a culture for usually six to seven days in (GM-CSF+IL-4), followed by maturation for mostly one to three days, induced by autologous monocyte-conditioned medium. To provide an effective cryoconservation for dendritic cells or their precursor cells has proven extremely difficult, except in the presence of FCS (Taylor et al. (1990) Cryobiology 27, 269; Makino et al. (1997) Scand. J. Immunol. 45, 618). However, since FCS must not be present in vaccinations, it has still been necessary to prepare DCs freshly for each DC vaccination, either from fresh blood, from fresh leucapheresis products or from frozen PBMC (“peripheral blood mononuclear cells”) aliquots from leucapheresis products (Thurner et al. (1999) J. Immunol. Methods 223, 1). Frozen PBMCs also have the disadvantage that following the thawing the cells must first be cultured for several days to differentiate them into DCs. Lewalle et al. (2000) J. Immunol. Methods 240, 69-78, disclose a method for the freezing of immature DCs, but only obtain poor yields of surviving cells (p. 71, top of left column). The freezing of immature dendritic cells prepared from monocytes by means of GM-CSF and IL-4 has also been disclosed in WO 99/46984.
SUMMARY OF THE INVENTION
[0005] Therefore, one object of the present invention is to provide a composition, such as a vaccine, which contains mature DCs, that can be stored for extended periods of time without a substantial loss in activity, and that can be administered within a short time when needed.
[0006] The DCs employed according to the invention are preferably derived from the same patient who is treated with the vaccine (autologous). Alternatively, the DCs may also be derived from other patients (allogenic), for example, from leucapheresates from normal volunteers, as described, for example, in Thurner et al. (1999) J. Immunol. Methods 283, 1-15.
[0007] Surprisingly, it has been found that only fully matured DCs (hereinafter also briefly referred to as “mature DCs”), which are obtainable by culturing in the presence of a suitable “maturing cocktail” with specific maturing stimulants, will survive to a high percentage after freezing without FCS and thawing, and have immunostimulant activities which are comparable to those of freshly prepared mature DCs. During the culturing with the maturing cocktail, the immature DCs are differentiated into mature DCs. A particularly preferred maturing cocktail contains interleukin-1β (IL-1β), interleukin-6 (IL-6), prostaglandin E 2 (PGE 2 ) and “tumor necrosis factor α” (TNFα).
[0008] Thus, the present invention relates to
[0009] (1) a method for the preparation of ready-for-use cryoconserved mature dendritic cells, comprising
[0010] a) providing immature dendritic cells (DC);
[0011] b) culturing the immature DCs in a culture medium containing a maturing cocktail with one or more maturing stimulants to obtain mature DCs;
[0012] c) freezing the mature DCs in a freezing medium which does not contain any heterologous serum;
[0013] (2) a method as defined above under (1) which is suitable for the preparation of a vaccine from mature cryoconserved DCs;
[0014] (3) frozen mature antigen-loaded dendritic cells, especially those dendritic cells which are obtainable by the method (1);
[0015] (4) a vaccine comprising dendritic cells as defined in (3); and
[0016] (5) a method for finding advantageous conditions for the freezing of DCs, comprising the steps of:
[0017] a) providing immature DCs;
[0018] b) performing different cultures with the immature DCs in the presence of different maturing stimulants;
[0019] c) then culturing the DCs in medium with or without cytokines, culturing without cytokines being preferred;
[0020] d) determining the fraction of living cells after at least 1 day of culture in said medium with or without cytokines; and
[0021] e) establishing that maturing stimulant which gave the highest survival rate.
[0022] In methods (1) and (2) of the invention, immature DCs are first cultured, a suitable maturing cocktail with one or more maturing stimulants being added to the culture medium. Suitable maturing stimulants include IL-1, such as IL-1β etc., IL-6, TNF-α, prostaglandins, such as PGE 2 etc., IFN-α, lipopolysaccharides and other bacterial cell products, such as MPL (monophosphoryllipid A), lipoteichoic acid etc., phosphorylcholine, calcium ionophores, phorbol esters, such as PMA, heat-shock proteins, nucleotides, such as ATP etc., lipopeptides, artificial ligands for Toll-like receptors, double-stranded RNA, such as poly-I:C etc., immunostimulant DNA sequences, CD40 ligand etc. According to the invention, it is particularly preferred for said culture medium or maturing cocktail to contain IL-1β, IL-6, PGE 2 and TNFα, or for said maturing cocktail to be monocyte-conditioned medium (MCM) or MCM supplemented with PGE 2 . In a preferred embodiment of methods (1) and (2), the DCs can be loaded with antigen during or after the culturing step.
[0023] After maturing and optionally loading with antigen, the DCs are frozen in freezing medium which does not contain any heterologous serum, such as FCS. “Heterologous serum” within the meaning of this application is a serum which is not derived from the human species. However, according to the invention, it is possible to use both autologous serum or plasma (which is derived from the same human as the DCs) and allogeneic serum or plasma (which is derived from a different human than for the DCs).
[0024] Immature DCs within the meaning of this application are CD83 (and/or p55/fascin and/or DC-LAMP) negative (or only weakly positive and/or to a low percentage) leukocytes which express only low amounts, as compared to mature DCs, of class-I and Class-II MHC as well as adhesion or costimulatory molecules (e.g., in particular, CVD86, CD80, CD40), which will differentiate into mature DCs upon a suitable maturing stimulant.
[0025] Mature DCs within the meaning of this application are leukocytes which have developed from immature DCs under the action of a maturing stimulant, exhibit an enhanced expression of CD83 (and/or p55/fascin and/or DC-LAMP) and of class-II and class-I MHC molecules and adhesion or costimulatory molecules, especially of CD86, CD80, CD40. Further, the mature DCs exhibit a clearly increased T-cell stimulatory capacity as compared to immature DCs (e.g., in contrast to immature DCs, they exhibit a clear stimulatory activity in allogenic MLR even at a DC:T ratio of about ≦1:100); in addition, one characteristic of the mature DCs within the meaning of this application is the fact that these DCs are stable, i.e., will keep their properties of a mature phenotype and a strong T-cell stimulatory capacity even if cultured in the absence of cytokines for 1-2 days or longer. In contrast, DCs which have not yet fully matured are not stable and will differentiate into immature DCs or, e.g., into adherent macrophages.
[0026] The immature DCs can be provided from various known sources. The precursor cells of the immature DCs are usually non-proliferating CD14-positive mononuclear cells (PBMCs; monocytes) or proliferating CD34-positive cells. For example, PBMCs can be isolated from leucapheresis products. The PBMCs can be differentiated into immature DCs as described (Thurner et al. (1999) J. Exp. Med. 190, 1669). Thus, the PBMCs are cultured in the presence of IL-4 (or IL-13; Romani et al. (1996) J. Immunol. Methods 196, 137-151) and GM-CSF (“granulocyte-macrophage colony stimulating factor”). From CD14-positive monocytes, immature DCs can also be prepared by culturing in the presence of GM-CSF and IFNα (Santini et al. (2000) J. Exp. Med. 191, 1777-1788). From CD34-positive cells, immature DCs can be obtained by culturing in the presence of GM-CSF, SCF (“stem cell factor”) and TNFα. The immature dendritic cells may also be obtained directly from fresh blood, such as described in Nestle et al. (1998) Nat. Med. 4, 328. Preformed CD11c+ and CD11c− DCs (O-Doherty et al. (1994) Immunology 82, 487-493) and M-DC8-DCs (Schakel et al. (1999) Pathobiology 67, 287-290) also exist in blood. These DCs may also be isolated from the blood and further used in the method according to the invention.
[0027] The preferred concentrations of the various maturing stimulants in the culture medium are within a range of from 0.1 ng/ml to 100 μg/ml, preferably from 1 ng/ml to 10 μg/ml. For the particularly preferred maturing cocktail of the present invention, the concentration of the maturing stimulants is from 0.1 to 100 ng/ml of IL-1β, from 0.1 to 100 ng/ml of IL-6, from 0.1 to 10 μg/ml of PGE 2 , and from 0.1 to 100 ng/ml of TNFα (most preferably, the concentration of these special maturing stimulants is approximately 10 ng/ml of IL-1β, 10 ng/ml of IL-6, 1 μg/ml of PGE 2 , and 10 ng/ml of TNFα). The concentrations stated are the final concentrations of the substances in the cell culture medium in which the DCs are cultured. One possibility of maturing the DCs in the presence of the mentioned active substances is to culture the immature DCs in the presence of monocyte-conditioned medium (MCM). MCM contains IL-1β, IL-6, PGE 2 and TNFα. It can be obtained by culturing PBMCs in medium without cytokines, as described, for example, in Romani et al. (1996) J. Immunol. Methods 196, 137. When the DCs are matured by MCM, the culture medium contains from 1 to 100%, preferably from 5 to 25%, of MCM. In another embodiment of the invention, the maturing of the DCs is effected by the addition of MCM and a defined amount of PGE 2 . Namely, it has been found that variations in the capability of MCM to mature DCs in the best possible way can be counterbalanced by the addition of PGE 2 (preferably in the concentrations as stated above). However, according to the invention, it is preferred to mature the DCs by the addition of defined optimum amounts of the active substances IL-1β, IL-6, PGE 2 and TNFα. This means that the maturing composition is prepared from purified formulations of the individual active substances. Better results are achieved thereby as compared with the maturing with MCM or MCM+PGE 2 . IL-1β, IL-6, PGE 2 and TNFα are available is GMP (“good manufacturing practice”) grade. Usually, the maturing is effected by cultivation in the presence of the substances mentioned for at least one hour, preferably 2 hours and more preferably at least 6 hours. Particularly preferred according to the present invention are maturing times of from 6 to 96 hours, preferably from 18 to 36 hours (when leucapheresates are used as the starting material) or from 36 to 60 hours (when fresh blood or buffy coat is used as the starting material).
[0028] According to the invention, the DCs are loaded with at least one antigen or an antigen-antibody complex during and/or after the maturing step mentioned. According to the invention, the antigen loading can be effected during or after the freezing. If it is effected after freezing, the DCs are loaded with antigen only after thawing. However, preferred is loading with antigen prior to the freezing of the DCs. This has the advantage that the DCs are ready for use immediately after thawing.
[0029] Antigens within the meaning of this application are proteins, protein fragments, peptides and molecules derived therefrom (e.g., glycosylated compounds or compounds having other chemical modifications), but also the nucleic acid encoding them, viruses, whole prokaryotic or eukaryotic cells or fragments thereof, or apoptotic cells. “Loading with antigen” means a process which causes MHC molecules on the cell surface of the DCs to “present” peptides, i.e., the peptides form a complex with the MHC molecules. While a direct loading of the MHC molecules. is possible through specific peptides, proteins (or protein fragments) must first be processed, i.e., first taken up by the cell. After intracellular cleavage of the proteins and loading of MHCs with peptide, MHCII-peptide complexes are presented on the cell surface. Suitable antigens primarily include proteins or protein fragments. The proteins may be of native origin or have been prepared recombinantly. Due to the maturing and loading with protein antigen, MHCII-peptide complexes which comprise the peptide fragments of the antigen added form on the cell surface. The concentration of the protein antigen in the culture medium is usually from 0.1 to 100 μg/ml, preferably from 1 to 50 μg/ml, most preferred from 1 to 10 μg/ml.
[0030] If a protein (i.e., a polypeptide having more than 50 amino acid residues) is employed as the antigen, the loading should preferably be effected during the maturing of the DCs. This causes a particularly effective presentation of the antigen fragments by MHCII molecules. The protein (fragment) need not be present during the whole maturing period, but at least for part of the maturing period, both the maturing composition and the protein (fragment) should be simultaneously present. Examples of protein antigens include KLH (keyhole limpet hemocyanin) as a widely used positive control antigen. MAGE-3 protein as an example of a tumor antigen, and hepatitis B surface antigen (HBsAg) or HIV-1 gp-160 protein as examples of a protein appropriate for the treatment of viral diseases.
[0031] When the loading is performed with “short polypeptides” or protein fragments (e.g., short polypeptides with up to 50 amino acid residues which exactly fit into the MHC molecules on the DC surface), loading after maturing, namely prior to freezing or after rethawing, is also possible in addition to the above mentioned loading during maturing. In such a loading after maturing, the short polypeptides are added to washed DCs.
[0032] Another possibility of loading with antigen is the addition of apoptotic or lysed cells to the culture medium. The added cells can then be phagocytosed by the DCs. This method has the advantage that, in addition to MHC class II molecules, class I molecules can also be effectively loaded. For example, it has been shown that presentation also occurs on MHC class I molecules even when proteins (especially of particulate nature) are added. For example, instead of culturing the DCs in the presence of Mage-3 tumor protein or peptide, cell fragments (of necrotic or apoptotic tumor cells) which contain Mage-3 can be added to the DCs.
[0033] DCs may also be loaded with antigen by fusing DCs, for example, with tumor cells. Such a fusion can be achieved with polyethylene glycol or electroporation.
[0034] In another embodiment of the invention, the DCs are loaded with antigen by being transfected or virally infected. Nucleic acids coding for antigens are thereby introduced into the DCs or induced to expression. For example, a DNA or RNA transfection or infection with adenoviruses can be performed in a suitable way. Loading of the MHC class I molecules is also possible thereby. For example, RNA prepared from tumor cells can also be transfected. For transfection, usual methods, such as electroporation, can be employed.
[0035] As set forth above, specific antigen peptide (i.e., “short polypeptides”) can be added during the maturing period or after the maturing period for directly loading MHC molecules of class I or II. The peptide antigen may be added to the cells before the maturing composition is added, but preferably, it is added simultaneously or thereafter. The antigen loading is preferably performed for at least 10 minutes, more preferably for 1 to 24 hours, most preferably for 3 to 12 hours.
[0036] The peptides (i.e., “short polypeptides”) usually have at least 8 amino acids. Preferably, such peptides have from 8 to 12 amino acids (MHCI) or from 8 to 25 amino acids (MHCII). The concentration of the peptide in the culture medium for loading is usually from 0.01 to 1000 μM, preferably from 0.1 to 100 μM, most preferably from 1 to 20 μM.
[0037] All peptides which can be presented by MHC molecules can be considered as peptides to be employed. Preferred are peptides which are derived from proteins derived from pathogens. These may also be peptides which exhibit variations of the naturally occurring amino acid sequence. Such variations are usually one or two amino acid substitutions. Examples of peptide antigens are the influenza matrix peptide (IMP) having the amino acid sequence GILGFVFTL (SEQ ID NO: 1) or the Melan-A-analogue peptide having the sequence ELAGIGILTV (SEQ ID NO: 2). Examples of other possible peptides are represented in FIG. 26 .
[0038] In addition to “peptide/protein pulsing”, “peptide/protein transloading” may also be performed to load DCs with antigen.
[0039] As stated above, the DCs may also be loaded with antigen-antibody complexes. Suitable antigens for this purpose include all the antigens mentioned above. “Antigen-antibody complexes” according to the present invention are complexes of such antigens with suitable antibodies, e.g., antigen-IgG or antigen-IgE complexes. The loading of DCs with such antigens is described in Reynault, A. et al., J. Exp. Med. 189(2): 371-80 (1999), which is included herein by reference.
[0040] After the maturing and optionally antigen loading of the DCs, the mature DCs can be frozen in freezing medium. In addition to the serum component, the freezing medium may additionally contain one or more cryoprotectants (e.g., from 0.1 to 35% (v/v), preferably from 5 to 25% (v/v)). Suitable cryoprotectants preferably include the following compounds: DMSO, glycerol, polyvinylpyrrolidone, polyethylene glycol, albumin, choline chloride, amino acids, methanol, acetamide, glycerol monoacetate, inorganic salts etc. The preferred cryoprotectant is DMSO, which is preferably contained in the freezing medium in a concentration of from 5 to 25% (v/v), more preferably from 10 to 20% (v/v), most preferably about 10% DMSO. The freezing medium may contain a non-heterologous serum component, preferably in a concentration of from 2 to 90% (w/v), preferably from 5 to 80% (w/v), wherein human serum albumin, preferably in a concentration of from 10 to 30% (w/v), is particularly preferred. More preferably, however, the freezing medium contains autologous serum or plasma instead of human serum albumin. It may also contain human allogenic serum or pool serum. Also, the freezing medium may contain as an additive one or more polyol compounds derived from carbohydrates, especially those selected from glucose, dextrane, sucrose, ethylene glycol, erythritol, D-ribitol, D-mannitol, D-sorbitol, inositol, D-lactose etc., preferably in a concentration of from 2 to 30%, more preferably from 5 to 10%, most preferably about 5% (w/v). The most preferred freezing medium is pure autologous serum with about 10% DMSO and about 5% glucose. Usually, the cells are centrifuged off prior to freezing to be concentrated and taken up in freezing medium.
[0041] The preferred concentration of cells in the freezing medium is from 1 to 100×10 6 cells/ml, the most preferred concentration being from about 5×10 6 cells/ml to 20×10 6 cells/ml.
[0042] It has also been found that the survival rate of DCs is increased by contacting the DCs with an anti-apoptotic molecule prior to freezing or after thawing. Therefore, in a preferred embodiment of the method according to the invention, The DCs are contacted prior to freezing or after thawing with a molecule capable of inhibiting apoptosis. Preferred anti-apoptotic molecules include CD40 ligand (CD40L) (Morris et al. (1999) J. Biol. Chem. 274: 418), TRANCE (Wong et al. (1997) J. Exp. Med. 186: 2075) or RANKL (Anderson et al. (1997) Nature 390: 175). Preferably, at least one of the molecules is added to the culture medium prior to freezing or after thawing of the DCs for at least 10 min, preferably at least 1 hour, more preferably at least 4 hours. Preferred concentrations in the culture medium are 1 ng/ml to 5 μg/ml (RANKL/TRANCE) and 1 ng/ml to 1 μg/ml (CD40L). Particularly preferred concentrations are from 0.5 to 1 μg/ml (RANKL/TRANCE) and from 0.1 to 0.5 μg/ml (CD40L).
[0043] In a preferred embodiment of the method, the DCs are further cultured in the presence of immunosuppressive interleukin-10 (IL-10) or other immune/maturing modulators, such as vitamin D3 and its derivatives, fumaric acid and derivatives thereof, such as esters etc., mycophenolate mofetil etc. Cells thus treated are not employed for the stimulation of the immune system, but rather a tolerance against particular antigens is to be induced. The concentration of these modulators and of IL-10 in the medium is from 1 to 1000 ng/ml, preferably from 10 to 100 ng/ml.
[0044] According to embodiment (4), the present invention also relates to a vaccine obtainable by the method according to the invention. In addition to the mature antigen-loaded DCs, the vaccine according to the invention may further contain pharmaceutically acceptable adjuvants. After the thawing of the vaccine according to the invention, various substances may be added which are pharmaceutically acceptable and advantageous for administration.
[0045] According to embodiment (3), the invention also relates to frozen mature antigen-loaded dendritic cells. These cells according to the invention may be part of a pharmaceutical composition which contains usual additives suitable for the administration to humans, in addition to the cells.
[0046] The present invention for the first time provides a vaccine which contains mature antigen-loaded DCs and can be frozen. An essential advantage of the invention is that the survival rate of the DCs after thawing is very high. After the thawing of the frozen DCs, more than 75%, preferably more than 85%, of surviving DCs are usually obtained, based on the number of frozen DCs. Such high survival rates of thawed DCs have not been achieved previously without the addition of FCS. However, this is an important precondition for achieving an effective immunostimulation. A substantial advantage of the freezing of mature antigen-loaded DCs is that multiple aliquots of a vaccine can be prepared and frozen. Thus, the vaccine is immediately available when needed and can be applied without lengthy culturing steps within a very short time. By loading the mature DCs with the antigen only after the freezing and rethawing, it is possible to load the DCs variably depending on the respective circumstances. For example, when an overstimulation or allergy against one of the peptides employed for vaccination is developing, this peptide can be omitted in the loading.
[0047] Surprisingly, it has been found that, for finding suitable methods for the freezing of DCs, it is not sufficient to vary the immediate freezing parameters, such as freezing medium and cooling rate, and to determine the survival rate immediately after thawing. This immediate survival rate not necessarily corresponds to the survival of freshly prepared DCs during several days of culture in the absence of cytokines.
[0048] Rather, the maturing process or the maturing stimulant employed prior to freezing also play an important role to the survival of the cells. Thus, the invention is also based on the recognition that the maturing stimulant according to the invention not only leads to a full DC maturation, but also yields DCs which can survive better than DCs which have been matured by other stimulants. To date, the maturing stimulant was not considered at all in view of the freezing.
[0049] It has also been found that an excellent method for optimizing the process for the freezing of DCs is to mature DCs by means of different maturing stimulants and then to test the survival after culture in complete medium without any addition of cytokine as a read-out. The maturing stimulant which induces the most viable DCs is used for the preparation of DCs which are then frozen.
[0050] Therefore, another aspect of the invention is a method for finding advantageous conditions for the freezing of DCs wherein immature DCs are provided and cultured in the presence of various maturing stimulants, the cells are subsequently cultured in medium with or without cytokines, preferably without cytokines, the fraction of surviving cells is determined after at least one day of culture in a medium with or without cytokines, and finally that maturing stimulant which gave the highest survival rate of DCs is determined. This maturing stimulant is then used for the preparation of DCs which are frozen. Preferably, the number of living cells is determined only after at least 2 days of culture in a medium without cytokines, most preferably after at least 3 days.
BRIEF DESCRIPTION OF THE DRAWINGS
[0051] FIG. 1 shows the influence of the cell concentration in the freezing vessels on the yield of DCs after thawing. Mature DCs were prepared from leucapheresis products from healthy adults, wherein adherent monocytes were first converted into immature DCs by six days of culture in GM-CSF+IL-4, followed by maturing for one day by a four-component cocktail consisting of TNFα+IL-1β+IL-6+PGE 2 (see Example 1). Mature (day 7) DCs were frozen at a freezing rate of −1° C./min in pure autologous serum+10% DMSO+5% glucose at different cell densities (number of DCs/ml). After the thawing of the mature DCs, the yields of living DCs (stated as the percent fraction of the number of frozen DCs) were determined immediately (=d7) and after several days of culture (after 1 day=d8, after 2 days=d9, etc.). The latter determination was performed in complete medium, but without the addition of GM-CSF or IL-4, since this hard “wash-out test” is an established method for determining whether DCs have actually been fully matured and are stable. Freezing at 10×10 6 mature DCs/ml yielded the best results (p<0.05 on day 7, p<0.01 on all other days; n=3).
[0052] FIG. 2 shows the influence of various freezing media on the DC yield after rethawing. DCs were prepared as described in the legend of FIG. 1 , and aliquots were frozen at a concentration of 10×10 6 DCs/ml in HSA+10% DMSO, in autologous serum+10% DMSO, and in autologous serum+10% DMSO+5% glucose (final concentrations). The DC yields after freezing and rethawing were determined as described for FIG. 1 . Freezing in autologous serum+10% DMSO+5% glucose yielded the best results (p<0.05 on day 8; n=4).
[0053] FIG. 3 shows the survival rate of fresh DCs in comparison with that of frozen and rethawed DCs in “wash-out tests”. Mature d7 DCs were prepared as described for FIG. 1 , and then freshly prepared as well as frozen (−1° C./min in pure autologous serum+10% DMSO+5% glucose at a cell density of 10×10 6 DCs/ml) and rethawed after more than 3 hours of storage in the gas phase of liquid nitrogen) DCs were cultured for several days in medium without cytokines (“wash-out test”) as described in FIG. 1 . The yields of living DCs are stated as percent fractions of the total number of DCs sown into the wells on day 7. There was no statistically significant difference between freshly prepared and frozen/thawed DCs (n=4).
[0054] FIG. 4 shows that the freezing and rethawing does not change the characteristic morphology of mature DCs. Mature d7 DCs prepared as described for FIG. 1 were either immediately further cultured for another 2 days or were further cultured after freezing, at least 3 hours of storage in the gas phase of liquid nitrogen and rethawing. Even after 48 hours of further culture in the absence of cytokines (“wash-out test”), the non-frozen (left) and frozen/rethawed (right) DCs remained stable non-adherent cells.
[0055] FIG. 5 shows that the freezing and rethawing does not change the characteristic phenotype of mature DCs. Mature d7 DCs freshly prepared as described for FIG. 1 were phenotyped by a FACS analysis (fresh DC, day 7). Aliquots were frozen, stored for at least 3 hours in the gas phase of liquid nitrogen, rethawed, and subsequently their phenotype was determined immediately (DCs frozen/rethawed d7) or after another 3 days in culture ((DCs frozen/rethawed d10) in the absence of cytokines (“wash-out test”). Frozen/rethawed mature d7 DC maintained the characteristic phenotype of mature DCs (CD14−, CD83 homogeneously ++) even after the removal of cytokines and further culture for 3 days.
[0056] FIG. 6 shows that the freezing and rethawing does not change the stimulatory capacity of mature DCs in the primary allogenic MLR (“mixed leucocyte reaction”). Mature d7 DCs were prepared as described for FIG. 1 , and the allostimulatory potency of freshly prepared non-frozen DCs was compared with that of an aliquot of these DCs which had been frozen and rethawed (after 3 hours of storage in liquid nitrogen).
[0057] FIG. 7 shows that the freezing and rethawing does not change the ability of mature DCs to induce a strong IMP-specific CTL response. Freshly prepared or frozen/rethawed HLA-A2.1+ mature d7 DCs were loaded with influenza matrix peptide (=IMP) GILGFVFTL (SEQ ID NO: 1) or left untreated and cultured with autologous CD8+ T cells (T:DC ratio=10:1) without adding any cytokines. Additionally, purified CD8+ T cells were cultured without DCs±addition of IMP. After 7 days, the T cells were harvested and examined for their cytologic activity using a standard 51 Cr release assay. T2 cells pulsed without or with 10 μg/ml of IMP served as the target cells.
[0058] FIG. 8 shows that the freezing and rethawing does not change the ability of mature DCs to induce a strong IMP-specific CD8+ T cell response (HLA-A2.1/peptide tetramer analysis). Freshly prepared or frozen/rethawed HLA-A2.1+ mature d7 DCs were loaded with IMP (in the case of frozen/rethawed cells, prior to freezing or after thawing) or left untreated and co-cultured for 7 days with autologous non-adherent fractions of PBMCs (PBMC:DC ratio=30:1) without adding any cytokines, harvested and double-stained with HLA-A2.1/IMP tetramers (X axis) and anti-CD8 (Y axis). The expansion of IMP-peptide-specific CD8+ T cells (the percentage of tetramer-binding CD8+ T cells is stated in the Figure) is comparable for fresh and frozen DCs. Loading DCs prior to freezing or after thawing does not make a difference.
[0059] FIG. 9 shows that a contact with CD40L further improves the survival rate of thawed DCs. Mature d7-DCs were prepared as described for FIG. 1 . After thawing, soluble primary CD40L (100 ng/ml) was added for 4 hours, then the DCs were washed and cultured for several days in medium without cytokines (“wash-out test”) as described in the legend for FIG. 3 . The yields of living DCs (stated as the percentage of frozen DCs) were determined immediately (=d7) and after several days of culture (after 1 day=d8, after 2 days=d9, etc.). CD40L treatment of DCs yielded an improved survival rate, especially beyond day 2 of the further culture (p<0.01 on day 10 and day 11; n=5).
[0060] FIG. 10 shows that DCs can be successfully loaded with protein antigen prior to freezing. DCs were pulsed in their immature stage by adding the model antigen tetanus toxoid (TT) (10 μg/ml) on day 6. Mature DCs were then harvested on day 7 and frozen as described in the legend for FIG. 3 . Frozen TT-pulsed DCs were stimulatory like freshly prepared TT-pulsed mature DCs.
[0061] FIG. 11 shows that DCs can be successfully loaded with protein antigen prior to freezing. Frozen/thawed (see FIG. 3 ) HLA-A2.1+ mature d7 DCs were loaded with Melan-A-analogue peptide ELAGIGILTV (SEQ ID NO: 2) either prior to freezing or after thawing or left untreated and co-cultured for 7 days with autologous non-adherent fractions of PBMCs (PBMC:DC ratio-20:1) without adding any cytokines, harvested and double-stained with HLA-A2.1/Melan-A tetramers (X axis) and anti-CD8 (Y axis). The expansion of Melan-A-peptide-specific CD8+ T cells (the percentage of tetramer-binding CD8+ T cells is stated in the Figure) is comparable for frozen DCs which had been loaded prior to freezing or after thawing. See also FIG. 8 .
[0062] FIG. 12 shows the induction of a helper cell type 1 response against KLH in patients who were vaccinated as described in Example 6.
[0063] FIGS. 13-15 show the results of Example 7.
[0064] FIG. 16 shows a schematic representation of the experimental set-up of Example 8. The results of Example 8 are summarized in FIGS. 17 and 18 .
[0065] FIG. 17A shows the total number of DCs after loading with tumor cell lysate or necrotic tumor cells and subsequent cryoconservation.
[0066] FIG. 17B shows the allostimulatory potency of DCs after loading with tumor cell lysate or necrotic tumor cells and subsequent cryoconservation.
[0067] FIG. 17C shows the result of the FACS analysis after tumor loading and cryoconservation.
[0068] FIG. 18A shows the result of the determination of the total number of DCs after loading with apoptotic tumor cells and subsequent cryoconservation.
[0069] FIG. 18B shows the allostimulatory potency of DCs after loading with apoptotic MEL 526 melanoma cells and subsequent cryoconservation.
[0070] FIG. 18C shows the results of the FACS analysis of MAGE-1/HLA-A1 Ag expression on Mage-1 peptide-pulsed DCs prior to and after cryoconservation.
[0071] FIG. 18D shows a comparison of the expression of MAGE-1/HLA-A1 complexes (determined by means of antibodies against MAGE-1/HLA-A1 complex) prior to and after cryoconservation on DCs which had been loaded in different ways.
[0072] FIG. 19 shows a schematic representation of the experimental set-up of Example 9 in which adenovirus-infected dendritic cells with or without cryoconservation are compared. The results of Example 9 are summarized in FIGS. 20 to 23 .
[0073] FIG. 20 shows the recovery of adenovirus-infected dendritic cells after cryoconservation. The recovery rate of adeno-GFP infected DCs after freezing and rethawing is comparable with that of mock-treated (non-transfected) DCs.
[0074] FIG. 21 : CD4 T-cell stimulating activity of adenovirus-infected dendritic cells after cryoconservation. It can be shown that the cryoconservation does not change the allostimulatory activity of adenovirus-infected DCs.
[0075] FIGS. 22A and 22B show that a similar phenotype is observed in adenovirus-infected DCs with or without cryoconservation.
[0076] FIGS. 23A and 23B show a phenotype of adenovirus-infected DCs with or without cryoconservation.
[0077] FIG. 24 shows the schematic course of the experiment of Example 10 as compared with RNA-electroporated DCs with or without cryoconservation. The results are summarized in FIGS. 25 to 27 .
[0078] FIG. 25 shows that the recovery after cryoconservation of EGFP-RNA-electroporated DCs is similar to that in the control experiment.
[0079] FIG. 26 shows that the cryoconservation does not change the allostimulatory capacity of EGFP-RNA-transfected DCs.
[0080] FIG. 27 shows that the phenotype of RNA-transfected DCs is similar to that in the control experiment.
[0081] FIG. 28 shows MHC class I and II restricted melanoma and influenza viral peptides which can be employed in the method of the present invention. Abbreviations: AS=amino acids, NT=nucleotides, NP=nucleoprotein, ana*=analogue peptide
[0082] a Most frequent DR4 subtype, approximately 80%
[0083] b Most frequent DR4 subtype, approximately 80%
[0084] c To date, 30 different HLA DR13 alleles have been described. Restriction for DRB1*1301 and DRB1*1302, which together make up 80% of the DR13 alleles, was shown. It is possible that other DR13 alleles also present the peptide.
[0085] d The epitope is presented less effectively by this second HLA DP4 allele as compared to the allele DPB1*0401.
DETAILED DESCRIPTION OF THE INVENTION
[0086] The following Examples are intended to further illustrate the invention, but without any limitation thereto.
Example 1
[0087] The survival rates of freshly prepared immature DCs and of DCs matured by different maturing stimulants were determined.
[0088] The following different maturing stimulants were tested:
[0089] Monocyte-conditioned medium, prepared and used as described (Thurner et al. (1999) J. Immunol. Methods 223, 1);
[0090] 10 ng/ml TNFα;
[0091] 10 ng/ml TNFα+1 μg/ml PGE 2 ;
[0092] 10 ng/ml TNFα+10 ng/ml IL-1β+100 U/ml IL-6+1 μg/ml PGE 2 (“maturing cocktail”);
[0093] up to 1.0 μg/ml of LPS of Salmonella abortus equi;
[0094] double-stranded RNA (poly-I:C, 20 μg/ml);
[0095] from 50 to 1000 ng/ml CD40L.
[0096] Preparation of monocyte-derived DCs from PBMCs: As a complete medium, RPMI 1640 with 20 μg/ml gentamicin, 2 mM glutamine and 1% heat-inactivated (56° C., 30 min) autologous human plasma was used. Leucapheresis products were prepared as monocyte separation products from healthy cytapheresis donors as described (Thurner et al. (1999) J. Immunol. Methods 223, 1). Peripheral blood mononuclear cells (PBMCs) were then isolated by centrifugation in lymphoprep, and DCs were prepared from plastic-adherent fractions of the PBMCs as described (Thurner et al. (1999) J. Immunol. Methods 223, 1). For this purpose, immature DCs were obtained by a culture in complete medium with recombinant human GM-CSF (800 U/ml) and IL-4 (500 U/ml). On day 6, the different maturing stimulants mentioned above were added to the DCs, and on day 7, the mature DCs were harvested and further cultured for another two days in the absence of cytokines. The survival rates after two days of culture in percent of the sown DCs were:
[0097] 38.25% for immature DCs; 76.2% for (IL-1β+IL-6+PGE 2 +TNFα)-matured DCs;
[0098] 13.5% for TNFα-matured DCs;
[0099] 37.0% for (TNFα+PGE 2 )-matured DCs;
[0100] 31.8% for (poly-I:C)-matured DCs; and
[0101] 49.6% for CD40L-matured DCs (at 500 ng/ml).
[0102] The differences were statistically significant.
Example 2
[0103] Mature (day 7) DCs were frozen as follows: DCs were resuspended in cryovessels at different concentrations (5, 20, 40, 60 and 100×10 6 per ml) either in pure autologous serum or in 20% human serum albumin (HSA; consisting of 1000 ml of electrolyte solution supplemented with 200 g of human plasma proteins with at least 95% of albumin; DRK Blutspendedienst Baden-Wurttemberg, Baden-Baden, Germany). The DC suspension formed was mixed 1:1 with the different freezing solutions described hereinafter and then immediately transferred into a 1.0 or 1.8 ml cryovessel. Immediately thereafter, the vessels were cooled down to −80° C. in a “Cryo Freezing Container” (Nalgene Cryo 1° C. Freezing Container, cooling rate −1° C./min) and finally transferred into the gas phase of liquid nitrogen, where they were kept for up to seven months.
[0104] a) Freezing Media
[0105] HSA+DMSO±glucose (consisting of 20% HSA solution (see above)+10, 15, and 25% (v/v) DMSO±glucose (Glukosteril 40%™, Fresenius, Germany, active ingredient: glucose monohydrate) at 2, 4, 6, 10, 20 or 30% (v/v));
[0106] serum+DMSO±glucose (pure autologous serum+20% (v/v) DMSO±glucose added at 2, 4, 6, 10, 20 or 30%);
[0107] Erythrocyte Freezing Solution™ (Erythrocyte Freezing Solution™ (Fresenius, Dreieich, Germany), consisting of 38% glycerol, 2.9% sorbitol and 0.63% sodium chloride in sterile water);
[0108] Cell Processing Solution™+DMSO (Fresenius, Dreieich, Germany, consisting of 6% hydroxyethylstarch in 0.9% sodium chloride, usually used for the sedimentation of erythrocytes)+10 or 15% (v/v) DMSO.
[0109] b) Thawing Conditions
[0110] For the thawing of frozen mature (day 7) DCs, the following four methods were examined:
[0111] 1. DCs were thawed in a water bath at 56° C., then incubated without washing in 10 to 20 ml of ice-cold complete medium (supplemented with 800 U/ml of GM-CSF and 500 U/ml of IL-4) in Teflon dishes (Rotilabo boxes, Roth, Karlsruhe, Germany) at 37° C. and 5% CO 2 for two hours, then harvested and centrifuged for 10 minutes at 150×g and 22° C. Subsequently, the cells were counted and again sown on Teflon dishes in complete medium with GM-CSF and IL-4 (cell density 1×10 6 per ml) and cultured over night. On the next day, the cells were harvested for further use.
[0112] 2. Frozen mature (day 7) DCs were thawed as described under 1, and after a resting period of two hours at 37° C. and 5% CO 2 on Teflon dishes, the cells were harvested (centrifugation for 10 min at 150×g and 22° C.) for further use.
[0113] 3. Frozen mature (day 7) DCs were thawed as described under 1, and after a resting period of two hours at 37° C. and 5% CO 2 on tissue culture dishes (Falcon Becton Dickinson Labware, New Jersey, USA), the cells were harvested (centrifugation for 10 min at 150×g and 22° C.) for further use.
[0114] 4. Frozen mature (day 7) DCs were thawed in a water bath at 56° C., then added to 10 ml of ice-cold “Hank's Balanced Salt Solution” (Bio Whitaker) and immediately centrifuged for 12 min at 133×g and 4° C. Subsequently, the cells were harvested for further use.
[0115] c) Establishing of DC Survival Rate
[0116] The survival rate of frozen and rethawed DCs was examined by culturing in complete medium without the addition of GM-CSF and IL-4 over at least 4 days (=“wash-out test”) and compared with the survival rate of DCs which had been freshly prepared from non-frozen or frozen aliquots of PBMCs as described (Thurner et al. (1999) J. Immunol. Methods 223, 1). The respective amounts of living DCs were determined by a cell counter (Cassy Cell Counter and Analyser System, Model TT, Schrfe System, Reutlingen, Germany; this system uses “pulse area analysis” and allows the determination of cell counts, cell size and volume as well as whether living cells are present) and as a control also through standard trypan blue staining.
[0117] First, the influence of the DC concentration was examined, wherein freezing at 10×10 6 mature DCs/ml yielded the best results. The result is shown in FIG. 1 .
[0118] Further, the influence of the DMSO concentration (5 to 12.5% v/v final concentration) was examined. A change of the DMSO concentration had no significant effect on the survival rate of thawed DCs.
[0119] Further, it was examined whether HSA or pure autologous serum yielded better survival rates, and whether an addition of glucose (final concentrations v/v of 1, 2, 3, 5, and 15%) improves the survival rate. The result is shown in FIG. 2 . The survival rate of DCs after several days was reproducibly increased if HSA was replaced by autologous serum. An addition of glucose in a final concentration of 5% (v/v) further improved the results.
[0120] Various commercially available freezing media, such as Erythrocyte Freezing Solution™ or Cell Processing Solution (Fresenius) were also examined. However, these yielded worse results as compared with the freezing media already tested.
[0121] Also, the various thawing conditions mentioned under b) were examined for minimizing the stress to which the cells are subjected after thawing. None of the four methods tested showed a clear superiority over the others.
[0122] Mature (day 7) DCs were prepared as described in Example 1 and frozen under the following conditions:
[0123] Cooling rate 1° C. per min in pure autologous serum+10% DMSO+5% glucose at a cell density of 10×10 6 /ml. After at least three hours of storage in the gas phase of liquid nitrogen, the cells were thawed. After thawing, the percentage of living DCs was directly determined (=D7). Aliquots of the DCs were sown, and the survival rates were determined after up to 4 days in culture in medium without cytokines (“wash-out test”) as described in Example 1c) (n=20). The result is shown in the following Table.
[0124] Yield of Frozen/Thawed DCs after Thawing (Day 7) and in “Washout Tests” (Days 8 to 11).
[0000]
Days
Yield in %
95% confidence interval
7
93.3
100.0-85.8
8
74.1
81.7-66.6
9
63.3
70.8-55.7
10
55.8
63.4-48.2
11
47.1
57.9-36.2
Example 3
[0125] Optimally matured and frozen DCs are equivalent to freshly prepared DCs with respect to survival rate and T-cell stimulatory activity.
[0126] a) First, it was examined whether the survival rate of frozen and rethawed DCs is comparable with the survival rate of freshly prepared DCs from the same donor. Thus, the “wash-out test” was used as described in Example 2c). The result is shown in FIG. 3 . It was found that there is no difference between thawed DCs and freshly prepared DCs from the same donor.
[0127] Also, the morphology and the phenotype of thawed DCs were compared with those of freshly prepared DCs. The morphology of the cells was examined with an inverted-phase microscope (Leika DM IRB, Leika Mikroskopie and Systeme GmbH, Wetzlar, Germany) and recorded by photography. The phenotype of the cell populations was examined by a series of monoclonal antibodies and examined on a FACScan device (Becton Dickinson, New Jersey, USA) as described (Thurner et al. (1999) J. Immunol. Methods 223, 1). Dead cells were sorted out due to their light-scattering properties. The result is shown in FIGS. 4 and 5 . Frozen and rethawed DCs keep their characteristic morphological properties and their phenotype over several days.
[0128] b) Then, it was examined whether rethawed DCs also maintain their functional properties.
[0129] 1. Thus, it was examined whether rethawed DCs can induce primary allogenic MLRs as effectively as freshly prepared, non-frozen mature DCs. This test was performed as described (Thurner et al. (1999) J. Immunol. Methods 223, 1). DCs were added in graded doses to 2×10 5 allogenic T cells per well in flat-bottomed 96-well plates and co-cultured for 4 to 5 days in RPMI 1640 (supplemented with gentamicin, glutamine and 5% allogenic heat-inactivated human serum (pool serum)), and the proliferation was determined by the addition of 3 H-thymidine (4 μCi final concentration/ml) for the last 12 to 16 hours of the co-incubation. The result is shown in FIG. 6 . Frozen and rethawed DCs induce primary allogenic MLRs as effectively as freshly prepared mature DCs.
[0130] 2. It was also examined how effectively frozen and rethawed DCs can induce cytotoxic T lymphocytes (CTLs). For this purpose, the induction of IMP (influenza matrix peptide) specific CTLs by IMP-pulsed mature DCs was measured. This approach is specific for mature DCs when performed in the absence of T cell assistance and exogenic IL-2. The induction of CD8+ T cells specific for influenza matrix A2.1 peptide (IMP) or Melan-A A2.1 peptide was effected by the stimulation of purified CD8+ T cells (isolated from PBMCs by magnetic cell sorting/MACS with CD8 microbeads according to the supplier's specifications, Miltenyi Biotec, Bergisch Gladbach, Germany), or in other experiments of non-adherent PBMC fractions with DCs (prepared from autologous PBMCs from HLA-A2.1+donors) which were either unpulsed or pulsed with HLA-A2.1 restricted IMP (GILGFVFTL [SEQ ID NO: 1], 10 μM for 1 hour at 37° C. at 1×10 6 DCs/ml of complete medium) or Melan-A-analogue peptide (ELAGIGILTV [SEQ ID NO: 2], 10 μM) at a DC/T ratio of 1:10 or 1:30 for 7 days without the addition of cytokines. CTLs were quantified by a standard lysis assay (Bhardwaj et al. (1994) J. Clin. Invest. 94, 797) or by tetramer staining at 37° C. (Whelan et al. (1999) J. Immunol. 163, 4342). The target cells for the standard 4-hour 51 Cr-release assay, which was performed at different effector/target cell ratios, were IMP-pulsed (10 μg/ml for 1 hour at 37° C.) T2A1 cells, unpulsed T2A1 cells and K562 target cells (all .sup.51Cr-labeled). All experiments were performed with an 80 fold excess of K562 cells in order to block the natural killer cell activity. The specific lysis in % was calculated by the formula (specific release−spontaneous release)/(maximum release−spontaneous release)×100. Soluble IMP and Melan A/HLA A2.1 tetramers were prepared, and the formation of T cells was analyzed by flow cytometry at 37° C. as described (Whelan et al., 1999). 1 μl of tetramer (0.5 to 1 mg/ml) was added to 2×10 6 cells in about 60 μl (volume remaining in the vessel after centrifugation and pouring of the supernatant) of medium consisting of RPMI 1640 supplemented with gentamicin, glutamine and 5% allogenic heat-inactivated human serum (pool serum) for 15 min at 37° C. Subsequently, the cells were cooled down without washing and incubated on ice for 15 min with a triply stained monoclonal antibody against human CD8 (Caltag Laboratories, Burlingame, Calif.). After three washing steps, the cells were analyzed on a FACScan device (Becton Dickinson).
[0131] The result is shown in FIGS. 7 and 8 .
[0132] The freezing and thawing of DCs does not change the capability of mature DCs of inducing a strong IMP-specific CLT response. Also, the freezing and thawing does not change the capability of mature DCs of inducing strong IMP-specific CD8+ T cell responses, as shown by the HLA-A2.1/peptide tetramer analysis.
[0133] These experiments show that, after the freezing and thawing, living DCs were obtained which are absolutely equivalent with freshly prepared DCs.
Example 4
[0134] To achieve an increased survival rate of the frozen and rethawed DCs, the following different anti-apoptotic stimulants were added to the DCs in different concentrations and at different times:
[0135] 1. Recombinant murine or human trimeric TRANCE (Wong et al. (1997) J. Exp. Med. 186, 2075) at 100, 200, 500 ng/ml;
[0136] 2. RANKL (Anderson et al. (1997) Nature 390, 175) at 10 ng/ml, 50 ng/ml, 100 ng/ml and 1 μg/ml;
[0137] 3. Trimeric soluble CD40L (Morris et al. (1999) J. Biol. Chem. 274, 418) at 50, 100 and 500 ng/ml.
[0138] The DCs were subjected to the different anti-apoptotic stimulants at 37° C. over night for the last 12-16 h of culture prior to freezing, for 4 h prior to freezing (cell density 1×10 6 in complete medium with GM-CSF and IL-4), and also for 4 h after thawing (cell density 1×10 6 in complete medium with GM-CSF and IL-4).
[0139] A brief exposure of thawed DCs to the anti-apoptotic stimulants was as effective as the DC treatment prior to freezing and gave an increased survival rate, which often became visible only after 3 days in the “wash-out test”, however. CD40L ( FIG. 9 ) and TRANCE/RANKL (results not shown) yielded similar results. The results show that the addition of CD40L or TRANCE/RANKL improves the survival rate of DCs beyond day 3.
Example 5
[0140] In order to examine whether DCs can be successfully loaded with antigen prior to freezing, DCs were loaded with tetanus toxoid (TT) (as an example of a protein antigen) or with IMP (as a model peptide). For pulsing with TT, DCs were prepared from fresh or frozen aliquots of PBMCs from leucapheresis products (see above). TT was added to the immature cells on day 5 at 10 μg/ml. Mature DCs were harvested on day 7 and, either non-frozen or after freezing and thawing (after 4 h), examined for their capability of inducing TT-specific proliferative responses in PBMCs. Thus, graded doses of unpulsed and TT-pulsed DCs were added to PBMCs (10×10 4 /well) and pulsed with 3 H-thymidine on day 5 as described (Thurner et al. (1999) J. Immunol. Methods 223, 1). For loading with IMP, DCs were pulsed with 10 μM peptide (for 1 h, 37° C., 1×10 6 DCs/ml of complete medium) either prior to freezing or after thawing. The capability of successfully presenting IMP was tested as described above.
[0141] Frozen TT-pulsed DCs had the same stimulatory properties as freshly prepared TT-pulsed DCs ( FIG. 10 ). Both DCs loaded with IMP or Melan A prior to freezing and those loaded after thawing stimulated IMP- or Melan-A-specific CTLs equally well ( FIGS. 8 and 11 ). These results show that it is possible to prepare frozen aliquots of mature DCs which have already been loaded with antigen and can be used immediately after thawing.
Example 6
[0142] With stage IV melanoma patients, a vaccination was performed with peptide- and protein-loaded DCs prepared and antigen-loaded according to the method shown herein. FIG. 12 shows the induction of a helper cell type 1 response against KLH in all vaccinated patients. Each of the patients obtained a single subcutaneous delivery of 4 million mature DCs which had been prepared from leucapheresates using GM-CSF and interleukin-4 and the maturing composition as described in the application (e.g., FIGS. 1 and 3 ). In doing so, the control antigen KLH was added in a concentration of 10 μg/ml simultaneously with the maturing composition, and the DCs were then frozen in portions. Prior to vaccination and 14 days after said single administration of 4 million DCs, blood was removed and examined by a standard Elispot assay (addition of 10 μg/ml KLH to 500,000 PBMCs and measurement of the number of cells producing interferon-.gamma. or IL-4; the background without the addition of KLH is almost 0). It is found that neither interferon-γ nor interleukin-4 is produced upon KLH presentation prior to vaccination, whereas 14 days after the single vaccination with the KLH-loaded DCs, T cells which produced interferon-γ, but did not produce interleukin-4 or only minimally so were induced in all patients (in control experiments, it was shown by removing the CD4 cells from the PBMCs that the reactive cells are CD4-positive helper T cells).
Example 7
[0143] A patient from the study of Example 6 received several vaccinations with DCs, in which 4 million each of rethawed DCs were loaded with the peptides stated in FIG. 13 , 14 or 15 (i.e., only 1 peptide respectively per 4 million DCs) and injected subcutaneously. Respectively prior to the first vaccination and 14 days after the respectively preceding vaccination and immediately before the next vaccination, blood was removed, and a standard Elispot assay was performed as described in Thurner et al. (1999), J. Exp. Med. 190, 1669-1678, under Materials and Methods. The DCs used for the vaccination were prepared as stated in the legend for FIGS. 8 and 11 and in Example 5, and loaded with the respective peptides only after thawing. As can be seen from FIGS. 13 to 15 , immunity against several class-I ( FIGS. 13 and 14 ) and class-II peptides ( FIG. 15 ) was induced. The characteristics of the peptides employed can be seen from Table I. It is to be noted that the HLA type of the particular patient is HLA-A 2.1+ and HLA-A3+ as well as HLA-DR 13+, HLA-DP4+ (but DR4−). FIG. 13 shows the induction of immunity against the influenza peptides NP-A3 and IMP-A2 upon a single vaccination (No. 2 means the removal of blood and Elispot measurement briefly before the administration of vaccination No. 2) and shows an increase after another vaccination, but no change in EBV-A2 and IV-9-A2 peptides, which were not used for vaccination. FIG. 14 shows an induction of immunity against four class-I restricted tumor peptides, clearly and unambiguously against the peptide Melan A-A2.1. FIG. 15 shows an induction of immunity against two class-II restricted tumor peptides (Mage 3-DR13 and -DP4) but not against tyrosinase-DR4 and GP 100 DR4 (this is a negative control since the patient was DR4-negative, and the DCs thus could not be loaded with these peptides).
Example 8
Cryoconservation of Dendritic Cells After Antigen Loading with Tumor Cell Preparations
Tumor Cell Lysates, Necrotic or Apoptotic Tumor Cells
[0144] Dendritic cells (DCs) can be generated in large amounts from leucaphereses. A method for the cryoconservation of mature DCs has been developed which allows the portioned use of these cells for vaccination. To date, the mature DCs were loaded prior to use with peptides which correspond to the immunodominant sequences of tumor-associated antigens (TAA). In the experiments described here (see FIG. 16 ), it was examined whether immature DCs which were loaded with different tumor cell preparations and subsequently matured can also be cryoconserved.
[0145] Tumor cell preparation: For preparing the tumor cell preparations, the Mel526 melanoma cell line was used. Mel526 cells were washed in RPMI and treated by repeated heatings at 57° C. and subsequent coolings in liquid nitrogen. Then, the cell material was disrupted by means of an ultrasonic device. Since the heating/freezing cycles induce necrosis, this kind of tumor cell preparation which contains all cell components is referred to as necrotic cell material in the following. For obtaining lysate, we performed an ultracentrifugation after these steps to remove cell components and effected purification of the proteins in a Centricon centrifugation tube. According to the results of the Bradford analysis, we used the protein fraction having the higher activity, namely that of ≧10 kDa. Apoptotic tumor cells were induced with a broad-range UVB irradiation device and verified with an Annexin V Test.
[0146] Generation of DCs: DCs were generated from leucaphereses according to the technique used in experimental immunotherapy. PBMCs were plated in Nunc Cell Factories and cultured with RPMI (1% autologous heat-inactivated plasma) supplemented with 1000 IU/ml GM-CSF and 500 IU/ml IL-4. On day 5, the DCs, which were immature then, were used and loaded for 4 hours with the tumor cell preparations described in a concentration of 1:1.
[0147] Loading: The loading was effected in a 5 ml polypropylene reaction vessel at 37° C. and 5% CO 2 . After the loading, the DCs were plated in 12 ml tissue culture dishes and cultured with a maturing cocktail consisting of TNF-α, IL-1β, IL-6 and PGE 2 for 24 h.
[0148] Freezing/thawing: Half of the respectively loaded DCs were respectively cryoconserved in 1.8 ml Nunc freeze vials at −80° C. for 3 hours according to the method described (Feuerstein et al., J. Immunol. Methods 245: 15-29 (2000)). Thereafter, the cells were again thawed according to the method described and cultured for one hour in RPMI medium at 37° C. and 5% CO 2 . Subsequently, this fraction of the DCs as well as the non-frozen fraction were analyzed and used for further experiments.
[0149] The experimental set-up described is shown as a flow chart in FIG. 16 .
[0150] Cell count and viability: The total cell count and viability of the DCs were determined with trypan blue with a microscope after performance of the loading described and cryoconservation. Initially, 5×10 5 DCs were used. We found comparable cell counts and no difference in the viability of the loaded and cryoconserved DCs as compared with the non-cryoconserved cells ( FIGS. 17A , 18 A). A reduction of the cell count by the loading, but not by the cryoconservation, especially with necrotic cells, could be observed.
[0151] Functionality: For testing the functional capacity, a mixed-leucocyte reaction test (MLR) was performed. The loaded DCs were employed in an allogenic MLR (4 days of incubation with allogenic leucocytes) and then pulsed with radioactive thymidine ( 3 H-thymidine) for 13 hours. Comparable allostimulatory potencies were obtained for cryoconserved and non-cryoconserved loaded DCs ( FIGS. 17B , 18 B).
[0152] Phenotype: For evaluating the expression of the surface molecules relevant to antigen presentation and the functional condition of the DCs, a FACS analysis was performed with the corresponding antibodies. A comparable surface expression pattern was found both for the different loading methods and after cryoconservation ( FIG. 17C ).
[0153] Direct antigen detection: For the direct detection of tumoral antigen, an antibody was employed which recognizes MAGE-1 in an HLA-A1 context, i.e., the complex of Mage-1 peptide and the HLA-A1 molecule. The differently loaded DCs were dyed with this antibody and analyzed in the FACS. When peptide-loaded (20 μg MAGE-1 peptide for 3 hours/ml) DCs were used, it was found that after cryoconservation, a percentage of MAGE-1/A1 antigen could be detected which was comparable to that detected without cryoconservation ( FIG. 18C ). From this experiment, it can be concluded that the cryoconservation does not lead to a loss in antigen.
[0154] In a further experiment, the MAGE-1/A1 antibody was employed for determining the effectiveness of the different loading methods. With the tumor cell preparations (the melanoma cell line employed expresses the Mage-1-antigen), a significant loading could be achieved which reached about 20% of the antigen density of the peptide pulsing ( FIG. 18D ). The expression of the MAGE-1/HLA-A1 complex before and after the cryoconservation could be detected in comparable quantities (calculated as positivity against the background of unloaded DCs).
[0155] Conclusion: It could also be shown that the method of the present invention allows not only an effective cryoconservation of unloaded DCs or DCs loaded with peptide or protein (as shown in Examples 1-7), but also a similarly effective cryoconservation of DCs loaded with (tumor) cell preparations (simple necrotic tumor cells, lysates prepared from tumor cells, or apoptotic tumor cells). “Effectively” means that upon freezing, i) the cell loss after thawing is ≦25% as compared with non-frozen DCs, ii) the thawed DCs have a T cell stimulatory capacity comparable to that of the non-frozen DCs (tested in allogenic MLR), and iii) the surface expression of antigens and ligands for T cell receptors (i.e., specific MHC peptide complexes) is retained after the freezing and thawing process (shown in a model by the direct detection of a particular peptide/MHC complex, namely the MAGE-1/HLA-A1 complex, by means of a monoclonal antibody which specifically recognizes this complex).
Example 9
Cryoconservation of Dendritic Cells after Antigen Loading by Means of Adenoviral Transfection
[0156] Dendritic cells transfected with adenoviruses can be frozen by the method according to the invention in such a way that the properties of the dendritic cells are comparable with those of non-transfected dendritic cells. For this purpose, mature DCs were infected with an adenoviral vector (AD5) which contained a cDNA coding for the green fluorescent protein (GFP) at a multiplicity of infection (MOI) of 500 for 2 hours. After two washes, the cells were frozen at a concentration of 10×10 6 DCs/ml in HSA and 10% DMSO in 5% glucose (final concentration) and stored for 4 hours. After thawing, the viability of the cells was determined by trypan blue exclusion. The recovery rate of viable cells is stated in FIG. 20 as a percentage of frozen DCs.
[0157] Further, it could be shown that the allostimulatory activity of adenovirus-infected DCs is not changed by cryoconservation. Thus, mature DCs were infected with adeno-GFP at an MOI of 500 and cryoconserved as described above. After rethawing and a culturing period of 24 or 72 hours, the dendritic cells were co-cultured with allogenic CD4+ T cells (2×10 5 per well) under the conditions stated in FIG. 21 . After 4 days, the cells were pulsed with [ 3 H]-thymidine for 16 hours, and the incorporated radioactivity was determined. In FIG. 21 , the average values of three counts are stated with the corresponding standard deviations. The values for T cells alone or DCs alone were always less than 1000 per min.
[0158] Further, mature DCs are cryoconserved with adeno-GFP at an MOI of 500 as described above. After rethawing and the stated culturing time, the cells were counterstained using antibodies specific for CD83, CD25, CD86, CD80 followed by PE-conjugated goat/mouse IG (Fab′) 2 fragments. The results are shown in FIG. 22A . In a comparable experiment using antibodies specific for HLA class 1, HLA-DR and CD40, the results shown in FIG. 22B were obtained.
Example 10
Cryoconservation of Dendritic Cells after Antigen Loading by Means of RNA Transfection
[0159] Dendritic cells transfected with RNA can be frozen by the method according to the invention in such a way that the properties of the dendritic cells are comparable with those of non-transfected dendritic cells. The DCs can be transfected with RNA in an immature stage, then matured, and then frozen as mature DCs (not shown). Preferably, DCs which are already mature are transfected with RNA and cryoconserved. The results are summarized in FIGS. 25 to 27 .
[0160] Thus, mature dendritic cells were washed twice with RPMI and once in a washing solution of the Optimix kit (EQUIBIO), Maidstone Kent, UK). DCs were brought to a final concentration of 40×10 6 DCs/ml in Optimix medium. Then, 0.1 ml of the cell suspension were mixed with 40 μg of in-vitro transcribed EGFP RNA in a 1.5 ml reaction vessel. After incubation at room temperature for a maximum of 3 min, the cell suspension was transferred into a 0.4 cm gap electroporation cuvette and pulsed at a voltage of 260 V and a capacitance of 150 μF with a Gene Pulser II (Biorad, Munich, Germany). Control DCs were pulsed without the addition of RNA. The cells were frozen at a concentration of 10×10 6 DCs/ml in HSA (with 10% DMSO and 50% glucose (final concentration)) and stored for 4 hours. After thawing, the viability of the cells was determined by trypan blue exclusion. The recovery rate of viable cells is stated in FIG. 25 as a percentage of frozen DCs.
[0161] Mature DCs were electroporated with EGFP RNA and cryoconserved as described above. After rethawing and a culturing period of 48 hours, the dendritic cells were co-cultured with allogenic CD4+ T cells (2×10 5 per well) under the conditions stated in FIG. 26 . After 4 days, the cells were pulsed with [ 3 H]-thymidine for 16 hours, and the incorporated radioactivity was determined. In FIG. 26 , the average values for triplicate measurements (with standard deviation) are shown. The values for T cells alone or DCs alone were always less than 1000 per min.
[0162] The cryoconservation of RNA-electroporated DCs does not change the phenotypical DC marker. Thus, mature DCs were electroporated with or without EGFP RNA and cryoconserved as described above. After rethawing and a culturing time of 48 hours, the DCs were counterstained using the mouse monoclonal antibodies stated in FIG. 27 and PE-conjugated anti-mouse IG (Fab′) 2 fragments, followed by FACS analysis. The figures in the right bottom portion of the square in FIG. 27 relate to the EGFP-positive DCs, and those in the top right portion relate to the EGFP/DC-marker double-positive DCs.
[0000] What is Claimed:
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The invention relates to a method for producing ready to use, antigen loaded or unloaded, cryoconserved mature dendritic cells especially for the production of a vaccine containing said dendritic cells, wherein immature dendritic cells are cultivated in the presence of suitable maturation stimuli and the mature dendritic cells thus obtained are frozen. The dendritic cells can be loaded with antigen before freezing. The invention also relates to a vaccine which can be obtained according to the inventive method and to a composition containing frozen, mature dendritic cells which are loaded with antigen.
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BACKGROUND OF THE INVENTION
a. Field of the Invention
This invention relates to a device for cleaning the interior surfaces of pipes, propelled therethrough by a pressure gradient therein.
B. Description of the Prior Art
In the operation of pipelines, it periodically becomes necessary to clean from the inner surfaces of the pipes accumulations and deposits of sludge, scale, debris, and other material. These cleaning operations are most commonly carried out by propelling through the pipe, by a pressure gradient therein, devices known in the art as pigs.
There are a variety of designs of pigs available, most of which consist generally of a mass of resilient material having a generally circular cross section with diameter slightly greater than that of the pipe through which they are to be propelled. These pigs are most commonly cylindrical in shape, such as those described in U.S. Pat. Nos. 3,543,323 and 3,277,508. Among other designs for pigs are spheres, described in U.S. Pat. No. 3,543,324, and devices with resilient material mounted upon a rigid central shaft, as described in U.S. Pat. Nos. 3,484,886 and 3,541,628. Cylindrical pigs generally have rounded or pointed forward ends, examples of which are described in U.S. Pat. Nos. 3,538,531 and 3,277,508. Having a rounded or pointed forward end enables the pig to pass obstructions more easily and to negotiate bends in the pipe. Additionally, some cylindrical pigs have a concave back end -- examples of which are described in U.S. Pat. Nos. 3,538,531 and 3,602,934 -- which transmits a radial component of the force thereon caused by fluid pressure to the walls of the pipe, effecting a tighter fit. Finally, most cylindrical pigs are covered with strips of material which is harder than the resilient material of which the pig body is made. Additionally, some strips are applied to the pig in a helical pattern, serving to impart spin to the pig, thereby equalizing the wear over the surface of the pig. Examples of various striping patterns are shown in U.S. Pat. Nos. 3,204,274, 3,605,159 and 3,389,417.
One system for introducing pigs into a pipeline is described in U.S. Pat. No. 3,266,076. A supply of pigs is inserted into a launching tube having essentially the same diameter as the pipeline and joined to the pipeline in such a way as to allow a smooth passage of the pig into the line. Spaced longitudinally along the launching tube is a series of ports, connected by valved conduits, to a high pressure fluid supply line. The pigs are inserted into the launching tube in such a manner that spaces are left between the pigs, such spaces coinciding with the port spacing. To launch a pig, the valve immediately upstream of the most downstream pig in the launching tube is opened, allowing high pressure fluid to flood the space between the most downstream pig and the next most downstream pig. The pressure of the fluid upon the upstream end of the pig to be launched, being greater than that upon the downstream end thereof, forces the pig to move downstream in the launching tube and into the pipeline.
Cylindrical pigs, as presently known in the art, are manifestly unsuited for use in the launching system described above. Since the operation of the system depends upon there being spaces between the pigs coinciding with the location of the ports, each pig must be rather precisely placed within the launching tube. To achieve such placement, personnel are required to ram each individual pig, independently of the other pigs, a specified distance into the launching tube.
In addition to the problem associated with achieving proper initial spacing, a more severe disadvantage lies in the fact that the injection of high pressure fluid into the launching tube accomplishes not only the desired result of forcing the most downstream pig into the pipeline, but also the undesired result of forcing the upstream pigs further upstream in the launching tube. The upstream pigs may be so dislodged in the launching tube as to occlude the ports, making the system inoperable.
SUMMARY OF THE INVENTION
It is, therefore, an object of this invention to provide an improved cylindrical pipeline pig that will automatically achieve proper spacing when inserted into a pig launching tube. It is a further object of this invention to provide an improved pipeline pig that will not become displaced in the pig-launching tube as other pigs are launched.
Briefly stated, the improved pipeline pig comprises an elongated cylindrical body member formed of a resilient material, preferably polyurethane foam. Bonded within, and coaxial with, the body member is an elongated column member which is substantially imcompressible along the longitudinal axis thereof. The column member is of somewhat greater length than the body member and its ends extend beyond the ends of the body member. The column member is bonded within the body member so that the body member will not slide longitudinally along the column member. The invention may also include mechanical means for maintaining substantially constant the longitudinal position of the column member with respect to the body member.
The column member may be cylindrical in shape, or it may be flat sided. Further, the column may include disc shaped end portions of greater diameter than the column member, joined fixedly at, and generally coaxial with, the ends thereof.
The maintaining means may be in the form of one or more disc-shaped collars joined coaxially and immovably to the column member and within the body member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross sectional view showing three pigs of the preferred embodiment of this invention within a pig launching tube.
FIG. 2 is a partial cross sectional view of one preferred embodiment of the invention showing the relationship of the column member within the body member.
FIG. 3 is a cross sectional view taken along line 3--3 of FIG. 2 showing the relationship of the discshaped collar to the column member and body member.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 2, the pipeline pig of the invention is designated generally by the numeral 8. Pig 8 is generally comprised of a body member 1 molded around a column member 2.
Column member 2 is constructed so as to resist compression or buckling under longitudinal force, but so as to be flexible in response to forces perpendicular to the longitudinal axis thereof, in order that pig 8 will pass obstructions, such as dents, in the pipe and negotiate moderate bends. Column member 2 is a molded solid cylinder of high durometer polyurethane. However, the form of column member 2 need not be limited to that of a solid cylinder, nor need the material of which column member 2 is made be limited to polyurethane. Column member 2 may be of virtually any cross sectional shape. Likewise, column member 2 may be hollow. If, however, column member 2 is hollow, the ends thereof must be sealed in order that fluid will not flow therethrough. Additionally, column member 2 may be constructed of any material which is resistent to longitudinal compression yet flexible. Examples of such materials are fiber glass and spring steel. The overall length of column member 2 with any end portions 3, to be described hereinafter, affixed thereto must be substantially equal to the distance between the ports 12 of the launching system 10, also described hereinafter, with which pig 8 is to be used.
Column member 2 has immovably joined thereto one or more disc-shaped collars 4. Collar 4 is molded as an integral unit with column 2. However, collar 4 may also be formed as a ring and slid onto column 2 and there fixed in place. A function of collar 4 is to keep column 2 from sliding longitudinally in relation to body 1. A related function is to transfer longitudinal forces between body 1 to column 2. Collar 4 is of substantially larger diameter than column 2 so that the longitudinal interface of collar 4 and body 1 is of large enough area to transmit forces between body 1 and collar 2 without causing damage to body 1.
Joined immovably to the ends of column 2 are disc-shaped end portions 3. As with collar 4, end portions 3 are molded as an integral unit with column 2. Similarly they may be formed as rings and slid into column 2 and there fixed in place. The face 20 of each end portion 3 is substantially perpendicular to the longitudinal axis of column 2 so that forces exerted on a face 20 will be transferred to column 2 substantially parallel to the longitudinal axis thereof. The diameter of each end plate 3 is substantially larger than that of column 2 in order to provide a greater area of contact between adjacent end plates 3 for the transmission of force to column 2.
Body 1 is a generally cylindrical mass of polurethane foam molded coaxial with and bonded to column member 2. Body 1 is somewhat shorter than column member 2 and must be positioned so that neither end thereof extends beyond the ends of column member 2. Further, body 1 must be so positioned on column member 2 that no part thereof occludes any port 12 in launching system 10, to be described hereinafter. The primary function of body 1 is contact the inner surface of the pipe and thereby accomplish the cleaning purpose of pig 8. A secondary function of body 1 is to support column 2, thereby making said column more resistent to buckling.
Body 1 may also incorporate features which are generally known in the art with respect to cylindrical pigs. For example, body 1 may be covered with helical strips 5 of material which will impart spin to, and increase the durability of, pig 8. Further, the back 7 of body 1 may be concave and of a flexible fluid impermiable material so as to transmit a radial component of the force thereon caused by fluid pressure to the walls of the pigs. Similarly, the nose 6 of body 1 may be convex so as to allow pig 8 to pass obstructions and bends in the pipe more easily.
Referring now to FIG. 1, a portion of a typical pipeline pig launching system has been generally designated by the number 10. Launching system 10 is comprised generally of a launching tube 9, connected to the pipeline through a downstream valved opening (not shown) and closed by closure plate 15 at upstream end 17, a high pressure supply line 14, and a plurality of valved conduits 11 connecting high pressure supply line 14 to launching tube 9 at ports 12. Each conduit 11 is fitted with a launcher valve V to control fluid flow therethrough.
A plurality of pipeline pigs 8 (as many as there are ports 12) are inserted into launching tube 9 at upstream end 17. As each pig 8 is inserted into launching tube 9, each column member 2 thereof pushes against the column 2 of the next pig 8 in launching tube 9, causing the next pig 8 and any pigs 8 further downstream within launching tube 9 to advance. When the last of the pigs is inserted into launching tube 9, closure plate 15 is closed behind and abutts column member 2 of the most upstream one of pigs 8. Since column members 2 are of length essentially equal to the distance between ports 12, the loading operation automatically accomplishes proper spacing of said pigs.
To launch a pig 8, valve V in conduit 11 immediately upstream of the most downstream of pigs 8 is opened, allowing fluid to flow from high pressure supply line 14 into launching tube 9. The high pressure fluid exerts a force on the most downstream pig at back 18 thereof, and upon the next most downstream pig 8 at nose 19 thereof. The force exerted upon the most downstream pig 8, being greater at back 18 thereof than at nose 6 thereof, causes said pig to move downstream in the direction of arrow 16 and into the pipeline. The force exerted on nose 19 of the next most downstream pig is transferred to column member 2 thereof by the interaction of the material of body 1 of pig 8 with collar 4 thereof. The force is in turn transferred to closure plate 15 via column members 2 of the remaining upstream pigs 8.
Further modification and alternative embodiments of the apparatus and method of this invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the manner of carrying out the invention. It is to be understood that the forms of the invention herewith shown and described are to be taken as the presently preferred embodiments. Various changes may be taken in the shape, size and arrangement of parts. For example, equivalent elements or materials may be substituted for those illustrated and described herein, parts may be reversed, and certain features of the invention may be utilized independently of the use of other features, all as would be apparent to one skilled in the art after having the benefit of this description of the invention.
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A pipeline pig of the type to be propelled through a pipeline by a pressure gradient in the line to clear accumulations and deposits of sludge, scale and other material from the walls of the pipe. The pig includes an elongated cylindrical foamed elastomer body member and a substantially incompressible column member, located generally co-axially within, and with ends extending beyond the ends of, the body member.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to a control system for estimating the tongue length of a trailer being towed by a vehicle and, more particularly, to a control system for estimating the tongue length of a trailer being towed by a vehicle where the trailer includes a yaw rate sensor, and where the vehicle includes driver operated front-wheel steering with or without computer controlled rear-wheel steering.
[0003] 2. Discussion of the Related Art
[0004] Automotive vehicles that employ coordinated front-wheel steering and rear-wheel steering systems are known in the art. Typically in such coordinated vehicle wheel steering systems, the driver controls the steering of the vehicles front wheels and a computer-based on-board steering controller controls the steering of the vehicles rear wheels in response thereto. In one example, the computer controlled rear-wheel steering system employs an electric motor-driven rack and pinion rear-wheel steering actuator.
[0005] Backing up a vehicle-trailer is typically a complex task, and requires a significant level of skill. It is heretofore been known in the art to employ a coordinated front and rear-wheel steering system to assist a driver operating a vehicle pulling a trailer. Particularly, U.S. Pat. No. 6,292,094, issued Sep. 18, 2001 to Deng et al., assigned to the assignee of this application and herein incorporated by reference, discloses a vehicle/trailer backing up control system in connection with a computer controlled rear-wheel steering system. The '094 patent employs an algorithm that uses front-wheel angle, vehicle speed, vehicle yaw rate and hitch angle to control the rear-wheel steering angle to assist the operator in backing up the vehicle-trailer.
[0006] The vehicle-trailer back-up control system disclosed in the '094 patent has been shown to be effective in assisting the vehicle operator when backing up a trailer. However, because trailers come in a variety of different lengths, the performance of the back-up control system can be improved by providing an input to the system that gives an estimation of the tongue length of the trailer. The algorithm in the '094 patent uses the same average tongue length for trailers of all lengths.
[0007] U.S. patent application Ser. No. 10/336,120, filed Jan. 3, 2003, titled “Trailer Tongue Length Estimation Using a Hitch Angle Sensor,” assigned to the assignee of this application, and herein incorporated by reference, discloses a system that estimates the tongue length of a trailer being towed by using a hitch angle sensor that provides a measurement of the hitch angle between the vehicle and the trailer to determine the tongue length. That system has also been shown to be effective in estimating the tongue length of the trailer to improve the ability of the control system to assist the driver in backing-up the trailer. However, further improvements can be made to make the system more practical and more cost effective. For example, because trailer hitches come in a variety of styles, sizes, etc., providing a hitch angle sensor that accurately measures the hitch angle for all of the various types of hitches may be impractical and costly.
SUMMARY OF THE INVENTION
[0008] In accordance with the teachings of the present invention, a control system is disclosed for estimating the tongue length of a trailer being towed by a vehicle in connection with a coordinated front and rear-wheel steering system. The control system employs an algorithm that calculates an estimate of the yaw rate of the trailer based on a corrected trailer tongue length, a steering wheel angle, a rear-wheel angle, vehicle speed and vehicle yaw rate applied to a vehicle-trailer kinematics model. The estimated trailer yaw rate is compared to the actual trailer yaw rate measured by a trailer yaw rate sensor to generate a yaw rate error signal. The yaw rate error signal is converted to a tongue length error signal by a PID controller. The tongue length error signal is subtracted from an estimated tongue length to give the corrected trailer tongue length for the next computation period. After a few seconds of processing, the yaw rate error signal will be nearly zero and the tongue length error signal will be nearly zero, and thus, the corrected tongue length will be the actual tongue length of the trailer.
[0009] Additional advantages and features 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
[0010] FIG. 1 is a plan view of a vehicle towing a trailer, where the vehicle includes a coordinated front and rear-wheel steering system that provides an estimation of the tongue length of the trailer, according to an embodiment of the present invention;
[0011] FIG. 2 is a kinematics model of a vehicle-trailer system for the algorithm of the invention; and
[0012] FIG. 3 is a block diagram of a control system employing an algorithm for estimating the tongue length of the trailer shown in FIG. 1 by the kinematics model shown in FIG. 2 , according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The following discussion of the embodiments of the invention directed to a control system for estimating the tongue length of a trailer being towed by a vehicle employing a coordinated front and rear-wheel steering system is merely exemplary in nature, and is in no way intended to limit the invention or its applications or uses.
[0014] FIG. 1 is a plan view of a vehicle-trailer system 10 that estimates a tongue length (TL) of a trailer 12 being towed by a vehicle 14 . The system 10 is a variation of the backing up control system disclosed in the '094 patent that uses the coordinated front and rear wheel steering system to provide an intelligent vehicle-trailer backing-up system. The system 10 includes a similar controller 18 as the control system in the '094 patent. Further, the system 10 includes various other vehicle sensors used in the control system disclosed in the '094 patent, as will be apparent from the discussion below. The various vehicle sensors discussed below can be any sensor suitable for the purposes discussed herein, and need not be specifically limited to those types of sensors disclosed in the '094 patent. In other embodiments, the tongue length estimation process of the invention can be used in vehicles that do not have assisted rear-wheel steering.
[0015] The trailer 12 includes a trailer hitch post 20 , a trailer bed 22 and trailer wheels 30 rotatably mounted to a trailer axle 32 . In other embodiments, the trailer 12 may include more than one axle each including trailer wheels. The center of the turning radius for those trailers may be between the axles. The vehicle 14 includes a vehicle hitch post 24 having a hitch 26 that couples the hitch post 24 to the hitch post 20 in any known manner that allows the trailer 12 to be towed by the vehicle 14 . As defined herein, the tongue length of the trailer 12 is the distance from the pivot location at the hitch 26 to the rotating center or turning radius of the trailer 12 . When the vehicle 14 and the trailer 12 are backing up at a low speed and there is no side slip at the wheels 30 , the tongue length of the trailer 12 is the distance from the hitch 26 to the center of the trailer axle 32 .
[0016] The vehicle 14 includes a steering wheel 40 mounted to a steering column 42 that allows a vehicle operator to steer front wheels 44 of the vehicle 14 through a steering linkage and a front wheel axle 46 . A steering wheel angle sensor 48 is mounted to the steering column 42 to provide a front wheel angle signal δ f (t) indicative of the steering direction of the wheels 44 . The maximum angular movement for a particular vehicle's front wheels is generally fixed, and may be, for example, about +33° to the left or −33° to the right. The signal from the steering wheel angle sensor 48 is provided to the controller 18 .
[0017] The vehicle 14 also includes rear wheels 52 mounted to a rear wheel axle 54 . The rear wheels 52 are turned by an electric motor 56 in connection with a rack and pinion steering mechanism 58 mounted to the axle 54 . A rear wheel angle sensor 62 is mounted in combination with the rack and pinion steering mechanism 58 , and provides a rear wheel angle signal δ r (t) to the controller 18 indicative of the angle of the rear wheels 52 .
[0018] The vehicle 14 also includes a vehicle speed sensor 64 that measures the speed of the vehicle 14 and provides a vehicle speed signal V x (t) to the controller 18 . The vehicle 14 further includes a vehicle yaw rate sensor 66 that measures the yaw rate of the vehicle 14 and provides a vehicle yaw rate signal r v (t) to the controller 18 . The speed sensor 64 and the yaw rate sensor 66 can be any sensor suitable for the purposes described herein. Further, the trailer 12 includes a trailer yaw rate sensor 28 that measure the yaw rate of the trailer 12 and provides a trailer yaw rate signal r t (t) to the controller 18 .
[0019] The controller 18 provides driver signals and commands to a driver advisor 68 , including a suitable display, indicative of the operation of the system 10 . For example, the vehicle 14 needs to be turning for some period of time to provide the necessary signals to calculate the estimated tongue length of the trailer 12 . The driver advisor 68 can be used to instruct the driver to make the necessary turns when the trailer 12 is first connected to the vehicle 14 , and tell the driver that the estimated tongue length of the trailer 12 has been calculated thereafter. In one embodiment, the driver advisor 68 is part of an ultrasound rear parking aid (URPA) alarm system.
[0020] According to the invention, the vehicle speed signal V x (t), the front wheel angle signal δ f (t), the rear wheel angle signal δ r (t), the trailer yaw rate signal r t (t) and the vehicle yaw rate signal r v (t) are used to calculate an estimated trailer tongue length. The process of determining the tongue length is discussed below with reference to a kinematics model of a vehicle-trailer system 72 , shown in FIG. 2 , where reference number 74 represents the vehicle 14 and reference number 76 represents the trailer 12 .
[0021] FIG. 3 is a block diagram of a trailer tongue length estimation system 80 to be used in connection with the system 10 . The tongue length estimation system 80 would be included in the controller 18 . An initial or previous tongue length estimation signal {circumflex over (T)}L(t−Δt) is applied to a comparator, such as a summer 82 . The initial tongue length estimation signal TL (t−Δt) can be based on an average trailer tongue length, for example, 10-12 feet. A tongue length error signal ΔTL(t), described below, is subtracted from the tongue length estimation signal {circumflex over (T)}L(t−Δt) in the summer 82 to provide a corrected tongue length estimation signal {circumflex over (T)}L(t).
[0022] When the tongue length estimation process is first initiated, the tongue length error signal ΔTL(t) is zero, and thus the initial tongue length estimation signal {circumflex over (T)}L(t−Δt) outputted from the summer 82 is the corrected tongue length estimation signal {circumflex over (T)}L(t). For subsequent calculation periods, the corrected tongue length estimation signal {circumflex over (T)}L(t) will be closer to the actual trailer tongue length than the initial tongue length estimation signal.
[0023] The corrected tongue length estimation signal {circumflex over (T)}L(t) is applied to a vehicle-trailer kinematics model controller 84 that calculates variables for determining an estimated trailer yaw rate based on the kinematics model shown in FIG. 2 . At time t, the input signals of the vehicle speed along the x axis V x (t), the front wheel angle δ f (t), the rear wheel angle δ r (t), the vehicle yaw rate r v (t), and the trailer yaw rate r t (t) are provided to the system 80 . The controller 84 receives the steering wheel angle signal δ f (t) from the sensor 48 , the rear-wheel angle signal δ r (t) from the sensor 62 , the vehicle speed signal V x (t) from the sensor 64 and the vehicle yaw rate signal r v (t) from the sensor 66 .
[0024] The controller 84 calculates the lateral velocity component at the hitch 26 for the vehicle side as:
V yh ( t ) = - ( H + B + A tan ( δ r ( t ) ) - B tan ( δ f ( t ) ) - tan ( δ r ( t ) ) + tan ( δ f ( t ) ) ) * r v ( t ) ( 1 )
A is the distance from the center of the front axle 46 to the center of the gravity point of the vehicle 14 , B is the distance from the center of gravity point to the center of the rear axle 54 , and H is the distance from the center of the rear axle 54 to the hitch 26 .
[0026] The longitudinal velocity of the trailer 12 at the hitch 26 is:
V xh ( t )= V x ( t ) (2)
[0027] The magnitude of the hitch velocity is:
V h ( t )={square root}{square root over ( V xh 2 ( t )+ V yh 2 ( t ))} (3)
[0028] Using the corrected tongue length signal, the lateral hitch velocity for the trailer 12 can be written as:
U yh ( t )= {circumflex over (T)}L ( t )* r t ( t ) (4)
[0029] From the relationship between the vehicle side hitch velocities and the trailer side hitch velocities:
U yh ( t )=− V xh ( t )* sin(θ est ( t ))+ V yh ( t )* cos(θ est ( t )) (5)
[0030] A hitch angle estimation θ est (t) can then be calculated as:
θ est ( t )=−sin −1 ( U yh ( t )/ V h ( t ))+sin( V yh ( t )/ V h ( t )) (6)
[0031] The hitch angle rate can be estimated by differentiating the hitch angle estimation θ est (t) from equation (6) by:
θ . est ( t ) = θ est ( t ) - θ est ( t - Δ t ) Δ t ( 7 )
[0032] The estimated hitch angle rate {dot over (θ)} est (t) is then applied to a controller 86 that estimates the trailer yaw rate. The estimated trailer yaw rate r t est is calculated in the controller 86 as:
r t est ( t )= r v ( t )+{dot over (θ)} est ( t ) (8)
[0033] The estimated trailer yaw rate r t est is then applied to a subtractor 88 to compare the estimated trailer yaw rate r t est to the measured trailer yaw rate r t (t) from the sensor 28 . This difference is a yaw rate error signal Δr t (t) as determined by:
Δ r t ( t )= r t ( t )− r t est ( t )= r t ( t )−( r v ( t )+θ est ( t ))=( r t ( t )− r v ( t ))+θ est ( t ) (9)
[0034] The yaw rate error signal Δr t (t) is applied to a PID controller 90 to generate a tongue length estimation value as:
Δ TL ( t ) = K p * Δ r t ( t ) + K i ∫ Δ r t ( t ) ⅆ t + K d ⅆ ( Δ r t ( t ) ) ⅆ t ( 10 )
TL ( t )= TL ( t−Δt )+Δ TL ( t ) (11)
[0035] K p is a proportional gain constant, K i is an integral gain constant and K d is a derivative gain constant. The PID control gains (K p ,K i ,K d ) are assigned using the following PID gain assignment rule. If |Δr t (t)|>0.1 degree/sec, then the PID gains are:
K p =0.1, K i =0.03, K d =0.00005 (12)
otherwise,
K p =0.1, K i =0.2, K d =0.000001 (13)
[0037] The PID controller 90 provides the tongue length error signal ΔTL(t) in this embodiment. However, other controllers may output a different type of signal that needs to be modified to get the tongue length error signal ΔTL(t). In those embodiments, a tongue length modification system 92 can be employed to convert the output of the PID controller 90 to the tongue length error signal ΔTL(t).
[0038] In order to start the estimation process, some of the input parameters need to be greater than a certain value because the present invention may not work if the vehicle-trailer is moving in a straight path. In other words, the vehicle-trailer needs to move in a circular path to produce a vehicle-trailer yaw rate. For example, the conditions to start the estimation process can be:
|V x (t)|>0.05 (kph), |r v (t)|>0.005 (deg/sec), and |r t (t)|>0.005 (deg/sec). (14)
[0039] Although it has been observed that the best maneuver to produce an accurate tongue length estimation is a step steer forward or backward, other turning or sinusoidal steering maneuvers can be used for the estimation process. There is also a stop condition for the estimation process. When the trailer yaw rate estimation error is within a reasonable range for a certain period, the estimated tongue length is accepted as a true value. The stop conditions are dependent upon the noise characteristics of the input data as:
|Δ r t ( t )|<0.005 (deg/sec) for t duration >100 Δt (15)
[0040] The foregoing discussion discloses and describes merely exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion and from the accompanying drawings and claims, that various changes, modifications and variations can be made therein without departing from the spirit and scope of the invention as defined in the following claims.
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A control system for estimating the tongue length of a trailer being towed by a vehicle in connection with a front wheel steering with or without coordinated rear wheel steering associated with the vehicle. The control system employs an algorithm that calculates an estimated trailer yaw rate based on a corrected tongue length, a front wheel steering angle, a rear wheel steering angle, vehicle speed and a vehicle yaw rate. The estimated trailer yaw rate is compared to a measured trailer yaw rate to generate a yaw rate error that is converted to a tongue length error. The tongue length error is compared to the estimated tongue length to become a corrected estimated tongue length for a next computation period. After a few seconds of processing, the corrected estimated tongue length will be the actual tongue length of the trailer.
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BACKGROUND OF INVENTION
Background Art
A well bore may be drilled in the earth for various purposes, such as hydrocarbon extraction, geothermal energy, or water. After a well bore is drilled, the well bore is typically lined with casing. The casing preserves the shape of the well bore as well as provides a sealed conduit for fluid to be transported to the surface.
A common problem in well bores is the accumulation of metallic debris. The metallic debris can be in the form of small metal shavings. Metal shavings can enter the hydrocarbon producing formation and reduce production. Metallic debris may be generated by tools on a work string scraping against the inside of the casing. Also, metallic debris is created while milling metal objects downhole, such as a bridge plug or packer. Some of the metallic debris may be brought back to the surface by well fluids that are circulated in the well bore, but a significant amount may still remain in the well bore.
Corrosion and other damage degrades the interior of the metal casing over time, which leaves a rough surface. This condition is typically cured by running tools in and out of the well bore with wire brushes and scrapers to abrade the inside of the casing. A scraper typically includes steel blades disposed on the outside of a cylindrical tool. The blades are biased radially outward by springs so that the scraper abrades the inside of the casing. The scraper helps to dislodge rough particles that are magnetically attracted to the casing or embedded in the casing wall. Wire brushes serve a similar purpose, but typically remove smaller particles. Some of the removed material is in the form of small metallic shavings and flakes of metal. Fluid is circulated during this operation to lift the removed material to the surface, but some metallic debris is left in the well bore.
Many tools exist that use magnets to attract and hold metallic debris, allowing the metallic debris to be removed from the well bore. Typically, permanent magnets in the form of buttons or bars are spaced apart to cover the outside of the magnetic tool. Metallic debris is attracted to each magnet allowing the removal of debris. Increased removal of metallic debris is accomplished by using more and larger magnets.
An example of a magnetic tool used to remove metallic debris is provided in U.S. Pat. No. 6,591,117 B2, entitled “Apparatus for Retrieving Metal Debris from a Well Bore.” In the '117 patent, large bar magnets are spaced apart around and along a tool body to attract metal debris. The bar magnets are fitted into recesses in the tool body and arranged to have an area between each magnet for metallic debris to settle.
SUMMARY OF INVENTION
In one aspect, the present invention relates to a downhole tool for removing metallic debris from a well bore. The downhole tool includes a body that is able to connect to a work string. Two or more hoop magnets are disposed coaxially along the length of the body, and arranged in a bucking arrangement.
In one aspect, the present invention relates to a downhole tool for removing metallic debris from a well bore. The downhole tool includes a body with a mandrel and a central opening. The body is able to connect to a work string. A magnet assembly is disposed on the mandrel. The magnet assembly includes an inner sleeve designed to fit around the mandrel. A plurality of hoop magnets are disposed on the inner sleeve and spaced apart along the length of the inner sleeve. The plurality of hoop magnets are arranged in a bucking arrangement.
In one aspect, the present invention relates to a downhole tool for removing metallic debris from a well bore. The downhole tool includes a body that is able to connect to a work string. A plurality of magnets are distributed azimuthally around the circumference of the body. The plurality of magnets are arranged in a bucking arrangement.
In one aspect, the present invention relates to a downhole tool for removing metallic debris from a well bore. The downhole tool includes a body with a mandrel and a central opening. The body is able to be connect to a work string. A magnet assembly is disposed on the mandrel. The magnet assembly includes an inner sleeve designed to fit around the mandrel. A plurality of magnets are distributed azimuthally around the circumference of the inner sleeve. The plurality of magnets are arranged in a bucking arrangement.
Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a quarter-section of a magnet carrier in accordance with one embodiment of the invention.
FIG. 2A shows a cross-section of a magnet in accordance with an embodiment of the present invention.
FIG. 2B shows a cross-section of a magnet in accordance with an embodiment of the present invention.
FIG. 2C shows a cross-section of a magnet in accordance with an embodiment of the present invention.
FIG. 3 shows an arrangement of magnets in accordance with one embodiment of the invention.
FIG. 4A shows a tool body in accordance with one embodiment of the invention.
FIG. 4B shows a part adapted to attach to the tool body of FIG. 3A in accordance with an embodiment of the present invention.
FIG. 4C shows a downhole tool having a magnet carrier in accordance with one embodiment of the present invention.
FIG. 5 shows a downhole tool having a magnet carrier with attached metallic debris in accordance with one embodiment of the present invention.
FIG. 6A shows an arrangement of magnets in accordance with one embodiment of the invention.
FIG. 6B shows a magnet in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION
In one aspect, the present invention relates to an arrangement of magnets for removing metallic debris from a well bore. More specifically, embodiments of the present invention have a plurality of magnets spaced apart so that the magnetic field of each magnet interacts with the magnetic field of its neighbor to increase the effectiveness of the magnet arrangement to remove metallic debris from a well bore.
FIG. 1 shows a magnet carrier 110 in accordance with one embodiment of the present invention. A plurality of ring shaped magnets 101 are disposed on an inner sleeve 104 . Each magnet 101 may comprise an assembly of individual magnet rings 102 and spacer rings 103 . The magnet rings 102 may be permanent magnets made of any suitable magnetic material, such as neodymium iron boron, ceramic ferrite, samarium cobalt, or aluminum nickel cobalt. In one embodiment, spacer rings 103 may be made of a carbon steel with magnetic properties, or any other material that exhibits magnetic properties. The magnet rings 102 are aligned within each magnet 101 by their magnetic poles to attract each other. The spacer rings 103 are magnetized and attracted to the magnet rings 102 . The spacer rings 103 may be used to indicate the magnetic pole of each magnet. For example, two spacer rings 103 separated by a magnet ring 102 may represent the magnetic north of the magnet 101 , while one spacer ring 103 may represent the magnetic south of the magnet 101 . Alternatively, the spacer rings 13 may have markings to indicate the poles of the magnet 101 . Coloring magnet rings 102 or otherwise marking the magnets may accomplish the same purpose. This feature is used to clearly indicate which ends of the magnet 101 will attract other magnets for assembly and safety purposes.
In the embodiment shown in FIG. 1 , the inner sleeve 104 is designed to accommodate four magnets 101 . The inner sleeve 104 may be sized to fit around a mandrel (not shown). To prevent dissipation of the magnet strength, the inner sleeve 104 may be formed from an austenitic stainless steel, or other material that exhibits little or no magnetic susceptibilities. A center ridge 111 may be formed on the inner sleeve 104 for assembly purposes.
To assemble this embodiment, a first magnet 101 B may be placed against the center ridge 111 . The first magnet 101 B may be fixed in place by a retaining device, such as a retaining ring 106 or a snap ring. A second magnet 101 A may be installed on the same side of the center ridge 111 . The second magnet 101 A is oriented so that the same magnetic pole faces the first magnet 101 B, such as north to north. Both magnets 101 A and 101 B are in close proximity to each other so that their magnetic fields repulse each other, resulting in a substantial repulsive force. The second magnet 101 A may also be secured in place by a retaining ring 106 . The same procedure may be repeated for magnets 101 C and 101 D.
After all four magnets 101 A– 101 D are secured, an outer sleeve 105 may be placed around the magnets 101 A– 101 D. The outer sleeve 105 is preferably formed of a material exhibiting little or no magnetic susceptibility, such as an austenitic stainless steel, to prevent interference with the magnetic fields of the magnets 101 . The outer sleeve 105 provides protection for the magnets 101 and a gathering surface for magnetic debris. In one embodiment, grooves 107 are formed in the outside surface of the outer sleeve 105 . The grooves 107 help to retain metallic debris.
After the outer sleeve 105 is installed, end caps 108 may be placed on the magnet carrier 110 . The end caps 108 may be secured by an interference fit between the outer sleeve 105 and inner sleeve 104 . Alternatively, the end caps 108 may be threaded or secured by any other means known in the art. The end caps 108 are preferably formed of a material exhibiting little or no magnetic susceptibility to prevent interference with the magnetic fields of the magnets 101 . The individual features in this particular embodiment are intended to illustrate how a magnet carrier may be assembled in accordance with one embodiment of the present invention. However, they are not intended to limit the scope of the invention. For example, the magnets may be held in place by other means, such as an adhesive. In one embodiment, the magnets are assembled from one end of the inner sleeve without a center ridge. One of ordinary skill in the art will appreciate that magnets may be assembled into a magnet carrier in different ways without departing from the scope of the invention. Furthermore, some embodiments may not include the magnet carrier. Instead, the magnet arrangement may be disposed directly onto a tool body, for example.
While the above embodiment combines separate magnet rings to form a magnet, other magnet forms may be selected to use in a similar manner. For example, the magnet 101 may be a single piece instead of a combination of magnet rings 102 . Furthermore, the magnet 101 or magnet rings 102 need not be in a contiguous ring shape. Instead, they may comprise sections that substantially form a ring.
FIGS. 2A , 2 B, and 2 C show transverse cross-sections of magnets in accordance with some embodiments of the present invention. FIG. 2A shows a magnet having a slot 140 . Alternatively, the magnet may be a plurality of arcuate sections 150 , such as that shown in FIGS. 2B and 2C , and disposed circumferentially about the inner sleeve resulting in a substantially 360 degree magnetic field about the magnet carrier. One of ordinary skill in the art will appreciate that other shapes or groupings of magnets may be used to provide a substantially 360 degree magnetic field about the magnet carrier without departing from the scope of the invention. For the purpose of clarity, a single magnet or a set of magnets forming a substantially 360 degree magnetic field will be referred to hereinafter as a “hoop magnet.” For example, four quarter-sections of a magnet ring disposed circumferentially about the inner sleeve at about the same longitudinal position form a hoop magnet for the purpose of this disclosure. For the present invention, a hoop magnet has two poles oriented to be substantially parallel to the axis of the hoop magnet.
The magnetic orientation and distance of each hoop magnet relative to a neighboring hoop magnet allows for a magnetic field with an increased radial size to be created. As is known in the art, a magnet generally has a north and a south pole. When two magnets have opposite poles facing each other (i.e., north to south), the magnets are attracted to each other. Like magnetic poles repulse each other. FIG. 3 illustrates the effect of magnetic fields interacting in accordance with an embodiment of the present invention. The magnetic fields are represented by the lines arcing from the blocks labeled with N (north) and S (south). When magnets are oriented to repulse each other as in FIG. 3 , the magnetic field of each magnet is deflected by the neighboring magnet. This phenomenon is commonly referred to as “bucking.” The deflection of the magnetic fields in the manner shown in FIG. 3 results in magnetic fluxes oriented in the same direction between the neighboring magnets. The summation of the magnetic fluxes gives rise to a magnetic field that projects further outward from between the two magnets. This results in a magnetic field with greater outward reach than the magnetic field of a single magnet with the same strength. Arranging a plurality of hoop magnets in this manner allows for a larger apparent magnetic field for a magnet arrangement. The term “bucking arrangement” is utilized to clearly and concisely describe the type configuration for the two or more magnets as disclosed herein.
The longitudinal spacing of the hoop magnets vary depending the characteristics of the hoop magnets, such as the strength of the magnetic field. If the hoop magnets are too far apart, the bucking effect is reduced, causing the hoop magnets to act more individually. When moving the hoop magnets close together, the bucking effect increases, causing the magnetic field to expand radially. At the same time, the overall coverage of the magnetic field in the longitudinal direction is reduced for a given number of hoop magnets. Because the well bore is limited in diameter, the radial reach of the magnetic field is wasted much beyond the well bore. Therefore, it is desirable to balance the length and radial reach of the magnetic field created by the magnet arrangement. In one embodiment, six ceramic ferrite hoop magnets 1 inch in height are disposed ¾ of an inch apart longitudinally.
The number of hoop magnets spaced longitudinally in the magnet carrier may vary. Two or more hoop magnets may be spaced longitudinally in accordance with embodiments of the present invention. In one embodiment, six hoop magnets are used. In another embodiment, five hoop magnets are spaced apart in the magnet carrier. One of ordinary skill in the art will appreciate that the number of hoop magnets in the magnet carrier can vary without departing from the scope of the invention.
FIGS. 4A and 4B show a downhole tool body in accordance with one embodiment of the present invention. The downhole tool body shown in FIGS. 4A and 4B is adapted to connect to a work string on both ends by a box connection 304 and a pin connection 303 . The downhole tool body includes two components illustrated apart in FIGS. 4A and 4B . The component in FIG. 4A has a mandrel 301 adapted to accommodate additional components, such as a magnet carrier, scraper, brush, and centralizer. The additional components may be secured on the downhole tool body by connecting the end body in FIG. 4A to the tool body in FIG. 4B by connection 307 . While a threaded connection is shown, one of ordinary skill in the art would appreciate that other connections may be used without departing from the scope of the invention. The downhole tool body includes a central opening 306 to allow fluid to circulate through the work string.
Turning to FIG. 4C , an assembled downhole tool in accordance with an embodiment of the invention is shown. Several components have been disposed on the mandrel 301 and secured by connecting the component in FIG. 4A to the component in FIG. 4B . From bottom to top, the components are a lower centralizer 310 , a scraper module 312 , a magnet carrier 110 , two brush modules 311 , and an upper centralizer 314 . This is just one example of a module arrangement. An alternative arrangement may be a centralizer, two scraper modules, two magnet carriers, and a centralizer. A longer mandrel would allow for additional modules. One of ordinary skill in the art will appreciate that more or less modules with these or other known components may be used without departing from the scope of the invention. The combination of modules will vary depending on the purpose of the operation and the conditions of a particular well bore. For example, if the objective is only to remove metallic debris in the well, multiple magnet carriers may be deployed without any brush or scraper modules. In one or more embodiments, a boot basket module may be disposed on the mandrel to capture both metallic and non-metallic debris.
The module arrangement shown in FIG. 4C allows for the magnet carrier 110 to capture metallic debris (not shown) as it is dislodged from the casing (not shown) by the brush modules 311 and scraper module 312 . This reduces the amount of metallic debris that would normally settle to the bottom of the well bore and potentially reduce future production. The centralizers 310 keep the downhole tool centered in the well bore so that the inside of the casing is cleaned evenly. The centered arrangement also helps to ensure that the magnetic field of the magnet carrier is fully utilized to extract metallic debris from the well fluid.
Modules disposed on a mandrel as shown in the above embodiment may not be forced to rotate with the rest of the work string. The modules are confined longitudinally, but are free to rotate azimuthally. This reduces the wear on the casing and on the modules. This containment system also allows for simple replacement of modules when a module wears out or when other configurations are desired.
FIG. 5 shows a portion of the downhole tool of FIG. 4C in accordance with an embodiment of the present invention. The downhole tool has been run into a well bore to remove metallic debris, primarily metal shavings. In this embodiment, the magnet carrier has six hoop magnets. The metal shavings 501 have collected on the magnet carrier 110 at the location of each hoop magnet. The hoop magnet arrangement in accordance with an embodiment of the present invention provides a substantially continuous magnetic field around and along the length of the magnet carrier.
While the above embodiments have included a modular type of magnet carrier, it should be understood that the hoop magnet arrangement that has been disclosed may be used in other downhole tools for the purpose of removing metallic debris from a well bore. For example, the inner sleeve may not be required if the hoop magnets are disposed directly onto a tool body adapted to attach to a work string. Additionally, the hoop magnets may be disposed at one end of a tool body adapted to attach to a work string at the other end. Hoop magnets disposed at the end of the tool may be able to effectively remove metallic debris that has settled at the bottom of the well bore. One of ordinary skill in the art will be able to utilize the disclosed hoop magnet arrangement in other downhole tool applications to remove metallic debris from a well bore without departing from the scope of the invention.
While the above embodiments have used hoop magnets, one having the benefit of this disclosure could utilize the bucking phenomenon with other magnets. FIG. 6A shows a magnet arrangement in accordance with one embodiment of the present invention. The magnets 601 are aligned such that the poles are oriented substantially transverse to the axis 603 of the tool body 602 . The magnets 601 are distributed around the circumference of the tool body 602 . The azimuthal spacing of the magnets 601 is selected so that bucking occurs between each adjacent magnet 601 . The azimuthal spacing of the magnets 601 may vary based on several factors, such as magnetic strength, size of the tool body 602 , and quantity of magnets 601 desired. Closer azimuthal spacing of the magnets 601 does not affect the longitudinal length of the magnetic field, because that is determined by the length of each magnet 601 . A closer azimuthal spacing may result in difficulty in assembling the magnets 601 to the tool body 602 . Additionally, a closer azimuthal spacing would require additional magnets 601 to surround the tool body 602 . One of ordinary skill in the art will appreciate that the azimuthal spacing and quantity of the magnets 602 may vary without departing from the scope of the invention.
The magnets 601 may be secured by any means known in the art, such as a bolt, straps, or adhesive. While the magnets 601 are shown directly attached to a tool body 602 , the magnets 601 may be attached to a module similar to that shown in FIG. 1 . To prevent depletion of the magnetic field, the tool body 602 or module may be formed from a material having little or no magnetic susceptibility, such as an austenitic stainless steel.
While the magnets 601 shown in FIG. 6A are rectangular in cross-section, other shapes of magnets may be used in a similar manner. FIG. 6B shows a cross-section of a magnet 605 that may be used for the magnet arrangement of FIG. 6A in accordance with one embodiment of the present invention. The magnet 605 shown in FIG. 6B has an arcuate shape that conforms to a circular tool body (not shown). One of ordinary skill in the art will appreciate that other shapes of magnets may be used in a similar manner without departing from the scope of the invention.
Embodiments of the present invention provide one or more of the following advantages. Metallic debris, especially small metal shavings, are suspended in the well fluid. As the magnet carrier passes by the metal shavings, the metal shavings are only attracted by the magnet carrier if they are within a strong portion of the magnetic field. To capture the metal shavings throughout the well fluid, the magnetic field must extend radially to the casing from the magnet carrier. This can be accomplished by utilizing bucking between the magnetic fields of two or more hoop magnets. As the magnet carrier passes through the well bore and well fluid flows by, metal shavings are pulled from the well fluid and attached to the magnet carrier.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
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The present invention relates to a downhole tool for removing metallic debris from a well bore. The downhole tool includes a plurality of magnets disposed on the tool body. The plurality of magnets are arranged in a bucking arrangement such that repulsing forces are generated between neighboring pairs of the plurality of magnets. The bucking arrangement results in an expanded reach of the magnetic fields of the magnets to enhance the removal of metallic debris.
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BACKGROUND OF THE INVENTION
This invention relates to partition systems for dividing large rooms, office spaces, or the like into smaller areas with movable, portable panels or partitions and, more particularly, to a system of connecting such partitions or panels while including brackets or other elements for supporting shelves or other work surfaces in conjunction with such panels and partitions.
Many systems are available for joining and supporting movable partitions and panels in various arrangements to subdivide large areas or rooms into smaller work areas or the like. One such system is disclosed in U.S. Pat. No. 3,844,002 issued May 20, 1975, to Charles F. Logie and assigned to American Store Equipment Corporation, the same assignee as the present invention. In the system of U.S. Pat. No. 3,884,002, movable partitions or panels are joined together by one or more connecting pins extending between end or side surfaces of the panels, the connecting pins being secured in place by threaded fasteners inserted through the sides of the panels. A particular feature of that system is the inclusion of tapered heads on such fasteners which mate with tapered countersunk areas in the apertures in the panels through which the fasteners are received for wedging the joined panels tightly together.
In certain applications of prior partition and panel systems, and especially that disclosed in the above-described U.S. Pat. No. 3,884,002, it has been desired to include shelving, work panels, or other work surfaces along the generally vertical sides of such panels or partitions. However, the provision of protruding flanges or supports, apertures, recesses, or other supporting mechanisms extending from or into the actual side surfaces of the panels themselves has been undesirable both because such additional structure can weaken the structural integrity of the panels and because it detracts from the aesthetic qualities of the panels. When no shelving is desired, such structure has been difficult to conceal. Moreover, supporting such shelving or work surfaces from free edges of the panels, or from intermediate edges of the panels which are abutting and adjacent one another when the system is assembled, has been inconvenient because of the difficulty in suspending such shelving entirely from top or bottom free edges or because of disruption of the normal panel joinder apparatus intermediate the panels. Many partitions are manufactured with slotted standards incorporated at each end of the panel as standard features. Shelves are suspended on the slotted standards. When no shelves are desired, however, the slotted standards represent a fairly substantial and unwanted built-in expense.
Accordingly, the provision of adequate shelf or other work surface supporting apparatus in partition and panel systems such as that disclosed in U.S. Pat. No. 3,884,002 has been a significant problem. The present invention provides a solution to that problem and includes apparatus for both connecting partition panels to like panels or wall or other surfaces, as well as apparatus for supporting shelving and other work surfaces along such partition panels.
SUMMARY OF THE INVENTION
The present invention provides a partition system in which shelf-supporting means can be incorporated at the option of the customer. Provision is made for incorporating brackets and other hardware for supporting shelving and other work surfaces over the side surfaces of such panels without any physical alteration or modification of the panels themselves. In its basic form, the invention includes spaced apertures in each of the pins used to connect the panels in various arrangements. The apertures are engaged alternately by fasteners depending on the inclusion or removal of a shelving bracket or standard between the panels. Thus, the same panels and the same panel joining pins can be used with or without the inclusion of shelf supporting standards.
These and other objects, advantages, purposes, and features of the invention will become more apparent from a study of the following description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded, perspective view of the partition system of the present invention illustrating various arrangements of the individual panel elements with shelving support brackets included therebetween;
FIG. 2 is a side elevation of a first form of the connecting pin used to join the panel elements of the present invention;
FIG. 3 is a side elevation of a second form of a connecting pin of the present invention;
FIG. 4 is a side elevation of a third form of a connecting pin of the present invention;
FIG. 5 is a side elevation of a fourth form of a connecting pin of the present invention;
FIG. 6 is a side elevation of a fifth form of a connecting pin of the present invention;
FIG. 7 is a fragmentary, sectional, plan view of three partition panel elements joined together with a shelving support bracket secured between two of the elements and taken along plane VII--VII of FIG. 1;
FIG. 8 is a fragmentary, sectional, plan view of two partition panel elements joined at right angles to one another including a shelving support bracket therebetween taken along plane VIII--VIII of FIG. 1;
FIG. 9 is a fragmentary, sectional, plan view of three joined partition panel elements including shelving support brackets secured therebetween taken along plane IX--IX of FIG. 1 with a fourth panel element shown in phantom;
FIG. 10 is a fragmentary, sectional, plan view of one of the partition panel elements joined to a wall with a shelving support bracket secured therebetween;
FIG. 11 is a fragmentary, sectional, plan view similar to FIG. 10 but illustrating a modified form of a panel element with a shelving support bracket recessed in one end for securing the panel element to a wall;
FIG. 12 is a broken, side elevation of one of the slotted, shelving support brackets utilized in the present partition system;
FIG. 13 is a broken, side elevation of another slotted, shelving support bracket used in the present partition system; and
FIG. 14 is a fragmentary, side elevation, shown partially in cross section, illustrating the attachment of a cantilevered, shelving support arm on one of the slotted, shelving support brackets used in the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings in greater detail, FIG. 1 illustrates a typical partition arrangement which may be formed utilizing the panels and connection apparatus of the present invention. The panels are formed in various heights and widths such as those shown at 12, 14, 16, 18, and 20. Each of the panels has a thickness less than its height and width and is formed from wood, compressed composition material or the like. The panels are typically rectangular and include end edges 22 which are oriented generally vertically and receive the connection apparatus for supporting and joining the panels together. Typically, three or four elongated connecting pins and their associated fasteners are spaced vertically along the panels. Additionally, any shelving support channel brackets 26 are inserted and secured between the vertically oriented end edges 22 as is more fully described below. The free top edges of the panels may be capped with channel-like top edge moldings 28 or the like. The channel-like shelving support brackets 26 when inserted on either end edge 22 of a panel are used to support cantilever type shelf arms 27 and generally horizontal shelves 29 as shown in FIG. 1.
Referring now to the remaining figures, the connecting pins shown in FIGS. 2-6 and the slotted, shelving channel brackets or standards shown in FIGS. 12 and 13 are used to arrange the partition panel elements 12-20 in the various relationships shown in FIG. 1. Certain of the joints between the panels, brackets, and pins are specifically illustrated in FIGS. 7-11 and 14.
Five embodiments of the connecting pins are utilized to arrange the panel elements. As is shown in FIG. 2, the first type 30 includes an elongated, rectilinear, right cylindrical body or rod 31 having beveled or chamfered end edges 32, 34 and a series of threaded apertures or through bores extending entirely therethrough generally transverse to the longitudinal axis of the pin. A single aperture 35 is generally centered in the right half of the pin 30 while apertures 36 and 38 are spaced apart a distance A along the axis of the pin in the left half of the pin 30. Distance A corresponds to the thickness of a slotted standard or channel bracket 80 or 90 (FIGS. 13 and 14). In accordance with the concept of the invention, the spaced apertures 36, 38 alternately receive a threaded screw or fastener through a securing aperture in a side surface of one of the panel elements to secure the panel elements together depending on whether a standard or bracket 80 or 90 is received between the panels (see FIG. 7).
Other embodiments of the connecting pins include pins 40 and 50 which are utilized together to secure one panel element at a right angle to the side surface of another panel element (see FIG. 8). Pin 40 is an elongated rod-like pin having a rectilinear, right, circular, cylindrical body portion 42 including a pair of threaded screw bores or apertures 43, 44 spaced apart along the axis of the pin by the distance A and generally centered in body portion 42. The left-hand end 45 is beveled or chamfered and includes a screw driver slot for rotation. The right-hand end includes a bevel or chamfer 46 corresponding in shape and size to the heads of the fasteners received through the panels in apertures 43 or 44. A threaded cylindrical extension extends rectilinearly and coaxially outwardly from the taper or bevel 46 to provide a fastener for securing pin 40 to pin 50.
Pin 50 (FIG. 4) generally corresponds to the left-hand end of connecting pin 30 except that it includes only a single threaded securing aperture 54 in its body portion 52. The left-hand end 55, like the other pins, is beveled or chamfered while the right-hand end is cut at a right angle to the axis of the pin such that the pin will fit flush with the end surface of one of the panels in which it is inserted as is explained hereinafter. Aperture 54 receives threaded extension 47 from pin 40 when pin 40 is inserted in a panel such that that panel and the panel in which pin 50 is inserted are secured at right angles to one another (FIGS. 1 and 8).
As shown in FIG. 5, connecting pin 60 is similar to pin 40 and includes a right, circular cylindrical body 62, spaced apertures 63, 64, left and right tapered or beveled ends 65, 66 and a threaded, coaxial extension 67. Threaded extension 67 is approximately twice as long as extension 47 such that it will project through the entire thickness of one of the panels for receipt in the threaded, axial socket 72 in the end of pin 70.
Pin 70 (FIG. 6) is received in another panel so that its panel and that containing pin 60 may be secured at right angles to a central panel as shown in FIG. 9. Pin 70 is generally similar to pin 50 and includes a rectilinear, right, circular, cylindrical body 74, spaced, threaded throughbores or apertures 75, 76, a beveled or tapered left-hand end 77, as well as the threaded socket 72 which extends axially into the nontapered end 78 as shown in FIG. 6.
As shown in FIGS. 12 and 13, the slotted channel brackets for supporting shelving along the partition panels 12-20 include two embodiments. Embodiment 80 is adapted to secure a panel to a wall or other surface or for capping or covering an exposed end edge of one of the panels in a partition arrangement while supporting shelving thereon as shown in FIG. 1. The second embodiment 90 is generally designed for insertion between two of the partition panel elements.
As shown in FIGS. 10-12, bracket 80 includes a channel 82 having a base portion 83 extending between a pair of parallel side flanges 84a, 84b extending outwardly in the same direction from one side of the base. Each side flange 84a, 84b has a length which provides the bracket with an overall thickness equal to the distance A by which the fastener receiving apertures in the various connecting pins 30-70 are spaced axially apart. Each of the side flanges includes vertically aligned, regularly spaced slots 85 for receiving L-shaped flanges 27a of a cantilever-type shelving support arm 27 (FIG. 14). A series of connecting pin studs 86 extends normally outwardly from the inside of the channel base 83 and are welded or otherwise rigidly secured thereon. Pin studs 86 are similar to connecting pins 50 but include a pair of spaced, fastener-receiving apertures 87, 88 spaced apart along the axis of the right, cylindrical, circular pin body by a distance A. The outer free end of the pin stud is beveled or tapered at 89. The fastener-receiving apertures 87, 88 are located in the pin stud body outwardly beyond the plane of the ends of the side flanges 84a and 84b as shown in FIG. 12.
Embodiment 90 of the slotted channel bracket (FIGS. 7-9 and 13) is similar in all respects to bracket 80 except that it includes a series of circular apertures 92 extending through the center of its base 93 to allow connecting pins 30, 40, 60, or 70 to be inserted therethrough to secure any of partition panel elements 12-20 on either side of the bracket. It also includes side flanges having a length providing it with an overall thickness equivalent to distance A and a series of vertically aligned, vertically spaced slots 95 in each side flange for receipt of the flanges 27a of cantilever-type shelving support arms 27.
Referring now to FIGS. 7-9, three typical arrangements of the partition panel elements 12-20 are shown. In FIG. 7, panel elements 20a and 20b are arranged generally rectilinearly with one another with two of their end surfaces 22 facing each other and a channel bracket 90 inserted therebetween. A connecting pin 30 extends from a receiving aperture 101 in panel 20a through aperture 92 in base 83 of channel 90 into a receiving aperture 102 in panel 20b. A threaded screw 103 having an inwardly tapered head 104 is inserted through a securing aperture 105 extending at a right angle to receiving aperture 102 and communicating therewith. When connecting pin 30 is secured in panel 20a as will be described below by a fastener, and channel bracket 90 is inserted between end surfaces 22 of panels 20a, 20b, threaded aperture 38, which is closest to end 34 of pin 30, is in alignment with securing aperture 105. Thus, when channel 90 is between the panels, threaded aperture 36 is not used and in fact is spaced inwardly toward the channel 90 out of registry with aperture 105. Typically, as shown in FIG. 7, brackets 80 and 90 have a width less than the panel thickness so that they are recessed behind the side or end surfaces of the panels. Should channel bracket 90 be removed from between end surfaces 22, panel 20b is slid along pin 30 into abutment with the end surface of panel 20a, thereby automatically bringing securing aperture 105 into registry with threaded aperture 36 such that fastener 103 may be inserted therein. Accordingly, only the single securing aperture 105 is required to secure panels 20a, 20b together regardless of whether channel bracket 90 is inserted therebetween or not.
The end of pin 30 which is received in channel 20a and aperture 101 may be secured therein utilizing any type of fastening means. In the preferred system, however, a threaded fastener is inserted through a securing aperture 106 extending from a side surface of the panel at a right angle to the axis of aperture 101 and into communication therewith for receipt of a threaded fastener.
In the application shown in FIG. 7, a connecting pin 40 is utilized in place of a typical threaded screw such that an additional or third panel element 20c may be secured at a right angle in abutment with the side surface of panel 20a. In this case, no shelving channel bracket is secured between panels 20c and 20a. Accordingly, the securing aperture 108 extending from a side surface of panel 20c at a right angle to pin-receiving aperture 107 extending into the end surface of panel 20c is in registry with threaded aperture 44 of pin 40, not aperture 43. A threaded fastener 103 is received through aperture 108 and secured in threaded aperture 44 to fasten panel 20c against panel 20a. Should it be desired to utilize a channel bracket 90 between the panels 20a, 20c, panel 20c is merely slid outwardly along pin 40 with the spacing of apertures 43, 44 automatically bringing aperture 108 into registry with aperture 43 for receipt of fastener 103 when channel bracket 90 is included therebetween.
As shown in FIG. 8, another arrangement of the partition panels at right angles to one another may be formed using connecting pins 40 and 50. Connecting pin 50 is received in a pin-receiving aperture 110 formed in the end surface 22 of panel 20d. A securing aperture 112 extends at a right angle from a side surface of panel 20d into communication with receiving aperture 110. Similarly, a pin-receiving aperture 114 in one end of panel 20e receives the body portion 42 of pin 40, while its threaded extension 47 is inserted through aperture 112 and is secured in threaded pin aperture 54 in pin 50. Because a channel bracket 90 is inserted between end surface 22 of panel 20e and the side surface of panel 20d, a threaded fastener 103, inserted through securing aperture 116 which extends through a side surface of panel 20e and communicates with pin-receiving aperture 114 in panel 20e, is threaded into aperture 43 of a pin 40. Aperture 43 is farthest of apertures 43, 44 from panel 20d. Should it be desired to abut panel 20e and panel 20d against one another, channel bracket 90 may be removed and fastener 103 inserted through securing aperture 116 into threaded aperture 44 once panel 20e is slid up against panel 20d. A second threaded pin aperture is not required in pin 50 because a slotted bracket 90 is not secured at panel end 22 of panel 20d.
In the arrangement shown in FIG. 9, panels 20f and 14a are secured generally in rectilinear alignment with one another on either side of a third panel 14b. Panels 20f and 14a are spaced outwardly from panel 14b by the inclusion of channels 90a and 90b on either side of panel 14b. Panel 14b includes a throughbore or aperture 120 receiving therethrough the threaded extension 67 from connecting pin 60. Pin 60 is inserted in a pin-receiving aperture 122 extending into the end surface 22 of panel 20f. Extension 67 is threaded into the threaded socket 72 of connecting pin 70 which is received in pin-receiving aperture 124 formed in the end surface 22 of panel 14a. Since channel brackets 90a and 90b are included, threaded fasteners 103 are received through securing apertures 126, 128 which communicate with receiving apertures 122, 124, respectively, in threaded apertures 63 and 75. These apertures are the closest apertures to the free ends 65, 77 of the pins 60, 70, respectively. Should channel brackets 90a and 90b be removed, panels 20f and 14a would be slid into abutment with the side surfaces of panel 14b and threaded fasteners 103 would be received in threaded apertures 64 and 76 in those pins.
As shown in phantom in FIG. 9, it would also be possible to secure a fourth panel at right angles to panels 14a or panel 20f by substituting a connecting pin 40 for fastener 103 which secures pin 60 or 70. Such capability provides wide flexibility in the arrangements of partitions which can be provided and does not depend on one particular end of a connecting pin being available for use.
Referring to FIGS. 10 and 11, channel brackets 80 are used to secure the partition panels 12-20 to a wall surface or to cap the free end edges of such panels. In FIG. 10, a channel bracket 80 is secured with its base 83 flat against the wall surface of a typical plasterboard or sheet rock wall 130. Screws 132 are inserted through securing apertures provided through base 83 and include expandable wings or the like to form a secure retention of the channel brackets to the plasterboard in a vertical orientation. Side flanges 84a and 84b of bracket 80 extend outwardly as do the pin studs 86 which are received in corresponding pin-receiving apertures 134 extending into the end surface 22 of partition panel 14c. The end surface 22 abuts against the free end edges of the side flanges and is accordingly spaced from the wall 130 by the distance A. A threaded fastener 103 inserted through a securing aperture 136 communicating with pin-receiving aperture 134 from a side surface of panel 14c is threadedly secured in the outer threaded aperture 88 in pin stud 86 because of such spacing.
As shown in FIG. 11, a partition panel such as 14c may also be provided with an end recess 138 corresponding in shape and size to the channel bracket 90 for receipt of the same along the end edge of the panel. In such case, when the bracket 90 is secured to a wall 130 with fasteners such as 132 as described above, and pin studs 86 are received in receiving apertures 134, the end surface 22 of panel 14c will abut directly against wall 130 allowing fastener 103 to be inserted through securing aperture 136 into threaded aperture 87 in the pin stud instead of aperture 88. Such recess of the channel bracket provides a flush fit of the surface of the bracket with the end of the panel. It also provides a means for securing the panel directly against a wall when there is no necessity for supporting shelving along the panel side surfaces.
In each of the above arrangements, each of the securing apertures 105, 106, 108, 112, 116, 126, 128, and 136 may be provided in their respective panels with an inwardly tapered, countersunk area corresponding in shape and size to the inwardly tapered, head or beveled surface on the connecting pins 40, 60 or fasteners 103. As is described in commonly owned U.S. Pat. No. 3,884,002, such securing apertures have their center lines spaced to be slightly offset from the center lines of the threaded apertures in the various connecting pins when the panels are either in abutment with one another or have the slotted shelving support brackets therebetween. Such offset causes the tapered heads on the fasteners 103 or tapered beveled portions of the connecting pins 40, 60 to engage the countersunk areas and wedge or force the panels toward one another to form a secure, tight arrangement. Such a wedging system is fully described in U.S. Pat. No. 3,884,002, issued to Charles F. Logie on May 20, 1975, the disclosure of which is hereby incorporated by reference herein.
Accordingly, the present invention provides a system for joining, supporting, and arranging partition panel elements with one another and with walls and other similar surfaces and provides the flexibility for selective inclusion of shelving support brackets adjacent the end surfaces of the panels to support shelving along the side surfaces thereof. The connection apparatus utilizes the same securing apertures in the panels regardless of whether the shelving support brackets are included or not, while the connecting pins themselves include pairs of apertures spaced in a predetermined relationship to receive fasteners for securing the panels together in alternate fashion depending on the inclusion or removal of the shelving securing brackets.
While several forms of the invention have been shown and described, other forms will now be apparent to those skilled in the art. Therefore, it will be understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and are not intended to limit the scope of the invention which is defined by the claims which follow.
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The specification discloses a partition system for subdividing large rooms or work areas wherein shelving support apparatus may be selectively incorporated between or at the ends or sides of the individual panels without physical modification or alteration of the panels. The panel connection apparatus includes spaced apertures which are used alternately with securing fasteners depending on the inclusion or removal of the slotted or other shelf supports. The outward appearance of the panels themselves remains unchanged regardless of whether or not the shelf supports are included. If desired, the system may include a panel wedging system for firm, secure support such as that disclosed in commonly assigned U.S. Pat. No. 3,884,002.
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BACKGROUND OF THE INVENTION
This invention relates to an inflatable aircraft evacuation system and especially to an inflatable slide adapted to extend from a supporting surface such as an aircraft wing. This type of system requires the passengers to climb out on the wing surface and part of the slide before they reach the inclined surface of the slide. It is therefore important that the walking surface provide the necessary firmness and stability.
It is also important for the flight attendant to know whether or not the slide is properly extended without walking to the edge of the wing and looking down. This is important because the attendant must have this information without leaving the fuselage of the aircraft in order to direct the passengers to the escape slides which are operable.
Another requirement is to provide support of the wing mounted slide with the wing flap in the different operating positions of the wing flap so that the proper position of the slide will be maintained and especially if the evacuation is required with the flap set for landing.
SUMMARY OF THE INVENTION
According to an aspect of this invention, an escape slide is provided having an entrance ramp adaptable to rest on an inclined surface and being inflatable to provide the necessary rigidity of footing to support passengers entering and walking on the ramp.
Another aspect of this invention is to provide support for the slide by the wing flap at any position of the flap.
A further aspect of the invention is to provide a visible indicator which can be seen from the aircraft to indicate whether or not the slide is properly inflated and ready for use in evacuating passengers from the aircraft.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a partially schematic plan view of an inflatable escape slide assembly including walkway and slide mounted on an aircraft wing in the extended, inflated condition with the aircraft wing and fuselage being shown in dot-dash lines and parts being broken away to show the supporting tubes.
FIG. 2 is a side elevation taken along the plane of line 2--2 in FIG. 1 with the end of the flap at the outboard edge of the slide being shown in different operating positions.
FIG. 3 is a cross-sectional view taken along the plane of line 3--3 in FIG. 1.
FIG. 4 is a fragmentary schematic view in perspective showing the inflation tubes and inflation equipment for the assembly shown in FIG. 1.
FIG. 5 is a fragmentary cross-sectional view taken along the plane of line 5--5 in FIG. 1.
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2, a multitubular inflatable escape slide 10 is shown in the inflated condition in position for evacuating passengers from an aircraft fuselage 11 on which an escape slide supporting surface such as aircraft wing 12 is mounted. The escape slide 10 has an inflatable relatively horizontal entrance portion 13 positioned on the wing 12 and an inclined inflatable slide portion 14 shown in position for evacuating passengers from the aircraft. The slide portion 14 is positioned at an angle A to the ground in the normal condition of the aircraft. The angle A of the slide portion 14 is about 43 degrees to the horizontal or ground line G--G. The slide portion 14 extends from an entrance end 15 adjacent the entrance portion 13 to an exit end 16 at the lower end of the slide which is supported by the ground surface at the ground line G--G.
The escape slide 10 has a walkway 17 extending from the entrance end 15 of the slide portion 14 to an edge 18 where the passengers enter the slide. A walkway ramp 19 may be fastened to the edge 18 for facilitating movement of the passengers from the wing 12 onto the escape slide 10. The escape slide 10 is fastened to the fuselage 11 through a packboard 22 which is pivotally mounted on the fuselage about an axis A--A for rotation of the packboard and the packaged escape slide 10 from a position within a compartment 23 in the wall of the fuselage 11 to a position on the wing 12 as shown in FIGS. 3, 4 and 5. In the extended position of the packboard 22, the escape slide 10 is inflated by a suitable inflation system such as turbofans 24 and 25 mounted on the packboard and connected to the escape slide by inflating conduits 26 and 27, respectively. The packboard 22 has a girt strap 28 for attachment to the escape slide 10 to hold it in position on the wing 22.
As shown in FIGS. 1, 2 and 3, the escape slide 10 has a multitubular construction including a left-hand lower side tube 29, a right-hand lower side tube 32, and a central main tube 33, all of which extend longitudinally of the escape slide through the entrance portion 13 and the slide portion 14. At the edge 18 of the entrance portion 13 and at the exit end 16 of the slide portion 14, the lower side tubes 29 and 32 are connected by an upper transverse tube 34 and a lower transverse tube 35.
The escape slide 10 also has a longitudinally extending left-hand upper side rail tube 36 mounted on top of the left-hand lower side tube 29 and a right-hand upper side rail tube 37 mounted on the right-hand lower side tube 32. The left-hand upper side rail tube 36 and right-hand upper side rail tube 37 are connected at the edge 18 of the entrance portion 13 by a U-shaped transverse upper tube 38 and by a U-shaped transverse lower tube 39 at the exit end 16 of the slide portion 14, both of which are mounted alongside the upper transverse tube 34 and lower transverse tube 35. A center panel 42 is fastened to the lower side tubes 29 and 32 and to the central main tube 33 between the upper side rail tubes 36 and 37 providing a slide surface in the slide portion 14 and a walking surface along the walkway 17.
The lower side tubes 29 and 32 are spaced from the central main tube 33 and in the entrance portion 13 these spaces are filled by walkway supporting tubes 43 and 44 extending from the upper transverse tube 34 to the entrance end 15 of the slide portion 14 providing a plurality of supporting tubes in side-by-side relationship under the walkway 17. These supporting tubes 29, 32, 33, 43 and 44 as well as the upper transverse tube 34 and U-shaped transverse upper tube 38 are located above a plane such as the plane of the wing 12 to provide a stable support for persons traversing the walkway 17 to the entrance end 15 of the slide portion 14. All of these supporting tubes are also positioned below the walkway 17 to provide unimpeded travel of the passengers over the walkway.
An inflatable support means such as pillow member 45 is mounted on the bottom of the slide portion 14 at the entrance end 15, as shown in FIGS. 1 and 2, in a position for engagement with a flap 46 of the wing 12 in an extended position such as the position taken during landing of the aircraft. In other positions of the flap, designated at 46A, 46B and 46C, the edge of the flap 46 engages the lower side of the escape slide 10 and provides support for the slide portion at the entrance end 15. Additional supporting means such as pillow members 47 and 48 may be mounted between the central main tube 33 and lower side tubes 29 and 32 for engagement with the pillow member 45 to provide further support of the escape slide in the slide portion 14.
The walkway ramp 19 is mounted on the U-shaped transverse upper tube 38 and has an upper surface 49 and a lower surface 52 connected by bulkheads 53, 54 and 55 forming transverse tubular spaces. As shown in FIG. 5, the upper surface 49 is inclined from the walkway 17 at the edge 18 of the entrance portion 13 so as to facilitate walking of the passengers from the surface of the wing 12 to the walkway. The bulkheads 54 and 55 in close proximity to the edge 18 of the entrance portion 13 have a greater length than the bulkhead 53 at a position remote from the edge so that upon inflation of the ramp 19, the upper surface 49 will have the desired inclination. The ramp 19 is mounted on and connected to the U-shaped transverse upper tube 38.
A top side rail 56 may be mounted on top the left-hand upper side rail tube 36, as shown in FIGS. 1, 2 and 3.
The turbofan 24 and conduit 26 are connected to the lower side tubes 29,32, the central main tube 33, the walkway supporting tubes 43, 44 and pillow members 45, 47 and 48 in a first inflation system. The turbofan 25 and conduit 27 are connected to upper rail tubes 36,37, U-shaped transverse tubes 38 and 39, walkway ramp 19 and top side rail tube 56 in a second inflation system. With the two independent systems, the slide 10 may still be usable if one of the systems is inoperable.
To indicate the inflation of the inflation systems and therefore the extension of the escape slide 10 and particularly the slide portion 14, inflatable indicator tubes 57 and 58 are mounted on the left-hand lower side tube 29 and left-hand upper side rail tube 36, respectively. Upon inflation of the lower and upper inflatable systems, the indicator tubes 57 and 58 will be inflated and extend upwardly beyond a line of sight S--S, shown in chain-dotted lines in FIG. 2, of a flight attendant from the fuselage access door. The attendant can thereby tell by looking from within the fuselage whether the slide portion 14 is inflated and extended so as to evacuate the passengers safely from the aircraft. If either the lower inflatable system or upper inflatable system is damaged and not inflated, the appropriate indicator tubes 57 or 58 will not be inflated and this will be evident from inside the fuselage 11. The indicator tubes 57 and 58 have a sufficient diameter to provide rigidity and extend above the line of sight S--S while at the same time they have a diameter which is small enough to require a minimum of inflatable gas. Marking tape 59 and 60, which may be of a highly visible material, may be wrapped around the ends of the indicator tubes 57 and 58 to make them more visible to the aircraft attendant.
In operation, the packboard 22 may be extended and the escape slide 10 inflated by suitable controls from within the fuselage 11. The attendant then can look out the access door of the fuselage 11 and by observing the positions of the indicator tubes 57 and 58 determine if the slide portion 14, which is not visible from the fuselage, is in condition for evacuating passengers. The passengers may then walk on the surface of the wing 12 up the ramp 19 and over walkway 17 to the entrance end 15 of the slide portion 14. They may then slide on the center panel 42 from the entrance end to the exit end 16 of the slide portion.
The turbofans 24 and 25 inflate the upper and lower inflation systems of the escape slide 10 in about two seconds inflation time to a pressure of about three pounds per square inch (0.21 kilograms per square centimeter). The escape slide 10 may be constructed of a suitable flexible material such as square-woven nylon impregnated with neoprene to retain air or other inflation medium in the inflatable parts.
It is understood that this invention is capable of other modifications and adaptions by those having ordinary skill in the art and is more particularly defined by the appended claims.
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An escape slide for evacuating personnel from an aircraft wing or other elevated surface where persons to be evacuated must walk a short distance before sliding down the slide. The escape slide has an entrance portion with a walkway and a walkway ramp of an inflatable bulkhead construction providing a firm walkway surface. The slide portion joins the entrance portion and is inclined toward the ground. When used on an aircraft wing with flaps, the bottom of the slide portion is engageable with and supported by the flaps at different operating positions. A support pillow attached to the bottom of the slide portion is engageable with the flap in the fully extended landing position. Inflatable indicator tubes are also attached to and in communication with the inflatable members of the slide to indicate when the slide is inflated and ready for passengers.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the control of electrically powered devices such as piezoelectrically driven atomizer devices; and more particularly it concerns novel switch actuator mechanisms for controlling the operation of said devices.
2. Description of the Related Art
Many electrically controlled devices have been developed for producing desired mechanical effects and whose operation is controlled by operation of a button or actuator which is mounted on an outer cover of the device. By way of example, battery driven atomizers and aroma distributors are described in U.S. Pat. No. 5,547,616, No. 5,115,975, No. 4,804,821 and No. 3,661,323. These devices have, in most cases, an outer cover in which the atomizer or aroma distributor mechanism is mounted and whose operation is controlled by an electrical switch having a moveable switch element mounted on the outer cover.
The outer cover in many of these devices does not have sufficient strength to hold the moveable switch element securely without extra reinforcement. Further, the outer cover is often curved so that the moveable switch element must follow a curved path. This precludes the use of multiposition switches which have linearly moveable switch elements.
SUMMARY OF THE INVENTION
This invention in one aspect provides a novel switch actuating mechanism which comprises an elongated switch arm which is pivotally mounted near one end thereof on a support, a switch having a switch element which is moveable along a linear path, the switch being mounted in a fixed position relative to the support, and a lost motion interconnection between the switch arm and the switch element. The lost motion interconnection permits relative movement between the switch arm and the switch element in a direction perpendicular to the linear path but prevents relative movement in a direction parallel to that path. As a result, pivotal movement of the switch arm produces linear movement of the switch element.
In another aspect, the invention provides a novel electrically controlled device which comprises a mechanism for producing a desired result and an electrical circuit with a multi-position switch for controlling operation of the mechanism. The switch has a switch element that is moveable through a given range along a linear path; and the switch and switch element are mounted on a support structure within a shell-like outer cover that has a curved outer surface. An elongated switch arm is pivotally connected at one end to the support structure inside the outer cover such that said switch arm pivots about an axis that is perpendicular to the linear path of the switch element and such that the switch arm can swing through an arc that includes the given range of movement of the switch element. A lost motion mechanical interconnection is provided between the switch arm and the switch element and is located within the outer cover. The lost motion interconnection permits relative movement between the switch arm and the switch element in a direction perpendicular to the linear path but prevents relative movement in a direction parallel to that path. Thus, while the switch arm is supported solidly within, and not by, the outer cover, its movement follows the curved surface of the cover. At the same time, this curved movement causes the switch element to be moved along its linear path. The switch arm extends beyond the lost motion interconnection and out through a slot in the outer cover where it can be operated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an atomizer device according to the invention.
FIG. 2 is a plan section view taken along line 2 — 2 of FIG. 1; and
FIG. 3 is an elevational section view taken along line 3 — 3 of FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As seen in FIG. 1, an atomizer device 10 according to the invention has a shell-like outer cover 12 which is somewhat egg-shaped, but it is flattened on the bottom and it has a shallow dished upper region 14 formed in the top. An ejection opening 16 is provided in the dished upper region 14 . Atomized liquid droplets produced by the atomizer device 10 are ejected through the opening 16 . A horizontal slot 18 is formed in a curved front surface of the outer cover 12 ; and a switch actuator button 20 moves along the slot 18 . The button 20 can be set to any of several positions, indicated by vertical lines 22 on the cover 12 , to adjust the intensity of atomization produced by the device 10 .
As can be seen in FIGS. 2 and 3, a support chassis 24 extends horizontally within the outer cover 12 . The chassis 24 supports on its underside a liquid reservoir or bottle 26 (FIG. 3) which contains a liquid to be atomized. Liquid from the bottle 26 rises up out of the bottle by the capillary action of a wick 28 which extends through an opening 29 in the chassis. An atomization assembly 30 is mounted on the upper side of the chassis above the opening 29 and the reservoir or bottle 26 . The atomization assembly includes a retainer 32 which is supported on the upper side for the chassis over the opening 29 . The retainer 32 contains an orifice plate 34 and a piezoelectric actuator 36 which vibrates the orifice plate. The orifice plate 34 is pushed down against the top of the wick 28 by a spring 38 so that liquid from the bottle 26 will be supplied to the underside of the plate and will pass through its orifices and become ejected in the form of minute liquid droplets as the plate is vibrated by the piezoelectric actuator 36 .
As also shown in FIG. 3, the actuator 36 is supplied with alternating voltages from wires 40 which extend from a drive circuit which is mounted on a printed circuit board 42 . The printed circuit board is also supported on the upper side of the chassis 24 .
A multi-position switch 44 is mounted to the underside of the printed circuit board 42 . The switch 44 includes a switch clement 46 which is moveable along a horizontal linear path A—A (FIG. 2) to any of several positions. The switch is connected to the circuits on the printed circuit board 42 such that by moving the switch element 46 to a particular position, a corresponding rate of atomization will occur. In a particular design the switch 44 controls a duty cycle wherein atomization occurs for 50 millisecond intervals with the time between successive intervals being adjustable between, for example, 5 and 40 seconds.
An elongated switch arm 48 is pivotally mounted at one end by means of a pivot 50 on the chassis 24 . The pivot 50 has a pivot axis 50 a which is vertical so that the arm 48 also swings along a horizontal curved path B—B (FIG. 2 ). The arm 48 extends from the pivot 50 and out through the horizontal slot 18 in the outer cover 12 where it is connected to the actuator button 20 . Because the arm 48 is mounted on the chassis 24 by means of the pivot 50 , it is not guided by the sides of the slot 18 nor does it ride on or obtain support from the cover 12 . As can be seen in FIGS. 2 and 3, the switch arm 48 extends under the switch 46 ; and as seen in FIG. 2, the range of movement of the arm 48 is such that it sweeps over the entire path of linear movement of the switch element 46 .
The switch arm 48 is connected to the switch element 46 by a lost motion mechanism 51 which, as shown in FIGS. 2 and 3, comprises a pair of lug elements 52 which are fixed to the arm 48 and extend upwardly therefrom and along each side, respectively, of the switch element 46 . Movement of the switch arm 48 along the curved path A is communicated by the lug elements 52 to the switch clement 46 to move the switch element along the linear path B. It will be seen that the lost motion mechanism 51 permits relative movement between the switch arm 48 and the switch element 46 in a direction perpendicular to the linear path A of the switch element but it prevents relative movement between the switch arm and the switch element is a direction parallel to the path A. Thus, the switch actuator button 20 can be moved along the curved path B path while the switch arm 48 moves the switch clement 46 along the linear path B to each of its several switch positions.
Because the switch actuator button 20 is mounted on the switch arm 48 , it is supported entirely by the switch arm which in turn is supported on the chassis 24 via the pivot 50 . As a result no mechanical interconnection is needed between the outer cover 12 and the switch arm 48 or the switch actuator button 20 . Accordingly the cover 12 does not need to be reinforced to support the button 20 or the switch arm 48 and there is no danger of interference between the cover and the switch arm which might otherwise be caused by bending of the cover as the switch arm is moved.
It will be appreciated that other forms of a lost motion mechanism can be used to convert the curvilinear movement of the switch arm 48 to the linear movement of the switch actuator 46 . For example, the lug elements 52 could be fixed to the switch element 46 and extend to the switch arm 48 , or a single lug could be fixed to and extend from one of the switch element 46 and the switch arm 48 and extend therefrom into a slot formed in the other member. In such case the slot would extend in a direction which is generally perpendicular to the path A of movement of the actuator element 46 .
INDUSTRIAL APPLICABILITY
This invention permits a switch arm of an adjustable device to be mounted in a manner that does not put a strain on the outer cover of the device and that does not lead to a problem of interference or jamming as the switch arm is moved.
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An automated device ( 10 ) has a curved outer cover ( 12 ) through which a switch arm ( 48 ) extends. The switch arm is pivotally supported inside the cover and is connected therein by means of a lost motion mechanism ( 51 ) to a switch actuator ( 46 ) of a switch ( 44 ) to control operation of the switch.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional of U.S. patent application Ser. No. 10/804,881, filed Mar. 19, 2004, in the name of Dragan Veskovic and entitled SYSTEM TO CONTROL DAYLIGHT AND ARTIFICIAL ILLUMINATION AND SUN GLARE IN A SPACE, which application claims the benefit and priority of U.S. Provisional application Ser. No. 60/457,276, filed Mar. 24, 2003, entitled MULTI-ZONE CLOSED LOOP ILLUMINATION MAINTENANCE SYSTEM, and U.S. Provisional application Ser. No. 60/529,996, filed Dec. 15, 2003, entitled SYSTEM TO CONTROL DAYLIGHT AND ARTIFICIAL ILLUMINATION AND SUN GLARE IN A SPACE, and is related to U.S. application Ser. No. 10/660,061, filed Sep. 11, 2003, entitled MOTORIZED WINDOW SHADE CONTROL, and U.S. Pat. No. 4,236,101, granted Nov. 25, 1980, entitled LIGHT CONTROL SYSTEM, the entire disclosures of which are hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a system to provide sufficient and comfortable lighting within a space. In particular, the invention relates to a system for the automatic control of the light levels in a space by the control of the intensity of electric lighting and/or daylight in a space. In particular, in one embodiment, the present invention is directed to the control of the lighting level in a space, such as an interior room, by controlling both the artificial light in the space by control of the intensity of electric lighting in the space and the control of motorized window treatments in the space in order to achieve a reasonably constant illumination on task surfaces throughout the space. In addition, the invention is directed to a system to reduce or prevent sun glare, which can potentially occur at low sun angles due to sunshine through windows or other openings, e.g., skylights, surrounding the space. Such a condition is likely to occur at or near sunset or sunrise.
[0003] Further, the invention is directed to the control of electric lighting in a space in multiple zones of the space to achieve a preset lighting profile in the space. A “lighting profile” represents a desired distribution of target illumination values in various portions of the space. Additionally, the invention is directed to the control of window treatments such as shades based on light levels in the interior of the space so as to maintain a predefined illumination profile in the space and/or to minimize or eliminate sun glare through openings into the space. Further, the invention is directed to a system which performs the three functions of controlling electric lighting in the space, controlling natural lighting in the space in order to achieve a predefined illumination profile and minimizing or eliminating sun glare into the pace. The invention is thus directed to an illumination maintenance system for achieving a predefined illumination profile in a space where the light is provided by natural light or artificial light or both and further where sun glare is optionally minimized or eliminated.
[0004] One of the major problems of illumination maintenance systems, and in particular, closed loop (feedback) illumination maintenance systems, is the variation of incident light at the sensor or sensors employed for detecting the incident light due to occupants moving in the space or some other type of variation of surface reflections in the space. One of the prior art approaches to solve this problem is to average the illumination readings from multiple light level sensors. Another approach is to position or orient the field of view of the sensors such that the sensors are not influenced by the occupant traffic or other short or long term variations of the optical properties of the environment.
[0005] Further, open loop systems have been developed for illumination maintenance and daylight harvesting but such open loop systems are not suitable for window treatment control implemented based on the interior light sensors because when a shading or window treatment device is closed, access to exterior lighting conditions is prevented or restricted.
[0006] Currently available commercial solutions for daylight control of window treatments are mostly based on exterior light sensors and predictive control algorithms. Exterior light sensors cause maintenance problems and require exterior wiring. Predictive control schemes are difficult to configure. Usually a long process of measurements and computer or mechanical model simulations must be performed before the control system can be correctly configured.
[0007] Further, a conventional approach that attempts to solve the glare problem due to sunshine entering through windows at a low sun angle utilizes some form of open loop control of window treatments. In these systems, the algorithms are usually based on the use of exterior photosensors. These conventional systems employ a combination of strategies based on the exterior light level readings and a time clock in order to derive the required shade positions. A study of the expected lighting conditions is regularly performed in order to predict the times when the glare incidents are likely to occur. Some of the problems with this type of control are that it demands maintenance of exterior photo sensors exposed to the elements and there are problems with wiring and/or mounting sensors continuously exposed to the outside lighting conditions. Furthermore, preparation and creation of complex databases is required to define the lighting conditions for each space of a building throughout a year for large buildings, which is time consuming and expensive. Further, these systems require control database modifications in case exterior shading objects are added such as new buildings or plants and further, the controls cannot be fully optimized for each space of a large building and therefore do not result in optimal occupant comfort and energy savings.
SUMMARY OF THE INVENTION
[0008] The present invention provides a new approach to maintenance of illumination in a confined space where the sources of the illumination include combinations of daylight and electric lamps in the space. The space may be divided into illumination zones. The new approach allows for variable and flexible daylight compensation without using separate sensing for each illumination zone and for integrated control of window treatments. One or more sensors can be used to control a plurality of electric lamps in order to reasonably and accurately maintain a desired illumination profile in the space. In addition, a plurality of light sensors can be used to produce a control variable corresponding to the current overall illumination. This approach results in the ability to accurately control local illumination without requiring localized sensing for different parts of the space.
[0009] A further advantage of the present invention is that the overall illumination in the space can be maintained for multiple lighting profiles. Each of these lighting profiles can have different requirements for the overall illumination and the relations of illuminations in different portions of the space.
[0010] Two exemplary embodiments for the electric light control implementation are described herein, although variations of these embodiments will be apparent to those of skill in the art based on the descriptions contained herein. These embodiments may employ control options defined as “open loop” control and “closed loop” control. The term “open loop” is used to describe an electric light control system based on signals from interior light sensors that predominantly sense daylight entering the space. The term “closed loop” refers to electric light level control systems using interior light sensors which predominantly sense a combination of daylight entering the space and the light generated by the electric light sources being controlled.
[0011] The invention also describes a closed loop system for control of window shading devices. It is assumed that such closed loop system is implemented based on the light readings from a light sensor sensing dominantly daylight entering the space through the windows affected by the window treatments being controlled. Therefore the sensor incident illumination changes as a consequence of window treatment adjustment.
[0012] Based on one embodiment of the present invention the control of both the plurality of electric lights and window treatments can be achieved using only a single photosensor or a single averaged reading from a plurality of interior sensors. Thus the single signal (single input variable) from a single light sensor or group of light sensors can be used as an input for a closed loop algorithm for control of window treatments and an open loop algorithm for control of electric lights.
[0013] As discussed above, one of the problems with prior art systems is that exterior light sensors and predictive control algorithms are employed for control of window treatments. As described above, these systems require maintenance of exterior sensors and complex data gathering and setup procedures. The control approach of the present invention eliminates the need for exterior sensors and these data gathering and setup procedures, thus reducing the overall system cost.
[0014] In addition, the present invention also allows sun glare in the interior space to be controlled. The present invention can provide near optimal illumination control of the space. Furthermore, the properties of the space such as the aperture ratios or openings, geometric orientation of the windows or exterior shading objects do not need to be known prior to the installation and commissioning of the system. Both illumination and glare can be controlled without significantly sacrificing energy savings resulting from the use of daylight or interior illumination. The system has the potential to automatically recalibrate based on immediate or repeated occupant input resulting in increased occupant satisfaction.
[0015] Another object of the invention is to maximize daylight savings by closing the window treatment only during glare incidents and during times when the sunlight illumination near windows exceeds a preset calibration value.
[0016] In this application, it should be understood that “windows” refers to any openings into a space including, e.g., skylights or any other openings. Further, “window treatment” refer to any type of opening shading device, such as blinds, shades, controllable or glazing or any other device whose purpose is to control the amount of light entering or leaving the space through an opening of any kind, whether in a building wall or roof
[0017] According to one aspect, the invention comprises an illumination maintenance system for maintaining a desired illumination profile in a space throughout at least a portion of a day, the space being illuminable by both daylight and electric light, the system comprising a sensor for sensing an illumination level in at least a portion of the space; a plurality of dimmable electric lamps providing the electric light to supplement the daylight illumination of the space, the electric lamps arranged in one or more zones in the space, the zones defining predefined volumes of the space, each zone having at least one lamp; a control system controlling the dimming levels of the plurality of electric lamps, the at least one lamp of each zone being controlled to a dimming level to achieve a desired illumination level in the respective zone according to the desired illumination profile and compensate for the daylight illumination in the space throughout at least the portion of the day; wherein the dimming level of each lamp is selected by the control system from one of a plurality of lighting presets, each lighting preset comprising a combination of dimming levels of the lamps, and wherein the control system adjusts the dimming level of the electric lamps toward a preset that will result in an appropriate supplementing of the daylight illumination to achieve the desired illumination profile in the space.
[0018] According to yet another aspect, the invention comprises an illumination maintenance system for maintaining a desired illumination profile in a space throughout at least a portion of a day where the illumination sources include daylight and artificial light, the system comprising a sensor for sensing an illumination level in at least a portion of the space, a plurality of electric lamps providing artificial light to supplement the daylight illumination of the space; the electric lamps being dimmable and being arranged in one or more zones in the space, the zones defining predefined volumes of the space, each zone having at least one lamp, a control system controlling the dimming levels of the plurality of electric lamps to maintain the desired illumination profile in the space, the at least one lamp of each zone being controlled to a dimming level to achieve a desired illumination level in the respective zone according to the desired illumination profile, the control system controlling the plurality of electric lamps so that the dimming level of each lamp is adjusted to achieve the desired illumination profile and compensate for the daylight illumination in the space throughout at least the portion of the day, wherein the dimming level of each lamp is selected by the control system from one of a plurality of lighting presets, each preset comprising a combination of dimming levels of the lamps and wherein the control system fades the electric lamps toward a preset that will result in an appropriate supplementing of the daylight illumination to achieve the desired illumination profile in the space; and the control system operating such that, when the desired illumination profile is achieved within a predefined tolerance, the control system stops varying the dimming levels of the lamps.
[0019] According to another aspect, the invention comprises an illumination maintenance system for maintaining a desired illumination profile in a space throughout at least a portion of a day where the illumination source comprises daylight entering the space, the system comprising a sensor for sensing an illumination level in at least a portion of the space, at least one electrically controllable window treatment for at least one opening for allowing daylight into the space, the window treatment selectively altering the amount of daylight entering the space through the opening, a control system controlling the at least one window treatment, the control system controlling the at least one window treatment to achieve the desired illumination profile in the space throughout at least the portion of the day, and wherein the control system stops adjusting the at least one window treatment when the desired illumination profile within a predefined tolerance has been achieved.
[0020] According to a further aspect, the invention comprises a system for reducing sun glare through an opening into a space, the system comprising at least one electrically controllable window treatment for at least one opening for allowing daylight into the space, the window treatment selectively altering the amount of daylight entering the space through the opening, a sensor for sensing daylight illumination entering the space, a control system controlling the at least one window treatment, and the control system operating to adjust the window treatment in the event of sun glare through the opening to reduce the sun glare, and such that when the sun glare has been minimized, the control system stops the adjustment of the at least one window treatment.
[0021] According to yet another aspect, the invention comprises an illumination maintenance system for maintaining a desired illumination profile in a space throughout at least a portion of a day where the illumination source comprises daylight entering the space, the system comprising at least one electrically controllable window treatment for at least one opening for allowing daylight into the space, the window treatment selectively altering the amount of daylight entering the space through the opening, a sensor for sensing daylight illumination entering the space, a control system controlling the at least one window treatment to maintain the desired illumination profile in the space throughout at least the portion of the day, and the control system further operating to adjust the window treatment in the event of sun glare through the opening to reduce the sun glare, and such that when the desired illumination profile within a predefined tolerance is achieved, the control system stops the adjustment of the at least one window treatment.
[0022] According to still another aspect, the invention comprises an illumination maintenance system for maintaining a desired illumination profile in a space throughout at least a portion of a day where the illumination sources include daylight and artificial light, the system comprising a first sensor for sensing an illumination level in at least a portion of the space, at least one electrically controllable window treatment for at least one opening for allowing daylight into the space, the window treatment selectively altering the amount of daylight entering the space through the opening, a plurality of electric lamps providing artificial light to supplement the daylight illumination of the space, the electric lamps being dimmable, a control system controlling the at least one window treatment and the plurality of electric lamps to maintain the desired illumination profile in the space, the control system controlling the plurality of electric lamps so that the dimming level of each lamp is adjusted to achieve the desired illumination profile and compensate for the daylight illumination in the space throughout at least the portion of the day, and the control system further operating to adjust the at least one window treatment in the event of sun glare through the opening to reduce the sun glare, and such that when the glare is eliminated or reduced to a satisfactory level and the desired illumination profile within a predefined tolerance is achieved, the control system stops varying the dimming levels of the lamps and the adjustment of the window treatment.
[0023] According to a further embodiment of the invention, the illumination maintenance system for an interior space comprises a sensor for sensing illumination in one portion of the space or alternatively for sensing of average illumination in the space, a lighting source to supplement daylight illumination comprising multiple independently controllable dimmable electric lights, and optionally electrically controllable window and/or skylight shading devices to attenuate daylight illumination, for example roller shades, any type of blind or electrically controllable window or skylight glazing.
[0024] According to yet another embodiment, the invention comprises an illumination maintenance system for maintaining a desired illumination profile in a space throughout at least a portion of a day where the illumination sources include daylight and artificial light, the system comprising at least one interior sensor for sensing an illumination level in at least a portion of the space; at least one electrically controllable window treatment for at least one opening for allowing daylight into the space, the window treatment selectively altering the amount of daylight entering the space through the opening; a plurality of electric lamps providing artificial light to supplement the daylight illumination of the space, the electric lamps being dimmable; a control system controlling the at least one window treatment and the plurality of electric lamps to maintain the desired illumination profile in the space; the control system controlling the plurality of electric lamps so that the dimming level of each lamp is adjusted to achieve the desired illumination profile and compensate for the daylight illumination in the space throughout at least a portion of the day; wherein the control of the electric lamps is implemented based on an open loop control algorithm and the control of window shading devices is implemented based on a closed loop control algorithm; and wherein the control of both the electric lamps and the window treatments is based on a signal representing a single input variable derived from the at least one interior sensor.
[0025] Further, the system comprises an automatic control system operating both the window and/or skylight shading devices and the electric lights in order to maintain a desired illumination profile in the space.
[0026] According to a first electric light control method of the invention, the electric lights are controlled using a closed loop algorithm. Preferably, the lighting control system operates the electric lights so that the lights are dimmed between two or more fixed presets or scenes. Each preset comprises a combination of dimming levels to achieve the desired lighting profile and compensate for the daylight availability in the space through the day. The presets are ordered based either on the overall dimming level for each zone or the dimming levels intended for particular portions of the space. The correlation of dimming level of the individual lighting zones for each preset is set in the inverse proportion to the daylight available at a particular position in the space.
[0027] The control system automatically adjusts the dimming level of the electric lights towards a preset that would result in the appropriate supplementing of the available daylight. When the desired illumination is achieved, the system stops varying the light output from the electric lights and/or stops varying the position or transparency of the shading devices. The system adjusts a plurality of electric lights between presets corresponding to one or more daytime lighting conditions and a nighttime lighting condition. Both the window shading devices and the electric lights can be controlled using one or more interior photosensors representing a single input to the control system. Alternatively, the window shading devices can be controlled based upon one or more interior photosensors separate from the photosensors used to control the electric lights and connected to a lighting control processor.
[0028] The method for control of window treatments described by the present invention can also be combined with an open loop method for control of electric lights. This open loop method for electric light control can preferably be implemented as described in the referenced U.S. Pat. No. 4,236,101, the entire disclosure of which is incorporated by reference herein.
[0029] In the case when an independent second photosensor or a set of photosensors are used for the control of the window shading devices, the photo sensors are preferably mounted close to the window such that their field of view is oriented toward the windows such that they dominantly sense the daylight entering the space.
[0030] As mentioned, an independent set of photosensors can be used for the control of electric lights. These sensors can be of the same type as the photosensors controlling the window shading device and are in an exemplary embodiment connected to the lighting control system via a separate interface unit. The light level readings from these sensors are processed by an independent control algorithm. The photosensors used for the electric light control are preferably mounted at approximately two window heights away from the windows. In one particular implementation, the sensors are oriented so that their field of view is away from the windows. This orientation is suitable for a closed loop lighting control system. However, dominantly open loop system could also be employed for this purpose. In the case of dominantly open loop control, the field of view of the interior sensors for the electric lighting control is oriented towards the windows.
[0031] The invention also comprises methods for illumination maintenance.
[0032] According to one aspect, the invention comprises a method for maintaining a desired illumination profile in a space throughout at least a portion of a day where the illumination sources include daylight illumination and electric light illumination, the space containing a plurality of electric lighting zones defining predefined volumes in the space, each zone having at least one dimmable electric lamp, the method comprising the steps of: defining a plurality of lighting presets, each preset comprising a combination of dimming levels of the lamps; sensing an illumination level in at least a portion of the space; and adjusting the dimming levels of the electric lamps toward one of the lighting presets in response to the sensed illumination level in order to supplement the daylight illumination and to achieve the desired illumination profile in the space.
[0033] According to another aspect, the invention comprises a method for maintaining a desired illumination profile in a space throughout at least a portion of a day where the illumination sources include daylight and artificial light, the method comprising sensing an illumination level in at least a portion of the space, supplementing the daylight illumination of the space with a plurality of electric lamps providing artificial light, the electric lamps being dimmable and being arranged in one or more zones in the space, the zones defining predefined volumes of the space, each zone having at least one lamp, controlling with a control system responsive to the sensed illumination level the dimming levels of the plurality of electric lamps to maintain the desired illumination profile in the space, the step of controlling comprising adjusting the dimming level of the at least one lamp of each zone to achieve a desired illumination level in the respective zone and thereby maintain the desired illumination profile in the space and compensate for the daylight illumination in the space, wherein the dimming level of each lamp is selected by the control system from one of a plurality of lighting presets, each preset comprising a combination of dimming levels of the lamps and wherein the control system fades the electric lamps toward a preset that will result in an appropriate supplementing of the daylight illumination to achieve the desired illumination profile in the space; stopping varying of the dimming levels of the lamps when the desired illumination profile within a predefined tolerance is achieved, and repeating the above steps during the day to maintain the desired illumination profile throughout at least the portion of the day.
[0034] According to another aspect the invention comprises a method for maintaining a desired illumination profile in a space throughout at least a portion of a day where the illumination source comprises daylight entering the space, the method comprising, sensing an illumination level in at least a portion of the space, providing at least one electrically controllable window treatment for at least one opening for allowing daylight into the space, the window treatment selectively altering the amount of daylight entering the space through the opening, controlling the at least one window treatment with a control system responsive to the sensed illumination level to achieve the desired illumination profile in the space, stopping adjusting the at least one window treatment with the control system when the desired illumination profile within a predefined tolerance has been achieved, and repeating the above steps during the day to maintain the desired illumination profile throughout at least the portion of the day.
[0035] According to yet another aspect, the invention comprises a method for reducing sun glare through an opening into a space, the method comprising, providing at least one electrically controllable window treatment for at least one opening for allowing daylight into the space, the window treatment selectively altering the amount of daylight entering the space through the opening, sensing daylight illumination entering the space, controlling with a control system responsive to the sensed daylight illumination the at least one window treatment, and adjusting with the control system the window treatment in the event of sun glare through the opening to reduce the sun glare, and when the sun glare has been minimized, stopping adjustment of the at least one window treatment.
[0036] According to still yet another aspect, the invention comprises a method for maintaining a desired illumination profile in a space throughout at least a portion of a day where the illumination source comprises daylight entering the space, the method comprising, providing at least one electrically controllable window treatment for at least one opening for allowing daylight into the space, the window treatment selectively altering the amount of daylight entering the space through the opening, sensing daylight illumination entering the space, controlling with a control system responsive to the sensed daylight illumination the at least one window treatment to maintain the desired illumination profile in the space throughout at least the portion of the day, and further adjusting with the control system the window treatment in the event of sun glare through the opening to reduce the sun glare, and when the desired illumination profile within a predefined tolerance is achieved, stopping adjustment of the at least one window treatment, further comprising repeating the above steps during the day to maintain the desired illumination profile throughout at least the portion of the day.
[0037] Yet another aspect of the invention comprises a method for maintaining a desired illumination profile in a space throughout at least a portion of a day where the illumination sources include daylight and artificial light, the method comprising, sensing an illumination level in at least a portion of the space, providing at least one electrically controllable window treatment for at least one opening for allowing daylight into the space, the window treatment selectively altering the amount of daylight entering the space through the opening, supplementing the daylight illumination of the space with a plurality of electric lamps providing artificial light, the electric lamps being dimmable, controlling with a control system responsive to the sensed illumination level the at least one window treatment and the plurality of electric lamps to maintain the desired illumination profile in the space, controlling with the control system the plurality of electric lamps so that the dimming level of each lamp is adjusted to achieve the desired illumination profile and compensate for the daylight illumination in the space throughout at least the portion of the day, further adjusting with the control system the at least one window treatment in the event of sun glare through the opening to reduce the sun glare, stopping varying of the dimming levels of the lamps and the adjustment of the window treatment when the desired illumination profile within a predefined tolerance is achieved, and repeating the above steps during the day to maintain the desired illumination profile throughout at least the portion of the day.
[0038] Other features and advantages of the present invention will become apparent from the following description of the invention which refers to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] The invention will now be described in greater detail in the following detailed description with reference to the drawings in which:
[0040] FIG. 1 is a block diagram of a lighting maintenance system according to the invention;
[0041] FIG. 2 shows the floor plan of a typical room layout with the system of the invention connected to the various sensors, lighting sources and controllable window treatments;
[0042] FIG. 3 is a diagram showing a first example of a preset configuration for a flat lighting profile;
[0043] FIG. 4 shows a second example of a preset configuration for a different lighting profile;
[0044] FIG. 5 shows a third example of a preset configuration for yet a different lighting profile;
[0045] FIG. 6 shows a process flow of the system main loop;
[0046] FIG. 7 a shows the process flow for a first system controlling the electric lamps only, when the lighting in the space is too dark;
[0047] FIG. 7 b shows the process flow for the first system controlling the electric lamps only, when the lighting in the space is acceptable;
[0048] FIG. 7 c shows the process flow for the first system controlling the electric lamps only, when the lighting conditions in the interior space are that there is too much light;
[0049] FIG. 8 a show the process flow for a second system controlling both electric lamps and window treatments, when the lighting is too dark;
[0050] FIG. 8 b shows the process flow for the second system when the lighting is acceptable;
[0051] FIG. 8 c show the process flow for the second system when there is too much light;
[0052] FIG. 9 is the process flow of the system showing how the system varies a time delay to operate the window treatments in response to the amount of illumination;
[0053] FIG. 10 shows how the system varies the dead-band set point to reduce glare;
[0054] FIG. 11 shows an alternative process flow for reducing sun glare;
[0055] FIG. 12 shows the process flow in response to a manual override;
[0056] FIG. 13 , comprising FIGS. 13 a and 13 b , shows how sun angle is measured; and
[0057] FIG. 14 shows graphs of illumination levels and when glare control is needed throughout a day.
DETAILED DESCRIPTION OF THE INVENTION
[0058] With reference now to the drawings, FIG. 1 is a block diagram of an embodiment of the invention for controlling the illumination levels in a space such as a room, where both daylight and artificial lighting act as light sources, as well as for reducing sun glare. The system 10 comprises a central processor 100 which may be a Lutron GRAFIK 6000® central lighting processor, for example, Model No. GR6MXINP. The central processor 100 has coupled thereto a dimming panel 110 which has various lighting loads 120 which can be any light source type including but not limited to incandescent, fluorescent, HID (High Intensity Discharge), neon, LED (Light Emitting Diode), LV (Low Voltage) coupled thereto and which are controlled by the dimming panel 110 in response to commands from the central processor 100 communicated via a digital communication link 137 . The dimming panel may be a Lutron type GP12-1203ML-15. Photosensor interface 130 is coupled to the central processor via a digital communication link 135 . Coupled to the photosensor interface 130 are one or more photosensors 140 which may be microWATT® photosensors available from Lutron model No. MW-PS-WH. Photosensors 140 are for control of the interior lights 120 . A further photosensor interface 132 is coupled to the central processor 100 via the link 135 . Coupled to the photosensor interface 132 are one or more photosensors 145 which may be microWATT photosensors available from Lutron model No. MW-PS-WH. Photosensors 145 are for control of the motorized window treatments 170 .
[0059] One or more wall stations 150 may be provided which are coupled to the central processor 100 as well as the photosensor interfaces via the digital communication link 135 . These wall stations 150 are provided for manual control of the various lighting loads 120 . Also connected to the link 135 may be a window treatment controller 160 for manually controlling the window treatments 170 . This controller 160 may be a Lutron GRAFIK 6000 Sivoia® controller model No. SO-SVCI-WH-EO1. Window treatments 170 may comprise Lutron Sivoia motor drive units, e.g., model No. SV-MDU-20 or Lutron Sivoia QED™ electronic drive units, e.g. model No. SVQ-EDU-20 driving Lutron Sivoia roller shades, Kit no. SV-RS-KIT.
[0060] A computer, for example a personal computer 180 may be coupled to the central processor 100 via an interface adapter 190 and suitable connections such as a PC jack 200 for programming/monitoring of the central processor. Note that a Lutron GRAFIK 7000™ central lighting processor could be used in place of the GRAFIK 6000 central processor.
[0061] FIG. 2 shows a floor plan of a typical room layout. The central processor 100 and dimming panel 110 are shown located in an electrical closet. The various lamps 120 are also shown and are grouped into, for example, five zones, each zone controlled separately by the dimming panel. Zone 1 is closest to the windows 172 . A different number of zones can be employed, including a single zone. The photosensor interface 130 is coupled to the photosensors 140 and the interface 130 is connected to the central processor 100 . Photosensors 140 are preferably mounted such that there is no or minimal daylight shining directly into the photosensor and so that the photosensor measures the light reflected off the surfaces in the illuminated space. Photosensors 140 are preferably mounted at approximately two window heights away from the windows 172 . The window treatment controller 160 is coupled to the motorized window treatment motors 171 driving the window treatments 170 . The window treatment controller 160 , allows manual control of the window treatments 170 . The Photosensor interface 132 is coupled to a photosensor or photosensors 145 for sensing daylight entering the room and is connected to the central processor 100 . Photosensors 145 are directed so that their field of view is toward the window and are preferably mounted within one window height of the windows 172 .
[0062] The central processor 100 manages the lighting for an entire facility and allows the user to create and recall custom preset scenes (or presets) for common room activities, for example, general meetings, audio-video presentations, special events, etc. Scenes are set by adjusting the intensity of each zone of electric lights or motorized window treatments to generate a combination for the particular activity. Wall stations 150 , hand held controls, preprogrammed time clock events, occupancy sensors, and photosensors 140 , 145 can supply inputs to the system to select any scene in any area. The central processor 100 includes an astronomical time clock, which is capable of scheduling events based on sunrise and sunset times. System design and setup are accomplished using, e.g. Lutron GRAFIK 6000 setup software on a personal computer 180 . When system setup is complete, the computer 180 may be used for system monitoring and real time operation. One standard central processor 100 can control up to 512 zones and 544 scenes with up to 96 control points.
[0063] The motorized window treatments 170 allow the system to control natural light in addition to electric light. The motors 171 can be programmed to preset window treatment levels. The controller 160 allows for selection of the window treatment presets from the central processor 100 . Up to 64 motors can be controlled for each controller 160 .
[0064] The photosensor interface 130 is used for selection of preset lighting scenes and the interface 132 is used to set window treatment levels in response to available daylight or electric light for optimum light levels, energy savings, and reduced sun glare. The photosensor interfaces 130 , 132 process the light level information from photosensors 140 , 145 and transmit this measured illumination data to the central processor 100 via the digital communication link 135 .
[0065] In a preferred implementation of the invention, the central processor 100 runs two algorithms: 1) a first algorithm for the control of the window treatments and the second algorithm for control of the electrical lights both based on the readings of photosensors 140 communicated to the central processor 100 through photosensor interface 130 . Alternatively the first algorithm for control of window treatments can be implemented based on the readings of photosensors 145 communicated to the central processor through photosensor interface 132 . Yet another alternative approach is to base the operation of both control algorithms on the readings from photosensor 145 via interface 132 . In this case the control of the electric lights would be based on pre-existing control algorithms as described in U.S. Pat. No. 4,236,101 and implemented in Lutron daylight compensation products such as Micro Watt, Digital Micro Watt and Radio Touch.
[0066] In the preferred implementation described, the two algorithms are operated by the same processor. Alternatively, the two algorithms could work independently and be controlled by separate processors or the same processor, but operating independently. For example, one system could be provided to adjust only the shading and to reduce glare in the space. A separate system could be employed only to adjust electrical light levels. Alternatively, one system can handle all three functions, electric light control, shade control to maintain an illumination profile and shade control to minimize sun glare.
[0067] In order to control the electric lights according to the first aspect of the invention the implementation is based on a fixed number of presets, or lighting scenes, preferably four presets may be used. However, any number of presets can be provided, including only one. Each preset defines a target intensity for one or more electric lighting zones, for example, zones 1 - 5 shown in FIG. 2 . For a system with four resets, these presets will be referred to as Minimum Preset, Medium Low Preset, Medium High Preset and Maximum Preset.
[0068] In most cases, the Minimum Preset is configured so that all electric lights are turned off and is used to maximize daylight in the space. For spaces where daylight contribution deeper in the space is inadequate the minimum preset is configured to maintain adequate illumination under conditions of high daylight availability and with the window treatments fully open. This preset is preferably calibrated when there is adequate daylight availability in the majority of the space being controlled.
[0069] The Medium Low preset normally corresponds to the required contribution of electric lights to the overall illumination when enough daylight is available to achieve the highest required illumination in the space in close proximity to the windows or other openings.
[0070] The Medium High preset corresponds to the required contribution of electric lights when the available daylight is between the maximum and minimum amounts.
[0071] The Maximum Preset corresponds to the required illumination in the space by electric lights only with no daylight available.
[0072] The above is one possible way of programming the Minimum, Medium Low, Medium High and Maximum presets, but other values for these presets could be used.
[0073] Various preset or scene configurations are shown in FIGS. 3, 4 , and 5 . Each chart shows the electric light and daylight levels versus distance from the window. The dashed lines represent the level of the electric lights, which typically get higher farther from the window. The solid line represents the level of daylight coming in through the window at an instantaneous time in the day, which typically decreases with distance from the window. FIG. 3 is an example of a preset configuration for a flat lighting profile in which the Maximum Preset has all zones at maximum intensity (constant light level is desired across the space). The zones intensities for Medium High and Medium Low presets vary depending on distance from the window, so that zones farthest from the window have their lamps set brighter. FIGS. 4 and 5 show preset configurations, in which the presets have different graph shapes for different lighting profiles.
[0074] Average illumination contribution for each of the four presets must provide progressively higher overall illumination as detected by photosensors 140 installed in the space. Light level information from one or more photosensors 140 is processed by photosensor interface 130 , transmitted to central processor 100 , and compared to two thresholds. These thresholds correspond to:
1. The minimum of the acceptable range of illumination; and 2. Target value for the illumination; and 3. The maximum of the acceptable range of illumination.
[0078] A light level signal comparator for comparing the light level to the thresholds is preferably of a hysteretic type and can be implemented either as a digital or an analog component. Alternatively, the comparator function can be implemented as part of the central processor 100 . Preferably this comparator should be configurable so that a number of different lighting threshold groups can be selected based on a configuration input.
[0079] The resulting information will correspond to the following lighting conditions:
1. Illumination in the area is too dark (below minimum threshold); and 2. Illumination in the area is acceptable (above minimum and below maximum threshold); 3. Illumination in the area is too bright (above maximum threshold).
[0083] Based on this information, the central processor 100 controls one or more electric lighting zones to achieve the desired illumination profile. Further, as will be described in more detail below, the system preferably will control the window shading devices to prevent sun glare based on input from the photosensors 145 .
[0084] As discussed above, in the exemplary embodiment there are four presets, Minimum, Medium Low, Medium High and Maximum. The following paragraphs describe the steps taken to configure these four presets.
[0085] The calibration of the presets is performed with the control algorithms in the processor 100 disabled and the system is under manual control only. The Minimum Preset is configured by setting the electric light levels when a high level of daylight illumination is available dominantly exceeding the desired target illumination in the space. Lighting zone intensities for the zones closer to the windows are set to off for the Minimum Preset.
[0086] The Medium Low Preset is configured as follows: The central processor 100 is disabled and set to a manual control. With the electric lights off, the window treatment positions are selected such that the daylight illumination in the area around the middle of the room or under the second row of lights for deeper spaces is at the target level. Thereafter, the levels of all electric light zones are set such that the light level in the entire area is acceptable. This configuration is the Medium Low Preset.
[0087] To configure the Medium High Preset, the central processor 100 is disabled and set to manual control. Medium High Preset in conjunction with the Medium Low Preset defines a region of linear electric light response to daylight availability. This preset is adjusted such that a fixed increase of lighting intensity is added to all of the zone intensities as calibrated for the Medium Low Preset in such a way that no zone intensity exceeds the settings for the night time zone as calibrated in the next step. To simplify calibration the Maximum preset can be calibrated first.
[0088] The Maximum Preset is configured by first disabling the control system by setting it to manual control. If blackout window treatments are installed, the window treatments are closed fully, otherwise it is preferable to wait until evening when there is no daylight to set the maximum preset. The levels of all zones are set such that the light level of the entire area will be acceptable with no daylight through the window (nighttime level). This will define the Maximum Preset.
[0089] FIG. 6 shows a preferred implementation for the main loop process flow for a system according to the invention based on the closed loop control method for control of electric lights. The main loop will be substantially the same for a system that controls only the electric lamps as it will be for a system that controls both lamps and window treatments. FIGS. 7 a , 7 b and 7 c describe the process flow for a system controlling only the electric lamps. FIGS. 8 a , 8 b and 8 c describe the process flow for a system controlling both the electric lamps and the window treatment devices to achieve a desired illumination profile. FIGS. 9-14 explain the process flow for a system that seeks to reduce or eliminate sun glare. The various loops shown in FIGS. 6-8 c as well as FIGS. 10-12 run continuously or at regular intervals.
[0090] FIG. 6 shows the flow chart for the main control loop with the three conditions shown: too dark 500 , acceptable 510 , and too light 520 . If it is too dark ( 500 ), flow is into FIG. 7 a beginning at A. If the level is acceptable ( 510 ), the flow is to FIG. 7 b at B and if there is too much light ( 520 ), the flow is to FIG. 7 c at C. For each decision in FIG. 6 , the light level as sensed by photosensors 140 is compared to one of the two thresholds previously described.
[0091] FIG. 7 a shows the flowchart for the too dark condition ( 500 ). In more detail, the controller first checks at 630 to determine if the system is set at the Minimum Preset. If yes, the Medium Low Preset is selected at 640 . If not, a check is made to determine if the system is set to the Medium Low Preset ( 650 ). If yes, a check is made to determine if the electric lights are being faded ( 660 ), that is, still in the process of reaching the particular preset level. If yes, an exit is made back to the main loop ( FIG. 6 ). If fading (dimming level change) has been completed, the Medium High Preset is selected ( 670 ).
[0092] If the Medium Low Preset was not set at step 680 , the system checks for whether it is set to the Medium High Preset. Fading is checked at 690 , and if fading is completed, the Maximum Preset is selected at 700 .
[0093] If the system is not set at the Medium High Preset ( 680 ), a check is made to determine if it is at the Maximum Preset ( 710 ), still fading ( 720 ), done fading ( 730 ), and the Maximum Preset is selected at 740 and then an exit is made. If the system was not at Maximum Preset at step 710 , the Maximum Preset is set at 750 and an exit is made. Thus, if the Maximum Preset was determined to be the system status at step 710 , and if fading of the lighting at 720 , 730 to the Maximum Preset does not result in the desired illumination, the maximum preset is set at 740 . If the system status at step 710 was that the Maximum Preset (nor any of the other three presets) was selected, the system selects the maximum preset at step 750 . Thus, if selecting and fading to any of the four presets does not result in the desired illumination profile, the Maximum Preset is automatically selected at 750 , as this is the maximum artificial lighting illumination that can be achieved.
[0094] FIG. 7 b shows the flowchart for the acceptable lighting condition. As shown, if the illumination is in the acceptable range (as detected by each Photosensor 140 —the measurements of the photosensors 140 can be averaged or the thresholds for each photosensor can be different), the fading is stopped and delay times reset ( 760 ) and return is made to the main loop.
[0095] FIG. 7 c shows the flowchart for the too light condition.
[0096] At 830 , a determination is made if the system is at the Maximum Preset. If yes, the Medium High Preset is selected at 840 and an exit is made.
[0097] If the Maximum Preset was not set at 830 , a check is made to determine if the system has been set at the Medium High Preset at 850 . If so, a check is made to determine if the lights are still fading at 860 . If not, the Medium Low Preset is selected at 870 . If the lights are still fading, an exit is made. Once the Medium Low Preset is set, an exit is made.
[0098] If at step 850 the Medium High Preset was not set, a check is made to determine if the Medium Low Preset is set at 880 . If so, a check is made at 890 to determine if the lights are still fading. If yes, an exit is made. If not, the Minimum Preset is selected at 900 and an exit is made.
[0099] If at step 880 the Medium Low Preset was not set, a check is made at 910 to determine if the system is set to the Minimum Preset. If yes, a check is made at 920 to determine if the lights are still fading. If yes, an exit is made, if not a check is made at 930 to determine if fading is complete. If yes, an exit is made. If not the Minimum Preset is selected at 940 and an exit is made.
[0100] Finally, the Minimum Preset is selected at 950 if an acceptable lighting condition was not determined by the main loop ( FIG. 6 ) at any other point during the steps shown in FIG. 7 c.
[0101] Thus, the system operates by constantly operating in a main loop ( FIG. 6 ), leaving the main loop, depending on whether the lighting condition is too dark or too light ( FIGS. 7 a and 7 c ), constantly alternating between the main loop and the loops of FIGS. 7 a and 7 c while cycling through the loops of FIGS. 7 a and 7 c , and once an acceptable lighting condition is realized during the main loop at 510 , stopping fading at step 760 ( FIG. 7 b ). Should an acceptable lighting condition not be realized, the system defaults to the Minimum or Maximum preset, depending on whether the condition was too much light or too dark, respectively.
[0102] In order to compensate for the difference in the spectral sensitivity of the photosensors 140 for different types of light sources, the set point thresholds for the electric light control process flow are preferably varied. Due to the narrow frequency spectrum of the light produced by fluorescent lamps, even sensors designed with human eye corrected spectral sensitivity such as the Lutron MW-PS photosensors deliver a lower output signal for fluorescent lighting compared to that produced in the presence of equivalent daylight.
[0103] The set points for the electric light control process flow are adjusted based on the output control signal. Based on experimental measurements, the MW-PS photosensors feature around 30% lower sensitivity to fluorescent lighting compared to daylight. This difference does not present a problem in the usual open loop applications but must be corrected in closed loop applications. The sensitivity compensation is implemented such that the set point is proportionally scaled between 0% and −30% when the control signal for the electric lights near the windows changes from 100% to 0%.
[0104] One possible implementation of this set point formula is as follows:
[0105] Light Set point=Daytime Set point×(1−0.003×Window Lighting Zone Intensity in %). The constant 0.003 is derived from the known fact that the MW-PS Photosensor has 30% lower sensitivity to fluorescent lighting.
[0106] The set point can also be adjusted based on the time of day. Since the window treatments are automatically controlled, the overall variation of the daylight availability in the space during the day is significantly reduced. Therefore, the spectral sensitivity compensation will only effectively be required near sunset and sunrise and can be derived based on the sun angle for a given astronomic time clock reading. An astronomic time clock is contained within the central processor 100 .
[0107] One example of the alternative method of implementing the selection of the “too dark” and “too light” thresholds is to transmit the current time of day or the Window Lighting Zone Intensity from the central processor 100 to the photosensor interface 130 . The photosensor interface 130 can then make any appropriate adjustments to the set point, process the light level information from the photosensors 140 , compare the light level information to the set point, and transmit a signal to the central processor 100 corresponding to the current light condition, either “too dark” or “too light”. The central processor 100 can then act accordingly to either of these conditions.
[0108] The process flow for setting the electric light source levels has thus been described. A further process flow for controlling the window treatments in conjunction with the electric lights will now be described.
[0109] Turning to FIG. 8 a , it is substantially the same as FIG. 7 a , with the exception that an additional set of conditions is checked at steps 610 and 620 . In particular, at step 610 , a check is made to determine if the window treatments, for example, shades, are in the manual mode, that is overridden by manual control via wallstation 150 or window treatment controller 160 . If yes, the manually set position is not changed and the process goes to step 630 , previously described. The remainder of the process has already been described with reference to FIG. 7 a , and will not be repeated here. Thus, the system attempts to achieve the desired illumination profile leaving the window treatments as manually set.
[0110] If the shades are no longer in manual mode, the step 620 is performed and a check is made to determine if the shades are fully open. If yes, the process flows again to step 630 , and the system attempts to achieve the desired illumination profile so as to maximize daylight (the shades are left in the open position) and minimize electrical energy usage.
[0111] If the shades are not fully open, the system begins to open them at 625 , exits to the main loop and returns to the flow of FIG. 8 a as many cycles as necessary until the shades are fully opened, as determined at step 620 , in which case the process flow is to step 630 , where the electric lamps are then controlled.
[0112] FIG. 8 b is similar to FIG. 7 b , but shows that in a system controlling window treatments and lamps, when the lighting is acceptable, the adjustment of the window treatment is stopped ( 755 ), the fading of lights is stopped ( 760 ), and the shades are fully opened ( 770 , 775 ), maximizing the amount of daylight in the space and minimizing electric power usage. In another embodiment, it may be desirable, using a time clock, to either fully close or fully open the window treatments after dusk since there is no daylight and to address other concerns such as but not limited to privacy, aesthetic appearance of the building or nighttime light pollution.
[0113] FIG. 8 c corresponds to FIG. 7 c , except it shows the process flow for a system controlling lights and window treatments. Similarly to FIG. 8 a , a check is made to determine if the shades are in manual mode at 810 , fully closed at 820 (because there is too much light, as opposed to too much darkness) and begins closing the shades at 825 . The remainder of the flow chart is similar to FIG. 8 c and need not be discussed in detail again here.
[0114] There has thus been described a first system (FIGS. 6 to 7 c ) for controlling only the electric lights, based on whatever daylight is present, without adjusting window treatments and a second system controlling both lights and window treatments ( FIGS. 6, 8 a to 8 c ). A system to control only the window treatments, based on the flow of FIGS. 6, 8 a to 8 c , could also be provided. In such a system, the system would control the window treatments based on the available daylight.
[0115] Yet a further process flow of the preferred implementation describes an alternative control algorithm which, in addition to controlling diffused daylight illumination near windows, also controls the window treatments to minimize or eliminate sun glare based on the readings of photosensors 145 through photosensor interface 132 .
[0116] In order to prevent glare when the sun is at a low angle, for example, near sunset or sunrise, the system of the invention automatically controls the window treatments 170 to prevent glare. In an exemplary embodiment, for aesthetic reasons, the window treatments 170 are preferably controlled in such a way that only a set number of fixed stationary window treatment positions or presets is allowed. For example, the window treatments 170 may move between 4 to 5 fixed window treatment presets including fully opened and fully closed. The control is implemented in the form of closed loop control with a dead-band. This control is not, however, limited to a discrete control. The control could be continuous, as previously described, or it could have more or fewer than 4 to 5 window treatment presets.
[0117] The term “dead-band” is used to describe a range of photosensor 145 incident light level readings, which are considered by the system as acceptable and for which no action is performed other than to reset the window treatment delay timers. This will be described below.
[0118] The system will only change the window treatment settings when the incident light level on photosensors 145 is outside of the dead-band. In order to reduce the frequency of window treatment movements, all commands are delayed. Therefore, if the particular lighting condition is only temporary, no action will take place. However, glare control is a desirable capability of the system. Therefore, the system should respond quickly when a severe glare condition exists. Longer delays can be permitted when insufficient light is available because the electric lights in the space can compensate for the temporary low daylight availability.
[0119] In order to address the above variable timing, i.e., delaying window treatment changes for temporary conditions while responding to severe glare conditions quickly, the system employs a low sampling rate numerical integration of the light level error. When the incident light level seen by the photosensors 145 is out of the range defined as the dead-band, the difference between the upper or lower limit of the band and the actual light level is numerically accumulated. As shown in FIG. 9 , at 1000 and 1010 , the light level is checked to determine if it is higher than the upper limit or lower than the lower limit and thus outside of the dead-band. If it is within the dead-band ( 1015 ), a delay timer accumulator is reset ( 1017 ) and an exit made. If the light level is higher than the upper limit, control is to 1020 ; if it is lower than the lower limit, control is to 1220 . In either case, when the light level is outside the dead band, the actual light level is numerically accumulated as shown at 1040 and at 1240 . When the accumulated sum exceeds predefined limits, the window treatments are moved in order to bring the light level within the dead-band. The actual timing thresholds are different depending on the sign of the error. As mentioned above, the response time for the high illumination condition is shorter than the response time for the low illumination condition. Time delays are reduced in case of consistently low or consistently high sunlight illumination.
[0120] In more detail, if the light level is higher than the upper limit of the dead-band, at 1020 the previous light level is compared to the lower limit to determine if it was previously below the lower limit. In such case, the difference between the upper and lower limits is adjusted at 1030 to reset the lower limit. If the light level was not previously below the lower limit, or after the adjustment at 1030 , the difference between the light level and the upper limit is accumulated, thereby resulting in a delay ( 1040 ).
[0121] At 1050 , the previous light level is compared to the upper limit. If the previous light level was also above the upper limit, a shorter timing threshold 1060 is employed. This indicates a persistent high light level condition. If the previous light level was not above the upper limit, a longer timing threshold 1070 is employed. As stated above, the time delays are reduced in the case of consistently high sunlight illumination. At 1080 , the accumulated difference between the light level and the upper limit is checked to determine if it is greater than the current timing threshold set at 1060 or 1070 . When the accumulated difference exceeds the timing threshold, the shade is moved to the next more closed preset as indicated at 1090 . At 1100 , a flag is set to indicate that the previous light level was above the upper limit as determined at step 1050 , for the next cycle.
[0122] If the light level was lower than the lower limit as indicated at 1010 , a similar process flow 1220 , 1230 , 1240 , 1250 , 1260 , 1270 , 1280 , 1290 and 1300 is employed. However, in this process flow the accumulated difference is between the light level and the lower limit. Similarly, a shorter timing threshold is used if the previous light level was below the lower limit (consistently low sunlight illumination). As discussed above, the response time for consistently high or low illumination conditions is reduced. Time delays are reduced in the case of consistently low or consistently high sunlight illumination. This is indicated at 1060 for the consistently high sunlight condition and at 1260 for the consistently low sunlight condition.
[0123] In order to correctly address the glare control problem, the window treatment control process flow employs a variable control setpoint or threshold. When the sun angle is low, the sunlight intensity drops but the likelihood of a glare incident increases. This is because the sunrays become nearly horizontal and can easily directly penetrate deeply into interior spaces. Spaces with windows facing directly east or west are especially susceptible to this problem since they get a direct sun exposure at very low sun angles, at sunrise and sunset, respectively.
[0124] The reduction of sun intensity early and late in the day can be expressed as a sinusoidal function of the sun angle above horizon multiplied by the atmospheric attenuation factor.
[0125] As is well known to those experienced in the art, based on the fact that the sun is substantially a point source, the sun illumination is Ev=dF/dA=I*cos γ/r 2 .
[0000] Where:
[0000]
γ is the sun angle in respect to direction perpendicular to the surface;
I is luminous intensity;
r is distance from the source;
F is luminous flux;
A is area.
[0131] Based on simple trigonometry it can be determined that the sun illumination on a horizontal task surface is a sinusoidal function of the sun angle above the horizon. The atmospheric attenuation factor varies with pollution and moisture content of the air and these factors also affect the extent of perceived glare but can be neglected when determining how much the set point needs to be varied. Based on experiments, it can be concluded that variation of the control set point based on the sun angle alone produces satisfactory glare control performance. The central processor 100 features an astronomic time clock so the sunrise and sunset times are available. The window treatment process flow set point is therefore varied indirectly based on the astronomic time clock readings. In an average commercial building the correction is only required during a limited interval of time approximately three hours after sunrise and three hours before sunset. A set point correction factor based on the sinusoidal function of the predicted sun angle gives good practical results. The correction factor can also be implemented in a digital system based on a lookup table directly from the astronomic time clock reading.
[0132] For small sun angles, a linear approximation of the sinusoidal function can be applied, that is, since sin α˜α, where angle α measured between the earth's surface and the sun's inclination above the surface.
[0133] According to the invention, two alternative methods for calculation of set point correction to control interior illumination and glare are described below. The symbols used are:
LSCF=low sun angle correction factor; CTM=current time in minutes; TSSTM=today's sunset time in minutes; TSRTM=today's sunrise time in minutes; CI=predefined correction interval after sunrise and before sunset expressed in minutes (CI is typically 120-180 min depending on the window height and proximity of furniture to windows); NTSR=night time photosensor reading resulting from electric lights only; NTUT=night time upper threshold derived from night time sensor reading (value influenced by electric lighting only)—by default this can be set to 20% above the NTSR; NTLT=night time lower threshold—preferred value is 10% above NTSR to ensure that window treatments remain open after sunset. Lower values may be selected, for instance, to ensure that the window treatments remain closed after sunset for privacy; CUTHR=sun angle corrected upper threshold of the dead-band; CLTHR=sun angle corrected lower threshold of the dead-band set point; DTUT=upper threshold set point; DTLT=lower threshold set point; TARGET=target set point (preferably half way between LTHR and UTHR); PSR=actual photosensor reading; CPRS=corrected photosensor reading.
The following algorithm was successfully applied:
If (current time is within the predefined correction interval CI before sunset)
LSCF=(TSSTM−CTM)/CI
Else if (current time is within the predefined correction interval CI after sunrise)
LSCF=(CTM−TSRTM)/CI
Else
LSCF=1
CUTHR=(DTUT−NTUT)*LSCF+NTUT
CLTHR=(DTLT−NTLT)*LSCF+NTLT
[0149] Alternatively the sensor (Photosensor) gain can be changed based on astronomic time clock readings to achieve an effect equivalent to lowering the thresholds:
[0000] If (current time is within the correction interval before sunset)
LSCF=(TSSTM−CTM)/CI
Else if (current time is within the correction interval after sunrise)
LSCF=(CTM−TSRTM)/CI
Else
LSCF=1
CPSR=PSR*DTUT/((DTUT−NTUT)*LSCF+NTUT)
[0150] Based on the above, it can be seen that during the correction interval after sunrise and before sunset, a linear approximation of the sun correction factor is made by dividing the time difference (in minutes) between sunrise (or sunset) and the current time during the correction interval by the correction interval. This results in a good approximation of the correction factor. This is illustrated in FIG. 14 , which shows the two glare control intervals A (sunrise) and B (sunset). It can be seen that the target illumination is bounded by lines having slopes. The instantaneous value of these lines represents the correction factor at a particular time during the glare control intervals. Note that for the preferred embodiment, a correction interval of 180 minutes is used.
[0151] The default set point (before correction) is manually set during calibration based on the desired illumination in the space in front of the windows. Therefore the functions of illumination maintenance and glare control can be integrated in a single control algorithm. These variable target illumination values are preferably set such that they are, during the likely glare interval, below the sinusoidal curve representing the vertical daylight illumination variation on a clear day and above the sinusoidal curve representing the variation of vertical illumination on a cloudy day. This allows the algorithm to differentiate between the clear sky condition and the overcast condition.
[0152] Based on the astronomic timeclock, the system at night time automatically detects and updates the component of the photosensor 145 reading caused only by the electric lighting. This component is preferably further subtracted from the daytime reading of the light sensor to determine the component of the sensor signal caused only by daylight.
[0153] Two alternative ways to correct for the decrease of illumination with the sun angle which have essentially the same effect are thus described above. As discussed, since the incident illumination drops with the sun angle either the dead-band thresholds can be reduced for low sun angles above the horizon or alternatively the photosensor gain can be increased and the midday dead-band thresholds maintained throughout the day.
[0154] FIGS. 10 and 11 show the process flow for the above sun angle correction algorithms. FIG. 10 shows one embodiment and FIG. 11 shows the above described alternative embodiment. Turning to FIG. 10 , this figure shows how the system varies the dead-band set point or threshold in order to reduce glare, as described above. If the current time, as determined by the astronomical time clock is either within the correction interval before sunset ( 1300 ) or after sunrise ( 1310 ), the low sun correction function is adjusted at 1320 , 1330 . If the time is not within the correction interval, the correction factor is set at 1 ( 1340 ). At 1350 the dead-band thresholds are corrected by the correction factor. The light levels are then processed based on the new dead-band thresholds.
[0155] FIG. 11 shows the alternative embodiment where the photosensor gain is increased. It is identical to the flow of FIG. 10 , except step 1352 is substituted for step 1350 of FIG. 11 . At step 1352 , the photosensor light reading value is divided by the correction factor to increase the photosensor value and the light reading, as corrected, is processed. Accordingly, in FIG. 10 , the dead-band thresholds are adjusted and in FIG. 11 , the photosensor readings are adjusted (by increasing them).
[0156] Since the window treatments must also be able to be controlled manually, the system must be able to account for manual overrides, i.e., when a user manually adjusts the window treatment. A manual override introduces a serious problem in a closed loop window treatment control system. Once the manual control command is executed, the interior illumination may exceed the range defined by the dead-band of the control process flow and the system would automatically cancel the override. This obviously is undesirable. To address this problem, the process flow readjusts the control set point after an override. Once the window treatments have stopped moving after a manual override, the process flow temporarily adjusts the control set point to match the currently measured interior light level. The newly established light level is also preferably copied into another variable used to establish the long term preferences of the occupants. During the low sun angle correction interval, previously described, the temporary override set point thresholds are corrected in exactly the same way as in the case where no manual override has been applied.
[0157] The temporary control set point can be canceled either based on the daylight exceeding the bounds of the predefined dead-band established by the temporary set point or based on a predefined time delay after an override or both. Once the override is canceled, the control system reverts to the default set point.
[0158] The system can optionally adjust the default set point based on repeated occupant input. As stated above, each time an occupant performs a manual override, the newly established light level when the window treatments stop moving is further processed. The processing can be based on averaging the override light level either continuously or based on the time of day for instance only during the time interval when the sun glare is likely to occur. Once the long term average tendency is identified, the system can make an adjustment of the default control set point to the usual or most likely user override.
[0159] FIG. 12 shows the process flow in the event of an override. At 1400 the system checks to determine if a manual override is currently applied. If so, at 1410 the system determines whether the shades are still moving as a consequence of the override. If yes, the system exits to return to the main loop. Once the shades stop moving, the system stores the current light level as a target set point for the control process at step 1420 . At 1430 , the system averages the override target level over time in order to change the default set point based on occupant input and at 1440 sets the flag to indicate that the setpoint has been manually overridden.
[0160] If a manual override is not currently applied, as determined at 1400 , the system checks at 1450 to determine if it is operating with a modified setpoint due to a previous manual override. If yes, the system checks at 1460 to determine if the modified upper or lower limit has been exceeded. If no, the system exits to the main loop. If yes, at 1470 the system determines if it is consistently overridden through a similar override set point. If yes, the system at 1480 modifies the default target light level toward the consistently used override level. If the system is not consistently overridden or after the modification at step 1480 , the system reverts at 1490 to the default setpoint for the target light level, clears the manual override flag and exits to the main loop.
[0161] FIGS. 13 a and 13 b shows the relationship between the sun angle and the direct sun penetration into the space. FIG. 13 a shows how at low sun angles the direct sun rays penetrate deeper into the space and affect the task surface basically representing a glare condition. FIG. 13 b shows the absence of direct incident sun rays on the task surface associated with larger sun angles.
[0162] FIG. 14 graphically shows the daylight illumination variation of the vertical daylight illumination throughout a day for two conditions (clear and overcast), the variation of target illumination and the time intervals A and B when glare control is needed and where the target illumination is corrected to account for the reduction of illumination caused by the sun angle above the horizon.
[0163] Accordingly, the system described provides for the maintenance of optimal light levels in a space based upon optimal use of both daylight and artificial lighting provided by electric lamps. In addition, the system preferably automatically detects and reduces sun glare when sun glare presents a problem.
[0164] Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. Therefore, the present invention should be limited not by the specific disclosure herein, but only by the appended claims.
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An illumination maintenance system for maintaining a desired illumination profile in a space throughout at least a portion of a day, the space being illuminable by both daylight and electric light, the system comprising a sensor for sensing an illumination level in at least a portion of the space; a plurality of dimmable electric lamps providing the electric light to supplement the daylight illumination of the space, the electric lamps arranged in one or more zones in the space, the zones defining predefined volumes of the space, each zone having at least one lamp; a control system controlling the dimming levels of the plurality of electric lamps, the at least one lamp of each zone being controlled to a dimming level to achieve a desired illumination level in the respective zone according to the desired illumination profile and compensate for the daylight illumination in the space throughout at least the portion of the day; wherein the dimming level of each lamp is selected by the control system from one of a plurality of lighting presets, each lighting preset comprising a combination of dimming levels of the lamps, and wherein the control system adjusts the dimming level of the electric lamps toward a preset that will result in an appropriate supplementing of the daylight illumination to achieve the desired illumination profile in the space.
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