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BACKGROUND OF THE INVENTION
The invention relates generally to the field of devices used for secondary containment of hazardous liquid spills from primary containers such as barrels, drums, tanks, tanker vehicles, tanker trailers, railroad tanker cars, or drums or other primary containers stored on or supported by the pallets, the secondary containment devices having a reservoir or sump area to retain liquid and prevent its loss into the environment. More particularly, the invention relates to such secondary containment devices which have a reservoir with expandable capacity, and even more particularly, to such devices where the expandable reservoir reacts automatically to contain large volume liquid spills.
Hazardous liquid materials are stored in primary container means such as large drums or barrels of 30, 55 or 83 gallon capacity, large rectangular containers known as intermediate bulk containers (IBC) with capacities in the range of 120 to 600 gallons, large capacity storage tanks, tanker vehicles, tanker trailers or tanker railroad cars. Often one or more drums or containers will be placed onto a pallet for easy movement by a forklift or hand truck apparatus. Because there is a high likelihood of leakage or spillage of the liquid, secondary containment reservoir devices or pallets have been developed which retain any liquid spillage in a large volume sump area. For secondary containment pallets, regulations promulgated by the Environmental Protection Agency require the sump area to retain 100% of the volume of the single largest storage drum to be supported on the pallet, while the Uniform Fire Code requires a minimum sump area volume of 66 gallons. The containment devices generally consist of four vertical walls and a solid bottom, with some sort of support means to elevate the drums, tanks, vehicles, etc., above the sump area. This support means usually takes the form of raised ridges or column members extending upward from the bottom of the sump area, means to support a separate perforated deck or platform above the sump area, either with centrally located support columns or a peripheral support shoulder incorporated on the inside of the walls, or provisions to allow the vehicle or trailer wheels to pass into the sump area. An example of a secondary containment pallet of the type discussed above is shown in U.S. Pat. No. 4,930,632 to Eckert et al.
For circumstances where pallets are used, because the storage drums or intermediate bulk containers can be very heavy when filled and because the drums are often stored in multiples of two or four drums on a single pallet, it is difficult to design a containment pallet with sufficient strength which has the necessary sump capacity, especially when taking into consideration that the optimum design will have low side walls and a low deck height to make loading and unloading the drums safer and easier. To maximize the volume of the sump area it is also desirable to reduce the number of internal support members for the deck, meaning that a peripheral support for the deck is the preferred construction. In those containment pallets having a deck supported on a peripheral shoulder or lip located near the top of the side walls however, the compressive forces push against the side walls, causing them to bow or flex outward and eventually leading to failure of the pallet wall structure. This deflection problem was addressed in U.S. Pat. No. 5,359,955 to Grebenyuk by providing internal supports which extend from the midpoint of each side wall, creating a T-shape in horizontal cross-section. The supports extended from the bottom of the sump area to the top, the supports creating a surface onto which the deck is placed. The problem with this solution is that the supports themselves occupy a large area of the sump area, which means that the side wall height must be increased to compensate for this lost containment volume. In circumstances with large volume containers, such as tanks, tanker vehicles, tanker trailers and railroad tanker cars, the extremely large volume of liquid stored in the primary containers is so great that providing a secondary containment device with a large enough reservoir which is still accessible by the vehicles yet does not occupy a large volume of space has likewise caused difficulty.
It is an object of this invention to provide a large volume secondary containment reservoir device which has a relatively small profile or configuration, such that the device does not occupy a large space, and which includes an expandable reservoir or sump area automatically responsive to large volume liquid spills, the device being applicable for use with all types of primary containers, including but not limited to drums, barrels, IBC's, tanks, tanker vehicles, tanker trailers and railroad tanker cars. It is a further object of this invention to solve the problem of providing a large volume reservoir or sump area integral with a containment pallet without significantly increasing the overall dimensions of the pallet, thereby providing the necessary strength for support of the drums or intermediate bulk containers without recourse to extensive heightening of the side walls. It is an object to provide such a pallet which is responsive to a large volume spill with an expandable reservoir, such that the reservoir maintains a low volume configuration until needed to retain the liquid. It is a further object to provide such a pallet where the space occupied by the pallet is minimal until expansion of the reservoir. It is a further object to provide such a pallet where the expandable reservoir comprises a non-rigid bladder maintained in a coiled configuration, the bladder being self-opening in response to pressure from the liquid spill.
SUMMARY OF THE INVENTION
The invention comprises in general a secondary containment reservoir device having a bottom, four side walls, means to support or position one or more primary containers of liquid above the sump area formed by the bottom and side walls, and expandable retention means, such as a bladder, automatically expandable in response to a large volume liquid spill to increase the total effective containment volume of the reservoir. In one particular embodiment the bottom and four side walls are themselves adapted as a pallet to allow insertion of a fork lift or hand truck for movement of the pallet and jointly form a reservoir to retain liquid, with the device further comprising support means to support primary liquid containers, such as drums, barrels or intermediate bulk containers, whereby the support means allows liquid to pass into the reservoir area, and where the expandable reservoir or bladder means has an inlet port connected to the reservoir, whereby liquid in the reservoir can flow into the interior of the bladder. The bladder is connected to the reservoir device or pallet in such manner that it is stored in a low volume configuration, it being coiled, rolled or folded, such that it expands to a large volume configuration by uncoiling, unrolling or unfolding when liquid begins to enter the inlet port of the bladder, the pressure of the liquid providing the necessary force to reposition the bladder. The bladder is preferably constructed of a non-rigid, relatively unstructured, liquid-impermeable material such as a rubber, coated fabric or polymer. The bladder may be attached to the exterior of the device or may be incorporated internally with expansion through a slot or door member. The bladder may incorporate a drain or sealed outlet, and may comprise multiple layers of material to increase strength or tear-resistance. Plural bladders may be connected to a single reservoir device or pallet such that the same total expandable volume for liquid retention is obtained through the combination of smaller individual bladders.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the general embodiment of the invention showing placement beneath a tanker trailer.
FIG. 2 is a perspective view illustrating the pallet embodiment with part of the support deck removed to expose the reservoir and showing the bladder in the expanded configuration.
FIG. 3 is a cross-sectional side view of the pallet embodiment.
FIG. 4 is an exposed perspective view of an alternative pallet embodiment of the invention.
FIG. 5 is a perspective view of another alternative pallet embodiment illustrating plural bladders attacked to the exterior of the pallet side walls.
FIG. 6 is a perspective view of another alternative embodiment showing the invention incorporated into an intermediate bulk container.
DETAILED DESCRIPTION OF THE INVENTION
With reference now to the drawings, the invention will be described with regard to the best mode and preferred embodiment. The invention is a secondary containment reservoir 10 generally comprising a bottom 18 joined with four upstanding side walls 11 to form an open-topped reservoir or sump area 13. In the pallet embodiment 20, the device further comprises an apertured or slotted support grate or deck 12 positioned above the reservoir 13 and typically resting on the side walls 11 and/or support members extending from the bottom 18 for supporting drums, barrels, intermediate bulk containers or other liquid containers. The reservoir 13 retains liquid leaked or spilled from the primary containers, thus preventing contamination of the environment in the case of hazardous waste storage.
Communicating with the reservoir 13 is a retention member 21, which can be generally referred to as a bladder, such that liquid within the reservoir 13 can enter the interior of the bladder 21 through an inlet port 22. Bladder 21 is comprised of any generally non-rigid, non-structured, liquid-impermeable material which allows bladder 21 to be folded, coiled, rolled or otherwise disposed into a low volume configuration. For example, suitable materials for the construction of bladder 21 may be coated fabric, rubber or polymers. Preferably the material for bladder 21 is also chemical, tear and abrasion resistant. Bladder 21 may be composed of a single thin layer of material or may be composed of multiple layers, and may be further reinforced along seams or the like to further protect the integrity of the bladder 21 against leakage or rupture. A sealed drain 31 may be added to the bladder 21 to provide for easy removal of the liquid from the bladder 21. The bladder 21 may be constructed to have lateral flaps or pleats to provide for greater expansion.
Referring now to FIG. 1, a secondary containment reservoir 10 in the nature of the invention is shown positioned under a large tanker trailer 99 with a leak which shows the bladder 21 in the expanded or filled state. The bladder 21 communicates with the reservoir 13 formed by the combination of the four side walls 11 and the bottom 18, such that when the fluid level in the reservoir 13 reaches the level of inlet port 22, the liquid then expands and fills bladder 21. In this manner the total liquid containment volume of the secondary containment reservoir device 10 can be greatly increased beyond the limited capacity of the reservoir 13 alone. When not required to retain a liquid spill, the bladder 21 is preferably rolled or coiled into a small configuration so as not to interfere with other operations in the area. Raised support ramps or pathways 91 elevate the tanker trailer 99 above the reservoir 13. In other embodiments, the support pathways 91 can incorporate railroad tracks for movement of railcars across the reservoir device 10.
Referring now to FIG. 2 and subsequent FIGS. 3 through 5, the embodiment of the device as a secondary containment pallet 20 is shown, the pallet 20 likewise comprising in general four side walls 11 and a bottom 18 forming the reservoir 13. The expandable retention means or bladder 21 communicates with the reservoir 13. The support deck 12, shown partially removed, supports the liquid containers (not shown). Liquid flowing through or around the edge of the support deck 12 is retained in the reservoir 13. When the volume of that liquid reaches a critical amount, the pressure within the inlet port 22 of the bladder 21 causes it to expand out through a slot 17 or hinged door 15 in one of the side walls 11. The door 15 may be attached to the pallet 10 by simple pivoting means 16, as shown in the figure. The bladder 21 when unrolled creates a large volume storage area of sufficient size to retain most or all the liquid contained above the device 20, thereby significantly increasing the storage capacity of the pallet 20 when necessary. This allows the pallet 20 to be constructed with a relatively small reservoir 13 and low side walls 11, which obviates the need for specialized designs to increase wall strength as is required for pallets with taller walls and which allows easier loading and unloading of primary containers onto the pallet 20. The pallet 20 may be constructed such that the bottom 18 includes fork lift insertion members 27, apertures adapted to receive the tines of a fork lift or hand truck, such that the entire unit can be easily transported.
As seen in FIGS. 3 and 4, the bladder 21 occupies a very small volume when in the non-expanded state. Preferably, the bladder 21 is rolled or coiled such that the pressure from liquid in the reservoir 13 will push against the roll or coil, propelling the bulk of the bladder 21 out from the pallet side wall 11 where there is ample space to allow for its expansion. As shown in FIG. 3, one embodiment provides for the bladder 21 to be constructed to allow it to encompass the entire reservoir 13, with its edge being attached to the side walls 11 by fastening means 25, such as mechanical fasteners, metallic or elastic bands, or other suitable means. In this embodiment the inlet port 22 envelops the support deck 12, such that any liquid spill immediately enters the interior of the bladder 21. An alternative embodiment is shown in FIG. 4, in which the inlet port 22 of the bladder 21 is connected to a reservoir outlet 14 by suitable fastening means 25. Here the initial liquid spill fills the reservoir 13 of the pallet 20. Once a large volume begins to collect, the surface of the liquid in the reservoir 13 reaches the reservoir outlet 14 and begins to fill the bladder 21. As before, when there is sufficient liquid volume to create sufficient pressure, the bladder 21 uncoils and expands out of the side wall 11, in this instance through a slot 17 with no covering. The location and size of the reservoir outlet 14 can be varied to control how quickly the bladder 21 will be expanded.
As shown in FIGS. 3 and 4, it is preferred to restrict the vertical movement of the bladder 21 in the coiled state by provision of restriction means 24, which is shown as a generally horizontally disposed plate. As the liquid begins to fill the bladder 21, the bladder 21 initially tends to move in the vertical direction rather than outward. By placing restriction means 24 above the coiled bladder 21, the only direction of free expansion for the bladder 21 is out through the door 15 or slot 17. Restriction means 24 can be a separate component attached to the pallet 20 or it may be an integrally designed component of the pallet 20 itself, comprising for example part of the shoulder to support the support deck 12. Additionally, the preferred embodiment provides for a barrier means 26, shown in FIG. 4 as a ridge member having a sloped or curved surface directed toward the bladder 21, which further channels the pressure from the liquid into the bladder 21 such that the bladder 21 is easily uncoiled.
Still another alternative embodiment for the invention is shown in FIG. 5, in which multiple bladders 21 are contained in external bladder housings 23 with doors 15. The provision of multiple bladders 21, whether housed externally or internally relative to the reservoir 13 and pallet side walls 11, and whether provided with doors 15, slots 17 or simply mounted externally with no housings 23, allows for the use of individual bladders 21 with smaller overall volume when expanded--the total volume of all the bladders 21 equalling or even surpassing that of a large single bladder 21. This construction is useful where there are impediments to the complete expansion of a large bladder 21, such as in situations with relatively limited floor space. When multiple bladders 21 of large capacity are provided, such that the overall capacity of the reservoir 13 and multiple bladders 21 far exceed the projected maximum required volume, the bladders 21 act as a fail-safe mechanism which provides adequate containment volume in the event that one or more of the individual bladders is impeded from opening fully. While shown in FIG. 5 on the pallet 20 embodiment, it is contemplated that multiple bladders 21 can be provided on the basic general device 10 or any of the alternative embodiments.
Still another alternate embodiment is shown in FIG. 6, in which the expandable retention means 21 is incorporated directly into an intermediate bulk container (IBC) 30. An IBC 30 comprises a rigid outer framework 32 with a platform 33 to support a primary liquid container 34. The bladder 21 is integrated into the bottom of the IBC 30 in any of the manners described above which allows for expansion in the event of leakage or rupture of the non-rigid primary liquid container 34.
It is contemplated that equivalents and substitutions to the above may be obvious to those skilled in the art, and the true scope and definition of the invention therefore is to be as set forth in the following claims.
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A secondary containment reservoir device having a bottom and side walls forming a reservoir, and communicating with the reservoir an expandable retention bladder which automatically expands to receive liquid from the reservoir, allowing the total capacity of the device to greatly exceed the capacity of the reservoir alone. The device can be adapted to receive or support any type of primary liquid container above the reservoir, including drums, barrels, tanks, IBC's, tanker vehicles, tanker trailers or railroad tankers. In one embodiment, the reservoir is formed within a pallet having a support deck to receive drums or barrels of liquid. A single bladder or multiple bladders may be used, and the bladders may be mounted internally or externally.
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The present patent application is a national stage application under 35 U.S.C. 371 of PCT/US2009/003486, filed Jun. 10, 2009, and claims the priority of U.S. Patent Application No. 61/060,196 which was filed on Jun. 10, 2008 and which is hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention describes a novel process for the conformal coating of polymer fibers on nonwoven substrates. Specifically, the process is based on the modification of polymer fiber surfaces by controlling the degree of etching and oxidation, which improves adhesion of initiators to the surface and facilitates subsequent conformal polymer grafting. The invention further includes the nonwoven substrates produced by this process.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 5,871,823 [Anders, Hoecker, Klee, and Lorenz] [1] reports using UV light in the wavelength range of 125-310 nm to activate polymer surfaces in the presence of oxygen with a partial pressure of 2×10 −5 to 2×10 −2 bar. The activated surface is subsequently grafted. However, this patent is limited to the use of surface hydroperoxides obtained from UV activation to initialize grafting.
U.S. Pat. No. 5,629,084 (Moya, Wilson) [4] discloses a composite porous membrane formed from a porous polymeric substrate and a second polymer which has been cross-linked by heat and UV. The modification of the second polymer is over the entire surface, which is attained by placing a membrane in contact with a second polymer solution and initiator and exposing everything to UV or mild heat in order to crosslink a second polymer on the substrate surface. This scheme can be categorized as a “grafting to” technique where the adsorption of a second polymer to the fiber surface is the critical step.
UV-initialized grafting is generally performed by exposing the substrate to UV light in monomer solutions. It can take place in the range 100-450 nm for a variety of molecules. U.S. Pat. No. 5,871,823 [Anders, Hoecker, Klee, and Lorenz] [1] reported using a preferred UV wavelength in the range 290-320 nm. PCT/WO/02/28947 A1 [Belfort, Crivello and Pieracci] [5] reported using UV wavelengths in the range 280-300 nm. These inventions do not refer to the use of a photosensitizer in the grafting process.
In addition, U.S. Pat. No. 5,468,390 [Crivello, Belfort, Yamagishi] [6] discloses a process to modify polysulfone porous membranes without photosensitizers. As a result, only the outer surface of the membranes described in this reference was modified through the treatment. The polysulfone membranes cannot be rewetted after drying.
U.S. Pat. No. 5,883,150 [Charkaudian] [7] reports that implanting a photosensitizer into the backbone of the polysulfone membrane results in better wetting properties. Nonetheless, it is difficult for most of these implanted photosensitizers to survive the high temperature conditions that are generally used for polymer processing. For example, fiber or nonwoven production with melt-blowing processes requires temperatures above 120° C.
In summary, while surface modification methods such as those described above may generate some coatings on the fiber surface of fiber nonwoven webs or mats, a conformal coating cannot be assured by these methods because they do not provide the necessary means either to overcome possible differences between the surface energies of the substrate and second polymers, or to generate a surface with a high density initiator.
It is, therefore, desired to have a surface modification method which can warrant conformal coating for a wide range of polymer fibers. It is also desired that this method be robust and easy to scale-up. The present invention seeks to meet these and related needs.
SUMMARY OF THE INVENTION
This invention describes a procedure to modify polymer fibers or fiber nonwoven webs or mats to achieve a conformal coating of a different second polymer on the fiber surface by grafting. Conformal coating refers to a coating that conforms to the curvature of the cylindrical or irregular shapes of fibers, thus achieving full coverage of the fibers by a uniform thickness of the grafted polymer. Conformal coatings are required for nonwoven system applications that necessitate complete control of surface properties, such as diagnostics, separations and other applications where the mats are to be exposed to complex mixtures.
The aim of the present invention is to modify polymer fiber surfaces by controlling the degree of etching and oxidization, which significantly improves the adhesion of initiators to the surface, and thus facilitates the subsequent conformal polymer grafting. The modified fiber surfaces render new functionalities to the surface such as increasing hydrophilicity, attaching ligands, or changing surface energy.
The present invention provides an alternative way to use UV activation to initialize grafting from that described in the prior art. While the current invention relies on the utilization of UV as a method to pretreat polymer substrates, it depends on a different effect of UV irradiation. It is well known that UV at certain wavelengths in combination with ozone can etch and oxidize polymer surfaces, leading to higher surface roughness and concentrations of hydroxyl and carbonyl groups [2, 3]. The present invention capitalizes on this effect in order to obtain an enhanced adsorption of initiators and a better contact between the polymer fiber surface and monomer from the solution to achieve a conformal coating. Advantageously, the invention does not rely on hydroperoxide for subsequent grafting. An external supply of ozone is not necessary, as ozone can be generated in air by UV at the same range of wavelength used for etching.
Rather than using a “grafting to” method as are known in the art, the present invention is a “grafting from” method, by which polymer grafts are grown from the substrate surface in a monomer and initiator solution. As the examples will show, without proper pre-treatment, it is impossible to get conformal grafting on certain types of polymer fibers, such as those of polyolefins. This is due to the mismatch of surface energies between the substrate polymer and the second polymer.
In further contrast to what is taught by the prior art, it has been found that in order to achieve a high density conformal coverage on polyolefin fibers, the presence of a photosensitizer or thermally decomposable initiators is/are indispensable, because the invention focuses on polymer nonwovens which are not photoactive. Moreover, it has been observed that peroxide compounds and radicals generated from the pre-treatment step are far less from sufficient to achieve a conformal coating. Therefore, a combination of a photosensitizer and a monomer is necessary for this purpose. However, contrary to the prior art, the photosensitizer is applied only in the monomer solvent at room temperature, which prevents it from decomposing.
Other objects, advantages and features of the present invention will become apparent upon reading of the following non-restrictive description of embodiments thereof, given by way of example only with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 —Polypropylene (PP) nonwoven fibers before and after grafting: A) Original PP nonwoven fibers; B) Surface of an original single PP nonwoven fiber; C) Grafted PP nonwoven before washing; D) Surface of a grafted single PP nonwoven fiber before washing; E) Grafted nonwoven after washing: and F) Surface of a grafted single PP nonwoven fiber after washing.
FIG. 2 —Cross sections of PP nonwoven fibers before and after grafting: A) Original PP nonwoven fibers; B) Cross section of an original single PP nonwoven fiber; C) Grafted PP nonwoven fibers; and D) Cross section of a grafted single PP nonwoven fiber.
FIG. 3 —FTIR of original PP, UV pre-treated PP, pure polyglycidyl methacrylate (PGMA) and PGMA-grafted PP.
FIG. 4 —PP nonwoven grafted at I:M=1:5: A) Grafted PP nonwoven fibers; B) surface of a grafted single PP nonwoven fiber; C) Cross section of PP nonwoven fibers; and D) Cross section of a grafted single PP nonwoven fiber.
FIG. 5 —SEM images of PGMA grafted PP fibers after 0-30 minutes of UV/O treatments: A) Zero (0) minutes; B) Five (5) minutes; C) Fifteen (15) minutes; and D) Thirty (30) minutes.
FIG. 6 —SEM Images of PGMA grafted PP nonwoven webs after 0, 15 and 30 minutes pre-treatment and the same 30 minutes grafting: A) Zero (0) minutes; B) Fifteen (15) minutes; and C) Thirty (30) minutes.
FIG. 7 —Relative benzophenone (BP) absorption as a function of UV pre-treatment time measured at different immersion times.
FIG. 8 —Comparison of grafting efficiencies: A) Grafting efficiency as a function of grafting time for samples at different pre-treatment times; and B) Grafting efficiency as a function of BP adsorption at different grafting times.
FIG. 9 —Influence of monomer and initiator concentration on grafting efficiency.
FIG. 10 —Nylon nonwoven fiber before and after grafting: A) A single original nylon nonwoven fiber; B) Surface of an original nylon nonwoven fiber; C) A single grafted nylon nonwoven fiber; and D) Surface of a grafted nylon nonwoven fiber.
FIG. 11 —Grafting on PBT nonwoven web with and without pre-treatment: A) Original PBT nonwoven; B) Grafted PBT nonwoven with pre-treatment; and C) Grafted PBT nonwoven without pre-treatment.
FIG. 12 —Difference in grafting effect between soaking substrate in BP and pre-treatment with UV/O: A) Soaking with BP; and B) UV ozone pre-treatment.
FIG. 13 —Transmittances of UV light through the dry PP nonwoven stack and PP nonwoven stack soaked with monomer solution.
FIG. 14 —Transmittances of UV light through PP nonwovens of different pore sizes.
FIG. 15 —Variation of grafting efficiency depending on the pre-treatment as a function of positions inside the nonwoven.
FIG. 16 —Variation of grafting efficiency depending on grafting as a function of position inside the nonwoven.
DETAILED DESCRIPTION OF THE INVENTION
This invention concerns a process to modify polyolefin (polypropylene) fibers or their nonwoven webs or mats to achieve a conformal coating of a different second polymer on the fiber surface by grafting. The process can also be applied to other polymer fibers, such as, without limitation, cellulose (cotton), polyamide (nylon), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), poly (phenol formaldehyde) (PF), polyvinylalcohol (PVOH), polyvinylchloride (PVC), aromatic polyamid (Twaron, Kevlar and Nomex), polyacrylonitrile (PAN), and polyurethane (PU), among others. The process depends on high density surface grafting polymerization of the second polymer on the fiber substrate. A conformal coating of second polymer on the fiber surface can always be warranted this way because the coverage of the graft on the fiber surface is high and chemical bonds formed between the graft and substrate create a huge energy barrier to prevent coating separation from happening.
The process starts with exposing fibers or their nonwoven web to UV irradiation in the range between 150 to 300 nm in air. During the exposure, ozone is simultaneously generated as a result of O 2 exposure to UV light. The objective behind the use of UV irradiation plus ozone treatment in this invention is not to generate radicals or peroxides on the fiber surface. Instead, the goal is to etch the surface to increase its roughness, and simultaneously to increase the concentration of hydroxyl and other oxygen-containing compounds [2, 3]. The combined effect significantly increases the adsorption of initiators in the subsequent grafting step. (See Example 5.)
Polymer fibers may have a smooth or glazed surface, which is the consequence of the fiber production conditions, as the polymer melts or solution passes through a fine nozzle at very high speed. A glazed surface prevents other molecules from attaching to the surface. On the other hand, a rough surface can increase the adsorption of other molecules, such as initiators, to the surface [8-10]. Initiators are molecules that can produce free radicals under mild conditions and initialize radical polymerization reactions. The interactions between polar groups such as hydroxyl and other oxygen containing compounds, and initiators, can further help stabilizing the adsorption [11]. UV irradiation plus ozone is very effective in etching only a very thin layer of the fiber surface to increase its roughness and simultaneously generating hydroxyl and carbonyl groups. Other approaches, such as plasma treatment, peroxide oxidation, base and acid or any method which can increase surface roughness and render oxidization, can also be used for this purpose.
Some polymers are made from monomers which already containing polar groups, such as amines, carbonyls and hydroxyls etc. Initiators may adsorb to these surfaces to such an extent that a conformal coating can be obtained even without pre-treatment. However, for polymer containing only hydrocarbons, e.g. polyolefins, pre-treatment is indispensable for a conformal coating.
After pre-treatment, the functional monomers can be grafted to the surface by free radical polymerization. This process can use UV-initialized radical polymerization or thermally-initialized radical polymerization. Photosensitizers and thermally decomposable initiators should be used in the respective processes. Photosensitizers include benzophenone, anthraquinone, naphthoquinone or any compound involving hydrogen abstraction for initialization. Thermally decomposable initiators include azo compounds or peroxide compounds. The monomer concentration is in the range of 1 to 20%. The initiator concentration is in the range of 0.5 to 7%. Alcohols and hydrocarbons can be used as solvents. The grafting is carried out between approximately 1 and 120 minutes.
Depending on the expected functionalities, a variety of acrylate monomers can be selected for grafting, for example, 2-hydroxylethyl methacrylate, acrylamide, acrylic acid, acrylonitrile, methyl methacrylate, glycidyl methacrylate and similar acrylate derivatives. In addition, any monomer which can be polymerized by radical polymerization can be used for grafting.
A continuous UV irradiation of 300-450 nm is required for UV-initialized grafting. A pre-treated substrate pre-soaked with the solution of monomer and photosensitizer is inserted between two thin glass plates (or a confined geometry) and exposed to UV for a determined amount of time. Confined geometry, forming a saturated vapor phase near the surface of the substrate, has the advantage of preventing fast loss of solvent. The confined geometry also minimizes the grafting solution and allows for the absence of degassing and inert gas protection. Before use, the glass plates may be pre-treated with mold release agents, for example Frekote®.
The grafting can be performed at room temperature or at an elevated temperature, but far below the boiling temperature of monomer solution. Cooling is necessary when solvent evaporates too fast.
An elevated temperature is required for thermally-initialized grafting, where initiators can decompose efficiently. Same confined geometries can also be used.
After grafting, the substrates are washed with appropriate solvents to extract unreacted monomers and unattached homopolymers. Water is a good solvent for monomers and homopolymers which are aqueous soluble. Otherwise, extraction can be done by alcohols, hydrocarbons, or with any other suitable solvent.
In one embodiment, the polymer nonwoven substrate is a flat sheet, a roll or a stack. In another embodiment, the polymer nonwoven substrate is a staple or continuous fiber. For the latter embodiment, the polymer nonwoven substrate has round, triangle, square, or any irregular shapes of cross-sections.
EXAMPLE 1
A specimen of polypropylene (PP) nonwoven 250 μm thick and of dimensions 2×4 cm was exposed to UV irradiation of 150 to 300 nm (UV/O) and intensity 50 mw/cm 2 for 15 minutes. The substrate was then soaked with 20% glycidyl methacrylate and benzophenone (Initiator:Monomer or I:M=1:25) in butanol solution. The substrate was sandwiched between two glass slides coated with Frekote®, and then exposed to UV of 300 to 450 nm and intensity 5 mw/cm 2 for 15 minutes for grafting. The grafted nonwoven substrate was then washed by sonication in THF and methanol to remove unreacted and unattached compounds.
FIGS. 1A ) and B) show the original PP nonwoven web and fiber. The surface of the original PP fiber is covered with cracks as a result of melt-blown process. FIGS. 1C ) and D) show the nonwoven web and fiber after grafting, but before washing. Very smooth coatings are formed on the fibers. However, these coatings are not permanent. FIGS. 1E ) and F) show the nonwoven web and fiber after washing. A high density coarse polyglycidyl methacrylate (PGMA) coating is covalently attached to the fiber surface. The porous structure of the web has not been changed.
FIGS. 2A ) and B) show the cross-sections of the original PP nonwoven web and fiber. FIGS. 2C ) and D) show the cross-sections after grafting. As it may be seen, the grafting is very conformal to the cylindrical and even irregular shaped fibers. The thickness is difficult to measure due to low contrast between the coating and fiber. It is estimated at between approximately 100 and 200 nm.
FIG. 3 shows the FTIR spectra of original PP, UV-pre-treated PP, pure PGMA and PGMA-grafted PP. The characteristic peak at 1720 cm −1 on the grafted nonwoven is a clear evidence of PGMA grafting.
EXAMPLE 2
Grafting results shown in FIG. 4 were from the same process producing FIGS. 1E ) and F) in Example 1, except that in Example 2 the benzophenone to monomer ratio (I:M) was 1:5. The results in FIG. 4 clearly indicate that this technique can change the morphology of the coating from very coarse to very smooth by simply adjusting the benzophenone to monomer ratio.
EXAMPLE 3
Four specimens of polypropylene nonwoven 250 μm thick and of dimension 2×4 cm were exposed to UV irradiation of 150 to 300 nm and an intensity of 50 mw/cm 2 for 0, 5, 15 and 30 minutes, respectively. The pre-treated samples were then grafted with PGMA in the same way as in Example 1. FIG. 5 indicates that both density and conformity of PGMA graft increase with the time of UV/O treatment.
EXAMPLE 4
Three specimens of polypropylene nonwoven 250 μm thick and of dimension 2×4 cm were exposed to UV irradiation of 150 to 300 nm and intensity 50 mw/cm 2 for 0, 15 and 30 minutes, respectively. The pre-treated samples were then grafted with PGMA in the same way as Example 1, except the grafting time was 30 minutes for this example. Approximately twice as much grafting as that for 15 minutes was obtained. However, an increase in grafting efficiency does not necessarily increase the conformity of the graft. In FIG. 6 , without pre-treatment, the grafting is not conformal to the fibers, which is in contrast with conformal grafting after 15 minutes and 30 minutes pre-treatment.
EXAMPLE 5
Adsorption of benzophenone on the PP fiber surface as a function of UV/O pre-treatment time was measured by the following procedure. The samples were first pre-treated for designated periods. Then, they were immersed into a 1.3% (w/w) benzophenone in butanol solution absent of UV irradiation. The concentration of benzophenone was the same as that used in the 20% grafting solution, and the immersion times were 1, 10, 15 and 30 minutes. After immersion, the samples were taken out, hard-pressed between two paper towels (Wypall® X60, Kimberley Clark) to remove the solution trapped in the pores, dried in air and analyzed by FTIR-ATR.
In FIG. 7 , relative BP adsorption values are plotted as a function of pre-treatment time. The standard error was estimated from data measured at different spots on the same specimen. The adsorption curves clearly indicate that BP adsorption increases with UV/O pre-treatment time. This can be explained as the result of increased roughness and concentration of hydroxyl groups from pre-treatment. Furthermore, regardless of various immersion times, adsorption curves collapse into a single curve within the experimental error. This implies that upon contacting BP solution, equilibrium of BP was quickly established between the solution and the fiber surface.
Since grafting density depends on the initiator density on a substrate, PP nonwoven pre-treated with UV/O leads to deeply enhanced conformity of the graft.
EXAMPLE 6
Specimens of polypropylene (PP) nonwoven 250-μm thick and of dimensions 2×4 cm were exposed to UV irradiation of 150 to 300 nm (UV/O) and intensity 50 mw/cm 2 for 0 to 15 minutes. The specimens were then soaked with 20% glycidyl methacrylate and benzophenone (I:M=1:25) in butanol solution, sandwiched between two glass slides coated with Frekote®, and then exposed to UV of 300 to 450 nm and intensity 5 mw/cm 2 for grafting of various durations. The grafted nonwoven substrate was washed by sonication in THF and methanol to remove unreacted and unattached compounds.
FIG. 8A ) shows that the grafting rate increases with the pre-treatment time. The increases are due to the initiator density or the adsorption of benzophenone on the fiber surface which increases with the pre-treatment time. High initiator density leads to more grafting sites on the surface. Therefore, the overall grafting rate is higher. It is also interesting to note that all the samples show a lag period of ˜5 minutes. This lag period is presumably from the trapped oxygen in the system which can delay the starting of the grafting. In addition, the curves for 10 and 15 minutes pre-treatments overlap with each other. This suggests that they have similar grafting rates despite their difference in initiator density. It has been hypothesized that not all the initiators on the surface are used for initializing graft because they are inhibited by steric effects from nearby grafts [12]. Therefore, there exists a cut-off initiator density, and the grafting rate increases little beyond that density.
FIG. 8B ) shows the grafting efficiencies measured at constant grafting times as a function of BP adsorption. Grafting efficiencies show a strong dependence on low initiator densities, but weak dependence on high initiator densities. The cut-off density lies around a relative BP adsorption of 0.08.
EXAMPLE 7
Specimens of polypropylene (PP) nonwoven 250 μm thick and of dimensions 2×4 cm were exposed to UV irradiation of 150 to 300 nm (UV/O) and an intensity of 50 mw/cm 2 for 0 to 15 minutes. The specimens were then soaked with 10, 15 or 20% glycidyl methacrylate and benzophenone (1:M=0 to 1:4) in butanol solution, sandwiched between two glass slides coated with Frekote®, and then exposed to UV of 300 to 450 nm and intensity 5 mw/cm 2 for grafting of various durations. The grafted nonwoven substrate was washed by sonication in THF and methanol to remove unreacted and unattached compounds.
Grafting efficiencies at three monomer concentrations are plotted. For each concentration, the ratio between initiator to monomer was varied from 0 to 24%. As shown in FIG. 9 , the grafting efficiency increases rapidly at low initiator to monomer ratios (I:M) for all three monomer concentrations. When the ratio is above 2%, grafting efficiency reaches a plateau. The independence of grafting efficiency on the initiator is due to the fact that the initiator density on the fiber surface for these initiator concentrations is already above the cut-off BP density. Further increase of the initiator induces little change on the grafting efficiency.
EXAMPLE 8
A specimen of nylon-6, 6 nonwoven 140 μm thick and of dimensions 2×4 cm was exposed to UV of 150 to 300 nm and intensity 50 mW/cm 2 for 15 minutes (UV/O). The substrate was then soaked with 20% glycidyl methacrylate and 1.3% benzophenone solution with butanol as solvent. The substrate was sandwiched between two glass slides coated with Frekote®, and then exposed to UV of 300 to 450 nm and intensity 5 mW/cm 2 for 15 minutes. The grafted nonwoven substrate was then washed by sonication in THF and methanol to remove unreacted and unattached compounds. FIG. 10 shows that conformal grafting has been formed on the nylon fiber. Even though the surface energy of nylon is very different from PP, the same technique can generate conformal grafting for both materials.
EXAMPLE 9
A specimen of polybutylene terephthalate (PBT) nonwoven 160 μm thick and of dimension 2×4 cm was exposed to UV of 150 to 300 nm and intensity 50 mW/cm 2 for 15 minutes. Another specimen was not pre-treated at all. Both substrates were then soaked with 20% glycidyl methacrylate and benzophenone (I:M=1:25) in butanol solution. The substrate was sandwiched between two glass slides coated with Frekote®, and then exposed to UV of 300 to 450 nm and intensity 4 mW/cm 2 for 15 minutes. The grafted nonwoven substrate was then washed by sonication in THF and methanol to remove unreacted and unattached compounds. FIG. 11 shows that PBT fibers on the nonowoven have been grafted with high density and conformal PGMA graft. Without pre-treatment, conformal grafting can still be formed on the PBT fibers. This is due to the fact that PBT is more polar than PP, and dipole-dipole interactions between benzophenone and PBT improve its adsorption. As a result, a high density of initiator can be obtained even without pre-treatment.
EXAMPLE 10
A specimen of polypropylene nonwoven 250 μm thick and of dimension 2×4 cm was soaked in 100 mM benzophenone (−2%) in methanol for 18 hours. Immediately after soaking, it was sandwiched between two glasses with 20% GMA and benzophenone (I:M=1:25) in butanol solution. The time for the grafting polymerization was 15 minutes. Another polypropylene nonwoven was treated in the same way as in Example 1. All the samples were extracted in THF overnight and washed by methanol. FIG. 12 clearly shows that the substrate pre-treated by UV/O exhibits much higher density of graft than soaking in the benzophenone.
EXAMPLE 11
Layers of nonwoven in the thickness of 40-60 μm were skimmed from the PP nonwoven 250 μm thick. Five skimmed layers were restacked together to obtain a nonwoven of the similar thickness to the original nonwoven. To study the effect of light penetration, nonwovens of different thicknesses were prepared. A UV sensor was placed on one side of the nonwoven stack with the sensor surface covered by the nonwoven and the UV lamp was placed the opposite side. The whole system was placed in an enclosure with the inside covered by black foil to avoid exposure to light from the surroundings. The distance between the sensor and light source were adjusted to obtain the desired initial intensity for each test.
FIG. 13 shows the transmittances of UV light through dry nonwoven and nonwoven soaked with monomer solution. It comes as a surprise that when the nonwoven fabric is soaked with monomer solution, its light intensity decays much more slowly than under the dry condition. Since the monomer solution is able to absorb UV light, it would have been a reasonable expectation that UV intensity should decay faster. The slowdown of the decay is actually related a phenomenon known as index matching. Basically, as the refractory index of the solvent is closer to that of substrate as compared to air, it can reduce the Fresnel reflection at the surface, and thus increase the net light transmission. The refractory index of PP is 1.471 [13], that for butanol is 1.397 [13] and that for air is ˜1.
Nonwovens made of the same material, but with different average pore sizes, show different penetration profiles. In FIG. 14 , as the average pore size decreases from 17.25 to 0 μm, the decay of the UV intensity versus depth increases.
Due to the decay of UV light through the nonwoven, grafting efficiency may also vary depending on the intensity of UV light exposed in both pre-treatment and grafting step. FIG. 15 shows the spatial variation of grafting efficiency caused by pre-treatment. FIG. 16 shows the spatial variation of grafting efficiency caused by grafting. Two controls, grafting with pre-treatment but without benzophenone (condition 2, b) and grafting without pre-treatment but with benzophenone (condition 3, c) are also plotted.
The plots of condition 1, a clearly show that the grafting efficiencies decreases as the depth increases. The plot of condition 2, b show only nominal grafting. These results indicate that without benzophenone grafting efficiencies are very low. If the nonwovens are not pre-treated, such as for condition 3, c, the spatial variation of grafting efficiencies is less than the treated nonwovens. But their grafting efficiencies are also much lower than those with pre-treatment.
The above-described embodiments of the invention are intended to be examples only. Variations, alterations and modifications can be made to the particular embodiments described herein by those of skill in the art without departing from the scope of the invention, as defined in the appended claims.
REFERENCES
1. Anders, C, Hoecker, H, Klee, D, Lorenz, G, “Hydrophilic coating of surface of polymeric substrates,” U.S. Pat. No. 5,871,823.
2. D. J. Carlsson, D. M. Wiles, “The photo-oxidative degradation of polypropylene. part-I photo-oxidation and photo-initialization processes,” Polymer Reviews, 14, (1976), 65.
3. J. H. Adams, “Analysis of nonvolatile oxidation products of polypropylene. III. Photodegradation,” Journal of polymer Science Part A-1, 8, (1970), 1279.
4. Moya; Wilson, “Porous membrane and process”, U.S. Pat. No. 5,629,084.
5. Belfort, G, Crivello J, Pieracci, J, “UV-assisted grafting of PES and PSF membranes,” PCT WO 02/28947 A1
6. Crivello, J C, Belfort, G, Yamagishi, Hideyuki, “Low fouling ultrafiltration and microfiltration aryl polysuifone,” U.S. Pat. No. 5,468,390.
7. Charkoudian J “Compositions of a copolymer including a sulfone polymer,” U.S. Pat. No. 5,883,150.
8. Zhang L L, Li H J, Li K Z, Li X T, Zhai Y Q, Mang Y L, “Effect of surface roughness of Carbon/Carbon composites on osteoblasts growth behaviour,”, Journal of Inorganic Materials, 23, (2008), 341.
9. Porwal, P K, Hui, C Y, “Strength statistics of adhesive contact between a fibrillar structure and a rough substrate,” Journal of the Royal Society Interface, 5, (2008), 441.
10. Fuller K N G, Tabor D, “Effect of surface-roughness on adhesion of elastic solids”, Proceedings of the Royal Society of London Series A—Mathematical Physical and Engineering Sciences, 345, (1975), 327.
11. L. F. Vieira Ferreira, J. C. Netto-Ferreira, I. V. Khmelinskii, A. R. Garcia, S. M. B. Costa, “Photochemistry on surfaces: matrix isolation mechanisms study of interactions of benzophenone adsorbed on microcrystalline cellulose investigated by diffusion reflectance and luminescence techniques,” Langmuir, 11, (1995), 231.
12. K. Matyjaszewski, P. J. Miller, N. Shukla, B. Immaraporn, A. Gelman, B. B. Luokala, T. M. Siclovan, G. Kickelbick, T. Valiant, H. Hoffmann, T. Pakula, “Polymers at interfaces: using atom transfer radical polymerization in the controlled growth of homopolymers and block copolymers from silicon surfaces in the absence of untethered sacrificial initiator,” Macromolecules, 32, (1999), 8716.
13. Polymer Handbook Fourth Edition (J. Brandrup, E. H. Immergut. E. A. Grulke), John Wiley & Sons, 1999.
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The present invention describes a novel process for the conformal coating of polymer fibers of nonwoven substrates. This process is based on modification of polymer fiber surfaces by controlling the degree of etching and oxidation to improve adhesion of initiators to the surface and to facilitate subsequent conformal polymer grafting. The modified fiber surfaces render new functionalities to the surface, such as increased hydrophilicity, attached ligands or changed surface energy. The invention includes the modified polymer fibers produced by the process described herein.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/131,765, filed Jun. 11, 2008, hereby incorporated by reference in its entirety for all purposes.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present disclosure relates generally to the field of electrical communications and radio wave antennas as well as remotely monitoring identification devices using electromagnetic waves. More particularly, it relates to the field of radio frequency identification (RFID) devices, sometimes called tags, in which a tag is interrogated by a probing platform, sometimes called a reader. Even more particularly, it relates to the field of radio frequency identification tags that allows phase modulation or a variation thereof (e.g. phase shift keying) in addition to amplitude modulation for the tag-to-reader communication. Even more particularly, it relates the field of radio frequency identification systems employing advanced techniques such that undesired clutter from non-tag items can be mitigated using a compensation technique.
[0004] 2. Description of the Related Art
[0005] Radio-frequency Identification Devices (RFID) are used in multiple asset tracking applications, e.g., automotive, airline baggage, consumer items, food items, garments, livestock etc. There are numerous medical and military applications too. Many RFID tags do not use a battery for power. These types of RFID tags predominantly use the principle of “passive backscatter” while employing a semiconductor chip that converts part of the received radio-frequency (RF) to DC power to energize the chip itself, as described in common literature such as K. Finkenzeller, RFID Handbook: Fundamentals and Applications in Contactless Smart Cards and Identification, 2 nd ed. (San Francisco, Calif.: John Wiley & Sons, 2003). The RFID ecosystem operates in multiple bands, e.g., low frequency (LF), high frequency (HF), ultra high frequency (UHF) and microwaves and usually employs amplitude shift keying (ASK) (or variations thereof) on the backscatter from the tag to carry the information embedded in the tag to the reader. LF and HF systems commonly operate under near-field conditions and have a limited range of 1 meter or so, whereas UHF and microwave tags predominantly operate under far-field conditions and are usually capable of longer range and higher data rates, as described in Smail Tedjini et al., “Antennas for RFID Tags” (Grenoble, France: Joint sOc-EUSAI Conference, October 2005). The modulation and coding formats are defined by various standards such as EPCglobal Class 0, Class 1, Gen II, etc. for UHF tags.
[0006] A passive backscatter tag does not transmit its own signal to the reader but simply modulates the signal that its antenna backscatters by changing the impedance presented to the antenna. In this fashion, the tag need only provide a switching function operating at a modest rate comparable to the data rate of a few hundred kbps, as described in D. Dobkin et al, “A Radio-Oriented Introduction to Radio Frequency Identification,” High Frequency Electronics, June 2005. A typical UHF RFID tag uses a dipole antenna (or a variation thereof) and is switched between open circuit and a matched load. In other words, the data from tag to reader is sent by amplitude modulating the radar cross section (RCS) during the time interval that the tag receives a continuous wave (CW) signal from the reader.
[0007] The performance of the tag to reader link is limited due to the amplitude modulated nature of the signal. Amplitude modulated signals usually require higher signal to noise ratios than the phase modulated counterparts like phase-shift keying (PSK). A PSK system will therefore provide longer range and be more tolerant to multipath fades. Moreover, a multiple level PSK system can be used to speed up the anti-collision reading process by assigning unique phase states to different categories of tags. Also, a phase modulation based system ideally can scatter back all the energy captured by the tag from the reader, minus the amount converted to DC. Furthermore, it does not require a precise impedance matching as commonly required in ASK systems.
[0008] ASK based systems suffer major limitations in the presence of reflected and scattered clutter from non-tag items, as well as leakage of reader transmissions into the reader receiver.
[0009] Using coherent PSK detection at the reader, and adding a compensation scheme, it is possible to separate these impairments from the desired backscatter from the tag. However, conventional methods to create phase modulated backscatter increases the complexity of the chip inside the tag and thereby increase cost.
[0010] A major obstacle in successful deployment of RFID tags is the lack of ability of detecting multiple RFID tags accurately by an RFID reader in a cluster. For example, an RFID reader may be asked to read 100 items in a supermarket cart with all of the items having RFID tags. Existing RFID systems have poor accuracy in accurately detecting all such IDs in parallel due to clutter.
[0011] Thus, a better solution is needed to extend the range of RFID tags, make operation robust in multipath situations, mitigate the effect of clutter and speed up reading among a cluster.
BRIEF SUMMARY OF THE INVENTION
[0012] Embodiments in accordance with the present disclosure relate to remote identification devices that illuminate a radio frequency identification (RFID) device (e.g., an RFID tag) with electromagnetic waves and coherently process the backscatter, the RFID devices according to various embodiments are capable of introducing amplitude and or phase modulation on the backscattered signal with an on/off (i.e. single pole single throw) switch, and an interrogator is equipped with a correction algorithm to mitigate the effect of clutter resulting from reflection/scattering from items containing electrical conductors (metal) or high dielectric constant such as water based liquids, as is common in a supermarket cart. Additional benefits are longer range, enhanced read speed in a cluster of devices (anti-collision reading) and enhanced throughput.
[0013] Passive backscatter RFID tags can receive a continuous wave (CW) signal from a reader or interrogator and convert a part of the wave into direct current (DC) used to power a chip inside the tag. The chip in the RFID tag decodes the information sent out by the reader and prepares a response. The response is a bit stream generated by impedance modulating the tag antenna.
[0014] One embodiment relates to a method of impedance modulation of a passive backscatter radio frequency identification (RFID) tag. The method includes receiving a wireless input signal into an antenna of an RFID tag, the antenna having a characteristic impedance and being operatively connected to a switch, switching the switch between a first circuit having a first impedance and a second circuit having a second impedance such that an output signal from the antenna is modulated both in a predetermined amplitude and a predetermined phase, the modulation in both the predetermined amplitude and the predetermined phase corresponding to a device signature of the RFID tag, and emitting the output signal from the RFID tag.
[0015] Another embodiment relates to a machine-implemented method of discerning a radio frequency identification (RFID) tag among non-RFID tag clutter. The method includes receiving a wireless signal into a reader antenna, the wireless signal including an emitted signal from an RFID tag and complex clutter, estimating an amplitude and phase of the signal in two or more distinct states, estimating an amplitude and phase of the complex clutter, and subtracting the complex clutter from the received signal.
[0016] Yet another embodiment relates to a passive backscatter radio frequency identification (RFID) tag. The tag includes a patch element, a switch connected to the patch element, and at least one circuit, each of the at least one circuit having a distinct predetermined impedance. The switch is adapted to switch an electrical connection between the patch element and the at least one circuit such that the RFID tag emits a predetermined pattern of signals when illuminated by an RFID interrogator, the pattern of signals corresponding to a device signature of the RFID tag.
[0017] The foregoing has outlined, in general, the physical aspects of the invention and is to serve as an aid to better understanding the more complete detailed description that is to follow. In reference to such, there is to be a clear understanding that the present invention is not limited to the method or detail of construction, fabrication, material, or application of use described and illustrated herein. Any other variation of fabrication, use, or application should be considered apparent as an alternative embodiment of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The following drawings further describe by illustration the advantages and objects of the present invention.
[0019] FIG. 1 illustrates how a reflection coefficient of a passive network at an antenna port can change the relative amplitude and phase of a backscattered signal in accordance with an embodiment.
[0020] FIG. 2 shows a two-port representation of a non minimum scatter antenna in accordance with an embodiment.
[0021] FIG. 3 describes a basic principle of a tag in accordance with an embodiment in which the tag antenna port is switched between N (where N≧2) passive networks.
[0022] FIG. 4 depicts a microstrip patch as a candidate for the tag antenna possessing the requisite property (non minimum scatter) described in FIG. 1 .
[0023] FIG. 5 shows a schematic for a preferred embodiment for generating binary phase shift keying (BPSK).
[0024] FIG. 6 shows a schematic for a preferred embodiment for generating quadrature phase shift keying (QPSK).
[0025] FIG. 7 is a phasor diagram illustrating how differential phase shift can be utilized to recover tag modulation in accordance with an embodiment, even in presence of heavy impairments (clutter).
[0026] FIG. 8 is a plot from mathematical modeling depicting a differential phase shift as a function of clutter phase angle for 180° and 90° keying, in accordance with an embodiment.
[0027] FIG. 9 depicts logic followed in an embodiment of the reader to recover tag modulation in presence of heavy impairments (clutter) in accordance with an embodiment.
[0028] FIG. 10 depicts an algorithm for mitigating impairments (clutter) in accordance with an embodiment.
[0029] FIG. 11 illustrates an RFID reader and tag in accordance with an embodiment.
[0030] The figures will now be used to illustrate different embodiments in accordance with the invention. The figures are specific examples of embodiments and should not be interpreted as limiting embodiments, but rather exemplary forms and procedures.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The present disclosure describes a novel technique and apparatus for modulating a backscattered signal from a radio frequency identification (RFID) device or tag. This technique does not require changes to the chip architecture inside an RFID tag. Generally, the only changes that are needed are within the tag antenna and associated circuitry. Because the tag antenna and associated circuitry can be fabricated using the same process as a typical tag antenna (e.g. single step printing) there is almost no additional cost to the tag.
[0032] This novel technique modulates the phase of a backscattered signal in addition to the amplitude. In one embodiment, this is implemented through connecting the antenna to relatively low cost and simple circuits that are external to the antenna through a switch. In another embodiment, low cost and simple circuits are integrated within the antenna.
[0033] To achieve control over both amplitude and phase modulation of the backscattered signal, a special category of antennas that scatters back a negligible quantity of signal energy when terminated by its characteristic impedance is used. These types of antennas almost invariably include at least one parasitic element in addition to the main element and may be termed “non-minimum scatter antennas” (see Mukherjee, S., “Antennas for Chipless Tags Based On Remote Measurement of Complex Impedance,” Proceedings of the 38th European Microwave Conference (Amsterdam, 2008)). The residual scattered power, under matched condition is due to structural scattering. By proper design, the structural scattering can be minimized.
[0034] One type of non-minimum scatter antenna is a “non-dipole antenna” because a dipole antenna is generally not suitable as a non-minimum scatter antenna. A non-dipole antenna generally can create a backscatter even when terminated by an external, lossless network, such as an open circuit or a short circuit.
[0035] The magnitude and phase of the scattered signal can be controlled by the mismatch between the antenna characteristic impedance and a passive external termination. Therefore, by proper selection of two (or more) passive networks connected through a switch to the antenna, amplitude and phase modulation of the backscatter is achieved.
[0036] If the external termination is (ideally) lossless, only the phase of the scattered signal is modulated. In this special case, a phase-shift keyed (PSK) system would be implemented. If the external network also includes a dissipative or resistive part in addition to a reactive part, both amplitude and phase modulations (e.g. quadrature amplitude modulation (QAM)) are achieved.
[0037] A received signal at a reader undergoes signal processing with an algorithm that uses the amplitude and phase information from the tag to mitigate the effect of clutter, usually coming from reflection scattering from metallic objects, water based liquids and leakage from the reader's transmit antenna.
[0038] There are several advantages to this technique. A PSK signal will operate with substantially lower received power than amplitude shift keying (ASK) and therefore increase the range of operation of the reader and tag. The system can be more frugal in utilizing the captured radio frequency (RF) power at the tag. Except for the power converted to direct current (DC), generally all power is scattered back to the reader. This is unlike RFID dipole antennas in which half the power is dissipated in the antenna during the ‘mark’ mode (no power scattered back during ‘space’ at all). Because the RFID device using PSK is more frugal with the power, this can allow operation with less power transmitted from the reader. This can reduce interference, help to comply with local regulatory standards, etc. Critical impedance matching between the tag antenna and the chip is not required since the antenna is operating almost always in mismatched condition for a PSK operation. Tags almost always operate in the presence of clutter coming from reflection/scattering from non-tag items and leakage from the transmit antenna of the reader. It is possible to mitigate the effect of this clutter by use of a compensation scheme described. It is possible to speed up an anti-collision read mechanism by creating several categories of tags and each category imbibed with unique phase states. Also, the tag to reader data rate can be increased through the use of an m-QAM system
[0039] Though Phase Shift Keying (PSK) is mentioned in the EPCglobal Gen II standard for Tag to Reader communication (see EPC Radio-Frequency Identity Protocols Class-1 Generation-2 UHF RFID Protocol for Communications at 860 MHz-960 MHz, version 1.1.0 (EPCglobal Inc., Dec. 17, 2005), section 6.3.1.3.1 on p. 27), usually various forms of Amplitude Shift Keying (ASK) are used due to simplicity of implementation. Amplitude shift keying of the backscatter is implemented by alternately terminating the tag antenna with its characteristic impedance and opening it. In other words, the radar cross section (RCS) of the tag undergoes amplitude modulation.
[0040] Several issues are evident from this disclosure:
1. It is possible to design certain class of antennas that ideally scatter back the entire signal captured provided the termination is purely reactive. An example is microstrip patch and a counter-example is a dipole. 2. The above category of antennas scatters back a negligible quantity of signals when terminated by the antennas' characteristic impedances. The residual scattered power under such conditions can be called structural scattering. By proper design, the structural scattering can be minimized. This type of antenna can be termed a non minimum scatter antenna. 3. The magnitude of the scattered signal can be controlled by the mismatch between the antenna characteristic impedance and the external termination. 4. The phase of the scattered signal can be controlled by the reactive part of the external network. 5. By the use of a switch to switch between two or more external networks, it is possible to control amplitude and phase of backscattered signals for multiple states. It is therefore not necessary to construct a separate amplitude/phase modulator in the tag chip.
[0046] FIG. 1 shows a non-minimum scatter antenna 102 terminated by a passive network 103 . Non-minimum scatter antenna 102 is preferably an antenna on an RFID tag. Table 1 below depicts relative amplitude and phase values for the scattered signal for some typical passive networks. For example, a (perfectly) matched termination to antenna 102 results in zero backscatter. For a resistive and reactive network with a reflection coefficient in the Euler complex phasor notation of Ae jα , (where j is the square root of negative 1), the relative amplitude of backscatter is A (where A<1) and the relative phase of the backscatter is α.
[0000]
TABLE 1
Amplitude of
Phase of
Backscatter
Backscatter
Type of Passive Network
(relative)
(relative)
Matched Termination
0
n/a
Open Circuit
0
0
Short Circuit
1
0
Lossless network of
1
φ
reflection coefficient 1 · e jφ
Lossy network of
A
α
reflection coefficient A · e jα
[0047] FIG. 2 illustrates passive network 103 of FIG. 1 as passive network 201 . Passive network 201 is represented by a reflection coefficient Γ, and the antenna 102 replaced by its equivalent two-port network 203 . The source impedance Z 0 204 is 120π ohms, i.e. the impedance of free space. The variable a is a transmitted wave, and the variable b is a reflected wave. Variables γ 11 and γ 12 are propagation functions (i.e. a measure of attenuation and phase shift due to propagation. Variables s 11 , s 12 , s 21 , and s 22 are scattering parameters. For an ideal non minimum scatter antenna, s 11 and s 22 are both zero, and (normalized) s 21 ×s 12 =1.
[0048] FIG. 3 depicts passive backscatter RFID tag 300 in accordance with an embodiment. Tag 300 has a non minimum scatter antenna 302 , which has a characteristic impedance, and an N position (i.e. N-tuple throw) switch 306 . N distinct amplitude-phase states can be created by connecting N passive networks 303 , 304 , . . . 305 to antenna 302 through switch 306 . Each passive network operatively connected to the i'th switch position is represented by A i e jφi , which represents a predetermined reflection coefficient resulting from a predetermined impedance.
[0049] In the exemplary embodiment, a wireless signal (not shown) is received into antenna 302 . Because switch 306 is connected to passive network 303 , incident wave 307 travels from antenna 302 to passive network 303 . Incident wave 307 is modified by passive network 303 to create a reflected wave 309 . Reflected wave 309 travels back through switch 306 and is radiated by antenna 302 .
[0050] Passive network 303 modifies incident wave 307 by its impedance or impedance mismatch between passive network 303 and antenna 302 , such that reflected wave 309 can be represented by A 1 e jφ1 , where A 1 is the relative amplitude of backscatter and φ 1 is the relative phase.
[0051] In the special case of A i =1, the corresponding i'th passive network is lossless. If A i is essentially equal to 1, then the corresponding passive network is substantially lossless. “Substantially lossless” can include amplitude coefficients within 1%, 5%, 10%, or greater of 1.
[0052] Other embodiments can have the ‘reflected’ or modified wave travel through a separate path than that from which it came. The separate path can lead to another antenna, such that the receive antenna is separate from the transmit/emit antenna.
[0053] While the wireless signal is received into antenna 302 , switch 306 can be switched between passive networks or circuits 303 , 304 , . . . , 305 such that reflected waves or output signals from each network temporally combine to form an output signal along the common (i.e. left terminal in switch 306 ), and an output signal from antenna is thus modulated in predetermined amplitude and predetermined phase. The predetermined amplitude/phase modulation corresponds to an identifier, serial number, or other device signature of RFID tag 300 . The output signal is emitted from RFID tag 300 through antenna 302 .
[0054] Switch 306 can be made from transistors, PIN diodes, micromechanical or other switches as known in the art. Solid state switches can be made from silicon, gallium arsenide, or other semiconductor materials.
[0055] FIG. 4 shows a microstrip patch 400 , which is a minimum scatter antenna. Patch 403 is a rectangular piece of conductive material. Circular, triangular, other simple shapes, and more complex, arbitrary patterns can also be used successfully for a patch element. Ground 402 lies in a parallel plane to patch 403 , separated by dielectric 401 . Dielectric 401 can be made from plastic; low loss dielectric material is preferred. In the exemplary embodiment, patch 403 is the main element in 400 and ground plane 402 may be considered the parasitic element.
[0056] FIG. 5 shows an exemplary scheme for generating a Binary Phase Shift Keyed (BPSK) scattered signal. Patch element 502 is similar to patch element 403 in FIG. 4 . Patch element 502 has radiating edges 501 a and 501 b and non-radiating edge 505 . One terminal of on/off switch 507 (i.e. single pole, single throw (SPST) switch) is connected to a point on non-radiating edge 505 . The other end of switch 507 is connected to the ground plane (see FIG. 4 ) through a via hole 504 .
[0057] While an electromagnetic wave is received into patch element 502 , on/off switch 507 is operated to modulate the output signal. The phase of the radar cross section of patch antenna 502 , rather than its amplitude, is changed by the switching process. This predetermined modulation corresponds to the identifier of the RFID tag.
[0058] FIG. 6 shows an exemplary scheme for generating a Quaternary Phase Shift Keyed (QPSK) scattered signal. The common terminal of four-position switch 606 (i.e. single pole, quadruple throw switch) is connected to non-radiating edge 608 of the patch. Circuits 601 a and 601 b are via holes to the ground plane connecting two different positions of 606 . Circuit 601 a generates a short circuit to ground, whereas circuit 601 b is connected through shorted transmission line 603 , generating an effective inductance. Transmission line 603 can be a simple transmission line, an inductor component, or other inductor. Terminal or position 609 of switch 606 generates an open circuit. Capacitive stub 604 is connected to the fourth position of 606 . The capacitive stub can be a triangle shaped metallic pattern or other metallic patterns on a dielectric. Lumped capacitors can also be used. Therefore, four phase shifts spaced at 90° apart can be generated by this scheme.
[0059] FIG. 7 illustrates how a clutter signal phasor 703 (at the reader) affect a signal from a tag. A ‘low state’ from the RFID tag is represented by the phasor 701 and a ‘high state’ by phasor 702 . The resultant signals, as received by the reader are represented by phasors 705 and 706 , in the low and high states of the tag respectively.
[0060] The following signals can be defined at the reader's receiver as follows (phase shift keyed signal):
[0000] s·e j0 =signal from the tag alone—low state (e.g. phasor 701); (Eqn. 1)
[0000] s·e jψ =signal from the tag alone—high state (e.g. phasor 702); and (Eqn. 2)
[0000] m·e jμ =signal from impairments (reflection/scattering from non-tag objects and transmitter leakage) alone (e.g. phasor 703), (Eqn. 3)
[0000] where ψ is the phase shift between the low and high states of the tag signal.
[0061] FIG. 8 is a plot generated through mathematical modeling showing how the phase angle ψ between phasor 705 and phasor 706 changes as a function of μ. The phase shift between low and high states ψ is used as a parameter (90° and 180°). m/s=5 was used in this plot.
[0062] FIG. 9 shows algorithm 900 to distinguish between low and high states from the tag in presence of heavy clutter. After beginning at step 902 , the phase shift states are set in step 904 at the tag to 0° and 180°. In step 906 , phase angles are measured at the reader for high and low levels emitted by the tag. In step 908 , the algorithm determines whether the phase difference between the measured angles is discernible. If it is determined in step 908 that the phase difference is not discernible, then the phase shift states are set at the tag to 0° and 90° in step 910 . In step 912 , the algorithm determines again whether the phase difference between the measured angles is discernible. If it is determined in step 912 that the phase difference is still not discernible, then the data is presumed lost in step 914 and the algorithm ends at step 916 . If the phase difference is discernible either in step 908 or step 912 , the algorithm then determines in step 918 whether the data is noisy (e.g. includes clutter). If it is determined that the data is noisy, then a correction is performed in step 920 . The data is then decoded in step 922 and the algorithm ends at step 924 .
[0063] FIG. 10 depicts a correction algorithm 1000 whereby an estimate of the clutter phasor is estimated and subtracted from the received signals at a reader to determine the low and high states from an RFID tag. After beginning at step 1002 , step 1004 computes an estimate of low and high level signals. Step 1006 computes an estimate of the magnitude and phase of the impairment signal (e.g. E[m·e jμ ]). In step 1008 , the estimate is subtracted from the signal received back from the tag. The algorithm then moves on to the next step 1010 of processing.
[0064] The estimates of signal at the reader in low and high states of the tag are:
[0000] E[L]=E[s·e j0 +m·e jμ ] (e.g. phasor 705—low level signal); and (Eqn. 4a)
[0000] E[H]=E[s·e jψ +m·e jμ ] (e.g. phase 706—high level signal). (Eqn. 4b)
[0000] Then, E[s]·(1−e jψ )=E[L]−E[H], such that:
[0000] E[s ]=|( E[L]−E[H ])/(1 −e jψ )| (Eqn. 5a)
[0000] and
[0000] E[m·e jμ ]=½ [E[L]+E[H]−E[s ]·(1 +e jψ )] (Eqn. 5b)
[0000] Therefore, it is possible to calculate E[m·e jμ ] from above equations. Afterward, the corrected signal is obtained by subtracting E[m·e jμ ] from the received signal.
[0065] FIG. 11 illustrates system 1100 in which reader 1102 reads a wireless signal from RFID tag 1120 . Reader 1102 includes display 1104 , memory 1106 , microprocessor 1108 , and data bus 1110 . Reader 1102 also includes reader radio frequency (RF) antenna 1114 connected to the other components through interface 1112 . Reader transmits wireless interrogation signal 1116 , which is received by RFID tag 1120 . In particular, RFID tag antenna 1124 receives the interrogation signal and, through active switching of switch 1122 connecting to two networks (e.g. open circuit and ground circuit), modulates the scattered wireless signal 1118 . Reader RF antenna 1114 receives wireless signal 1118 . Interface 1112 filters, amplifies, and coherently demodulates the signal. Based on the complex demodulated symbols, the microprocessor 1108 estimates an amplitude and phase of the signal in two or more distinct states (e.g. low and high states of the RFID tag). Microprocessor 1108 then estimates an amplitude and phase of complex clutter received in signal 1118 . Microprocessor 1108 then uses the estimate of the amplitude and phase of the complex clutter in the received signal to remove or otherwise subtract complex clutter from the received signal. In this way, microprocessor can determine the corresponding device ID of RFID tag 1120 among other tags and clutter.
[0066] In the foregoing specification, the invention is described with reference to specific embodiments thereof, but those skilled in the art will recognize that the invention is not limited thereto. Various features and aspects of the above-described invention may be used individually or jointly. Further, the invention can be utilized in any number of environments and applications beyond those described herein without departing from the broader spirit and scope of the specification. The specification and drawings are, accordingly, to be regarded as illustrative rather than restrictive.
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A technique that improves performance of passive backscatter RFID tags such as mitigation of read error in presence of clutter, provide enhanced range, speed up anti-collision reading, provide increased throughput etc. The technique utilizes amplitude and phase modulation at the tag and a compensation algorithm at the RFID reader without inflicting significant changes in the RFID chip and therefore has minimum cost impact. Modifications can be primarily in the antenna design and passive circuitry around it, printable by a single step process.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a §371 national phase filing of International Application No. PCT/FR96/00802, filed May 29, 1996.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a new polypeptide designated ΔP62, to its variants, to the corresponding nucleic acid sequences and to their therapeutic uses, in particular in anticancer gene therapy.
2. Description of Related Art
Various genes, referred to as oncogenes and suppressor genes, are involved in the control of cell division. Among these, the ras genes and their products, generally designated p21 proteins, perform a key role in the control of cell proliferation in all the eukaryotic organisms in which they have been sought. In particular, it has been shown that certain specific modifications of these proteins cause them to lose their normal control and lead them to become oncogenic. Thus, a large number of human tumours have been associated with the presence of modified ras genes. Similarly, an overexpression of these p21 proteins can lead to a deregulation of cell proliferation. An understanding of the exact role of these p21 proteins in cells, their mode of functioning and their characteristics hence constitutes a most profitable focus of attention for our understanding of carcinogenesis and the therapeutic approach thereto.
In vivo, the precise nature of the events responsible for transduction of the signal initiated by the p21 proteins is not known. However, an increasing. number of results highlight the multiplicity of effectors which interact directly and preferentially with the active form (bound to GTP) of the ras proteins. Among these effectors, the GAP protein has been the first one to have its involvement in the transduction of the signal documented. It is a cytosol protein, present in all eukaryotic organisms, which possesses the faculty of strongly accelerating the hydrolysis of the GTP bound to the normal protein. It possesses two domains providing for different functions. Its carboxy-terminal end carries the catalytic activity which interacts with the p21 proteins and which increases their GTPase activity. At its other end, downstream of the N-terminal portion, there is a juxtaposition of SH2 and SH3 domains which participate in the transduction of the message and interact with other proteins. Among these proteins, there are two, p62 and p190, of 62 kDa and 190 kDa, respectively, in which the tyrosine is strongly phosphorylated. These two proteins form a specific complex with GAP and are immunoprecipitated by antibodies directed against different epitopes of GAP. It is known, in particular, that the SH2 domains of GAP are the regions in which the interactions of p62 with GAP take place. Amino acids 271 to 443 of p62 contain phosphorylated tyrosines and appear to be involved in these interactions. These same phosphorylations appear, moreover, to participate in interactions between p62 and the adapter GRB2. Moreover, along the whole length of the p62 sequence, proline-rich consensus sites are distributed which participate in the binding to the SH3 domains of the tyrosine kinases of the src family, and also of phospholipase Cγ.
The p62 (or alternatively Sam68) protein was identified by Wong et al. (Cell 69 (1992) 551). It contains 443 amino acids, the sequence of which has been described in the literature (see SEQ ID No. 2).
In addition to the features mentioned above, the p62 protein displays several features characteristic of hnRNPs (heterogeneous nuclear ribonucleoproteins):
it is rich in glycines
it possesses regions rich in arginines
furthermore, its amino acids 145 to 247 define a region of strong homology with an hnRNP described previously, GRP33. This region contains a consensus binding site for RNAs which is homologous to the one contained in hnRNP K. This consensus site is designated KH domain (KH=hnRNPK Homologue). The conserved residues are essential to the binding to RNAs, and the impact of the non-integrity of this domain in a pathology has been shown for FMR1, which is the product of the gene associated with mental retardation which is observed in fragile X syndrome (Siomi et al., Cell 77 (1994) 33).
SUMMARY OF THE INVENTION
The present invention has its basis, in particular, in the demonstration of the importance of the p62 (Sam68) protein in cell proliferation and death. It is the outcome, more especially, of the demonstration that p62 derivatives are capable of interfering in the process of cell transformation, and in particular of inhibiting the signals transduced by the ras and arc proteins. It is the outcome, in addition, of the especially surprising demonstration that these derivatives are also endowed with apoptotic properties, and hence capable of inducing cell death.
A first subject of the invention hence relates to any p62 derivative capable of at least partially inhibiting the interaction between a GAP protein and p62. Preferably, the derivatives according to the invention are capable of at least partially inhibiting the oncogenic power of the ras and/or arc proteins. Still more preferably, the derivatives according to the invention are capable of inducing cell death by apoptosis. The derivatives according to the invention are also characterized by the loss of the capacity to interact with RNA of p62.
The present invention describes, in particular, the demonstration, cloning and characterization of a natural isoform of the p62 protein. This isoform, designated Δp62 (or ΔSam68), possesses a deletion in the zone of homology to the GRP33 protein, which covers the KH domain. As a result of this deletion, Δp62 does not possess the properties of p62 in their entirety. Thus, Δp62 possesses a domain of interaction with GAP and intact GRB2, as well as the various proline-rich sequences which are partners of SH3 (FIG. 1 ). However, Δp62 is no longer capable of interacting with nucleic acids as a result of the deletion of the domain of homology to the GRP33 protein. The Applicant also showed that the transfer of Δp62 cDNA in various normal or tumoral cell models impedes the cooperation between p62 and Ras and inhibits the signals transduced by normal and oncogenic Ras proteins. Hence, when overexpressed, Δp62 interferes with the processes of proliferation and differentiation and leads, in the different cell models, to cell death by apoptosis.
According to a preferred embodiment, the invention relates more especially to any p62 derivative carrying at least one deletion in the zone of homology to the GRP33 protein. More especially, the derivatives according to the invention contain at least one deletion in the region lying between residues 145 and 247 of the p62 protein as shown in the sequence SEQ ID No. 1, and which covers the KH domain. The deletion advantageously involves more than 10 amino acids, and more preferably involves more than 30 amino acids. It can affect one or several sites within this region, provided the resulting derivative displays the properties described above.
It is especially advantageous for the derivative according to the invention to be a polypeptide comprising all or part of the sequence SEQ ID No. 4 or of a variant of the latter. For the purposes of the invention, the term variant denotes any polypeptide whose structure differs from the sequence SEQ ID No. 4 by one or more modifications of a genetic, biochemical and/or chemical nature. Such modifications can entail, in particular, any mutation, substitution, deletion, addition and/or modification of one or more residues. Such derivatives may be generated for different purposes, such as, in particular, that of increasing the affinity of the peptide for its interaction site, that of improving its levels of production, that of increasing its resistance to proteases or of improving its passage through cell membranes, that of increasing its therapeutic efficacy or of reducing its side effects or that of endowing it with new pharmacokinetic and/or biological properties. Advantageously, the variants comprise deletions or mutations involving amino acids whose presence is not decisive for the activity of the derivative. Such amino acids may be identified, for example, by tests of cellular activity as described in the examples.
As a special preference, the derivatives of the invention retain at least a portion of the p62 protein permitting the interaction with the SH2 domain of GAP. This portion of p62 consists, more especially, of phosphorylated tyrosines localized between residues 200 and 443 of the p62 protein (see SEQ ID No. 2). A preferred derivative according to the invention hence comprises at least (i) a deletion in the region lying between residues 145 and 247 of p62, and (ii) a portion of p62 permitting the interaction with the SH2 domain of GAP. More preferably, the deletion involves residues 1 to 202.
In this connection, the Applicant also showed that derivatives according to the invention displaying especially advantageous properties can consist of polypeptides essentially comprising the region carrying the phosphorylated tyrosines of p62.
An especially preferred example of polypeptide according to the invention is represented by the polypeptide Δp62 of sequence SEQ ID No. 4, possessing a deletion of residues 170-208 of the sequence of p62. Another example is represented by the polypeptide p62-C comprising residues 203 to 443 of p62 (sequence SEQ ID No. 6).
The results presented in the present application show, in particular, that Δp62 can compete with p62 for GAP. Since GAP is one of the effectors of the Ras proteins, Δp62 blocks the mitogenic pathways dependent thereon. When overexpressed by gene transfer (transfection, infection, microinjection, and the like), Δp62 induces cell death by apoptosis in normal cells (NIH3T3 and Swiss 3T3 fibroblasts) or tumour cells (H460;HCT116), and is capable of inhibiting the formation of foci induced by ras. This same effect is obtained with the derivative p62-C (essentially comprising the C-terminal portion of Δp62, which covers the region lying between amino acids 203 and 443 and which corresponds to the domain of interaction with the SH2 domains of GAP and of GRB2). This C-terminal portion also contains three of the sites of interaction with the SH3 domains, those having most affinity for Fyn. The substantial therapeutic activity of the derivatives according to the invention is associated with their multifarious properties, and in particular their power of titration of the SH3 domains of proteins of the src family (for example fyn), their capacity for inhibition of the recruitment of GRB2 by titrating its SH2 domain and their capacity for inhibition of the effector function of the GAP protein for the Ras dependent pathways of signalling.
Another subject of the present invention relates to any nucleic acid coding for a polypeptide as defined above.
The nucleic acid according to the invention can be a ribonucleic acid (RNA) or a deoxyribonucleic acid (DNA). In addition, it can be a genomic DNA (gDNA) or complementary DNA (cDNA). It may be of human, animal, viral, synthetic or semi-synthetic origin. It may be obtained in various ways, and in particular by chemical synthesis using the sequences presented in the application and, for example, a nucleic acid synthesizer. It may also be obtained by the screening of libraries by means of specific probes, in particular such as the ones described in the application (see sequences SEQ ID No. 9 and 10, for example). It may also be obtained by mixed techniques including chemical modification (elongation, deletion, substitution, and the like) of sequences screened from libraries. Generally speaking, the nucleic acids of the invention may be prepared according to any technique known to a person skilled in the art.
Preferably, the nucleic acid according to the invention is a cDNA or an RNA.
The nucleic acid according to the invention is advantageously chosen from:
(a) all or part of the sequence SEQ ID No. 3 or SEQ ID No. 5 or of their complementary strand,
(b) any sequence hybridizing with the sequences (a) and coding for a derivative according to the invention,
(c) the variants of (a) and (b) resulting from the degeneracy of the genetic code.
As mentioned above, the Applicant has now isolated and characterized new nucleic acid sequences coding for polypeptides derived from p62, having altogether exceptional antiproliferative and apoptotic properties. These nucleic acids may now be used as therapeutic agents for producing in cells derivatives according to the invention capable of destroying or correcting cellular dysfunctions. To this end, the present invention also relates to any expression cassette comprising a nucleic acid as defined above, a promoter permitting its expression and a transcription termination signal. The promoter is advantageously chosen from promoters which are functional in mammalian, preferably human, cells. More preferably, it is a promoter permitting the expression of a nucleic acid in a hyperproliferative cell (cancer cell, restenosis, and the like). In this connection, various promoters may be used. For example, the p62 gene's own promoter may be used. Promoter regions of different origin (responsible for the expression of other proteins, or even synthetic regions) may also be used. Thus, it is possible to use any promoter or derived sequence that stimulates or represses the transcription of a gene, specifically or otherwise, inducibly or otherwise, strongly or weakly. The promoter sequences of eukaryotic or viral genes may be mentioned in particular. For example, the promoter sequences may be ones originating from the genome of the target cell. Among the eukaryotic promoters, it is possible to use, in particular, ubiquitous promoters (promoter of the HPRT, PGK, α-actin, tubulin, and the like, genes), promoters of intermediate filaments (promoter of the GFAP, desmin, vimentin, neurofilaments, keratin, and the like, genes), promoters of therapeutic genes (for example the promoter of the MDR, CFTR, factor VIII, ApoAI, and the like, genes), tissue-specific promoters (promoter of the pyruvate kinase, villin, intestinal fatty acid binding protein, smooth muscle α-actin, or the like, gene) or alternatively promoters that respond to a stimulus (steroid hormone receptor, retinoic acid receptor, and the like). Similarly, promoter sequences originating from the genome of a virus may be used, such as, for example, the promoters of the adenovirus E 1 A and MLP genes, the CMV early promoter or alternatively the RSV LTR promoter, and the like. In addition, these promoter regions may be modified by adding activating or regulatory sequences, or sequences permitting a tissue-specific or -preponderant expression.
The present invention now provides new therapeutic agents which make it possible, as a result of their antiproliferative and/or apoptotic properties, to interfere with a large number of cellular dysfunctions. For this purpose, the nucleic acids or cassettes according to the invention may be injected as they are at the site to be treated, or incubated directly with the cells to be destroyed or treated. It has, in effect, been reported that naked nucleic acids can enter cells without a special vector. Nevertheless, it is preferable in the context of the present invention to use an administration vector, enabling (i) the efficacy of cell penetration, (ii) targeting and (iii) extra- and intracellular stability to be improved.
According to an especially preferred embodiment of the present invention, the nucleic acid or cassette is incorporated in a vector. The vector used may be of chemical origin (liposome, nanoparticle, peptide complex, cationic polymers or lipids, and the like) viral origin (retrovirus, adenovirus, herpesvirus, AAV, vaccinia virus, and the like) or plasmid origin.
The use of viral vectors is based on the natural transfection properties of viruses. It is thus possible to use, for example, adenoviruses, herpesviruses, retroviruses and adeno-associated viruses. These vectors prove especially efficacious is from the standpoint of transfection. In this connection, a preferred subject according to the invention lies in a defective recombinant retrovirus whose genome comprises a nucleic acid as defined above. Another particular subject of the invention lies in a defective recombinant adenovirus whose genome comprises a nucleic acid as defined above.
The vector according to the invention can also be a non-viral agent capable of promoting the transfer of nucleic acids into eukaryotic cells and their expression therein. Synthetic or natural chemical or biochemical vectors represent an advantageous alternative to natural viruses, especially on grounds of convenience and safety and also on account of the absence of theoretical limit regarding the size of the DNA to be transfected. These synthetic vectors have two main functions, to compact the nucleic acid to be transfected and to promote its binding to the cell as well as its passage through the plasma membrane and, where appropriate, the two nuclear membranes. To mitigate the polyanionic nature of nucleic acids, the non-viral vectors all possess polycationic charges.
The nucleic acid or vector used in the present invention may be formulated for the purpose of administration topically, orally, parenterally, intranasally, intravenously, intramuscularly, subcutaneously, intraocularly, transdermally and the like. Preferably, the nucleic acid or vector is used in an injectable form. It may hence be mixed with any pharmaceutically acceptable vehicle for an injectable formulation, in particular for a direct injection at the site to be treated. The formulation may comprise, in particular, isotonic sterile solutions, or dry, in particular lyophilized, compositions which, on addition of sterilized water or of physiological saline as appropriate, enable injectable solutions to be made up. A direct injection of the nucleic acid into the patient's tumour is advantageous, since it enables the therapeutic effect to be concentrated in the tissues affected. The doses of nucleic acid used may be adapted in accordance with various parameters, and in particular in accordance with the gene, the vector, the mode of administration used, the pathology in question or alternatively the desired length of treatment.
The invention also relates to any pharmaceutical composition comprising at least one nucleic acid.
It also relates to any pharmaceutical composition comprising at least one vector as defined above.
It also relates to any pharmaceutical composition comprising at least one p62 derivative as defined above.
As a result of their antiproliferative properties, the pharmaceutical compositions according to the invention are most especially well suited to the treatment of hyperproliferative disorders such as, in particular, cancers and restenosis. Thus the present invention provides an especially effective method for the destruction of cells, in particular hyperproliferative cells. It may be used in vitro or ex vivo. Ex vivo, it consists essentially in incubating the cells in the presence of one or more nucleic acids (or of a vector or cassette or of the derivative directly). In vivo, it consists in administering to the body an active amount of a vector (or cassette) according to the invention, preferably directly at the site to be treated (tumour in particular). In this connection, the subject of the invention is also a method of destruction of hyperproliferative cells, comprising the bringing of the said cells or of a portion of them into contact with a nucleic acid as defined above.
The present invention is advantageously used in vivo for the destruction of hyperproliferating (i.e. abnormally proliferating) cells. It is thus applicable to the destruction of tumour cells or smooth muscle cells of the vascular wall (restenosis). It is most especially suitable for the treatment of cancers in which an activated oncbgene is involved. As an example, there may be mentioned adenocarcinoma of the colon, thyroid cancer, carcinoma of the lung, myeloid leukaemia, colorectal cancer, breast cancer, lung cancer, stomach cancer, cancer of the oesophagus, B lymphoma, ovarian cancer, bladder cancer, glioblastoma, hepatocarcinoma, cancer of the bone, skin and pancreas or alternatively kidney and prostate cancer, and the like.
The products of the invention are also useful for the identification of other partners of the pathways of signalling of oncogenes, by testing for inhibitors, agonists, competitors or molecules that interact in vivo with these products.
Moreover, the invention also relates to antisense sequences whose expression a target cell enables the transcription and/or translation of cellular mRNAs coding for p62 or Δp62 to be controlled. Such sequences can, for example, be transcribed in the target cell into RNAs complementary to the Δp62 or p62 cellular mRNAs, and can thus block their translation into protein, according to the technique described in Patent EP 140,308. Such sequences can consist of all or part of the nucleic acid sequences SEQ ID NO. 1, 3 or 5, transcribed in the reverse orientation.
The present invention also relates to the use of any compound capable of inducing the expression or overexpression of Δp62 in a cell, for the preparation of a pharmaceutical composition intended for the treatment of hyperproliferative disorders.
The present invention will be described in greater detail by means of the examples which follow, which are to be considered to be illustrative and non-limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
Legends to the Figures
FIG. 1 : Diagrammatic representation of the structural domains of p62 and Δp62.
FIG. 2 : Effect of p62 and Δp62 on the transactivation by ras proteins of an RRE derived from the enhancer of polyoma virus.
FIG. 3 : Demonstration of Δp62-induced cell death in NIH3T3 fibroblasts.
FIG. 4 : Demonstration of the expression of Δp62 in embryonic fibroblasts treated with various cytotoxic agents and by deprivation of serum.
FIG. 5 : Inhibition of oncogene-induced foci formation.
DETAILED DESCRIPTION OF THE INVENTION
General Techniques of Molecular Biology
The methods traditionally used in molecular biology, such as preparative extractions of plasmid DNA, centrifugation of plasmid DNA in a caesium chloride gradient, agarose or acrylamide gel electrophoresis, purification of DNA fragments by electroelution, phenol or phenol-chloroform extraction of proteins, ethanol or isopropanol precipitation of DNA in a saline medium, transformation in Escherichia coli, and the like, are well known to a person skilled in the art and are amply described in the literature [Maniatis T. et al., “Molecular Cloning, a Laboratory Manual”, Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y., 1982; Ausubel F. M. et al. (eds), “Current Protocols in Molecular Biology”, John Wiley & Sons, New York, 1987].
Plasmids of the pBR322 and pUC type and phages of the M13 series are of commercial origin (Bethesda Research Laboratories). To carry out ligation, the DNA fragments may be separated according to their size by agarose or acrylamide gel electrophoresis, extracted with phenol or with a phenol-chloroform mixture, precipitated with ethanol and then incubated in the presence of phage T4 DNA ligase (Biolabs) according to the supplier's recommendations. The filling in of 5′ protruding ends; may be performed with the Klenow fragment of E. coli DNA polymerase I (Biolabs) according to the supplier's specifications. The destruction of 3′ protruding ends is performed in the presence of phage T4 DNA polymerase (Biolabs) used according to the manufacturer's recommendations. The destruction of 5′ protruding ends is performed by a controlled treatment with S1 nuclease.
In vitro site-directed mutagenesis using synthetic oligodeoxynucleotides may be performed according to the method developed by Taylor et al. [Nucleic Acids Res. 13 (1985) 8749-8764] using the kit distributed by Amersham. The enzymatic amplification of DNA fragments by the so-called PCR [polymerase-catalysed chain reaction, Saiki R. K. et al., Science 230 (1985) 1350-1354; Mullis K. B. and Faloona F. A., Meth. Enzym. 155 (1987) 335-350] technique may be performed using a “DNA thermal cycler” (Perkin Elmer Cetus) according to the manufacturer's specifications. Verification of the nucleotide sequences may be performed by the method developed by Sanger et al. [Proc. Natl. Acad. Sci. USA, 74 (1977) 5463-5467] using the kit distributed by Amersham.
EXAMPLES
Example 1
Isolation of Δp62 Complementary DNA
Δp62 complementary DNA was isolated by PCR on a population of complementary DNA Synthesized from poly(A)+RNAs extracted from human placenta. 1 μg of DNA was used jointly with primers derived from the sequence of p62 and which cover amino acids 123 to 131 on the one hand (5′ oligo) and 437 to 443 on the other hand (3′ oligo).
The sequences of these primers are as follows:
5′ oligo: CAGCTGCTGACGGCAGAAATTGAG (SEQ ID No. 7)
3′ oligo: TTMTMCGTCCATATGGGTGCTC (SEQ ID No. 8)
The reactions were carried out at 55° C. and gave two products separated by agarose gel electrophoresis:
a band of 987 base pairs which corresponds to the PCR product of p62
a band of 870 base pairs which corresponds to the PCR product of Δp62.
The latter band was cloned, and its sequence corresponds exactly to the sequence of p62 except for a deletion of 117 base pairs in the domain of homology to GRP33. The complete sequence of Δp62 is presented as SEQ ID No. 3 (see also FIG. 1 ).
The existence of this isoform of p62 was confirmed by screening a library of human placental complementary DNA, established in the vector λgt 11. The oligonucleotide used for this screening is a 24-mer corresponding to the specific junction of the deletion present in Δp62. The sequence of this oligonucleotide is:
CAGTATCCCMGGAGGMGAGCTG (SEQ ID No. 9)
Example 2
Construction of Vectors for the Expression of Δp62 and p62-C
This example describes the construction of vectors which can be used for transfer of the nucleic acids of the invention in vitro or in vivo.
2.1. Plasmid vector:
For the construction of plasmid vectors, two types of vector were used.
The vector SV2, described in DNA Cloning, A practical approach Vol. 2, D. M. Glover (Ed) IRL Press, Oxford, Washington D.C., 1985. This vector is a eukaryotic expression vector. The nucleic acids coding for the variants p62-C and Δp62 were inserted into this vector in the form of EcoRI fragments. They are thus placed under the control of the promoter of the SV40 virus enhancer.
The vector pcDNA3 (Invitrogen). This is also a eukaryotic expression vector. The nucleic acids coding for the variants p62-C and Δp62 were inserted into this vector in the form of EcoRI fragments, and are thus placed under the control of the CMV early promoter.
2.2. Viral vector
According to a particular embodiment, the invention lies in the construction and use of viral vectors permitting the transfer and expression in vivo of the nucleic acids as defined above.
As regards adenoviruses more especially, various serotypes whose structure and properties vary somewhat have been characterized. Among these serotypes, it is preferable to use, in the context of the present invention, human adenoviruses type 2 or 5 (Ad 2 or Ad 5) or adenoviruses of animal origin (see Application WO94/26914). Among adenoviruses of animal origin which can be used in the context of the present invention, adenoviruses of canine, bovine, murine (for example Mavl, Beard et al., Virology 75 (1990) 81), ovine, porcine, avian or alternatively simian (for example SAV) origin may be mentioned. Preferably, the adenovirus of animal origin is a canine adenovirus, and more preferably a CAV2 adenovirus [strain Manhattan or A26/61 (ATCC VR-800) for example]. Preferably, adenoviruses of human or canine or mixed origin are used in the context of the invention.
Preferably, the defective adenoviruses of the invention comprise the ITRs, a sequence permitting encapsidation and a nucleic acid according to the invention. Still more preferably, in the genome of the adenoviruses of the invention, the E1 region at least is non-functional. The viral gene in question may be rendered non-functional by any technique known to a person skilled in the art, and in particular by total elimination, substitution, partial deletion or addition of one or more bases in the gene or genes in question. Such modifications may be obtained in vitro (on the isolated DNA) or in situ, for example by means of genetic engineering techniques, or alternatively by treatment by means of mutagenic agents. Other regions may also be modified, and in particular the E3 region (WO95/02697), E2 region (WO94/28938), E4 region (WO94/28152, WO94/12649, WO95/02697) and L5 region (WO95/02697). According to a preferred embodiment, the adenovirus according to the invention comprises a deletion in the E1 and E4 regions. According to another preferred embodiment, it comprises a deletion in the E1 region into which are inserted the E4 region and the nucleic acid of the invention (see FR94/13355). In the viruses of the invention, the deletion in the E1 region preferably extends from nucleotides 455 to 3329 on the sequence of the Ad5 adenovirus.
The defective recombinant adenoviruses according to the invention may be prepared by any technique known to a person skilled in the art (Levrero et al., Gene 101 (1991) 195, EP 185,573; Graham, EMBO J. 3 (1984) 2917). In particular, they may be prepared by homologous recombination between an adenovirus and a plasmid carrying, inter alia, the DNA sequence of interest. Homologous recombination takes place after cotransfection of the said adenovirus and said plasmid into a suitable cell line. The cell line used should preferably (i) be amenable to transformation by the said elements, and (ii) contain the sequences capable of complementing the portion of the genome of the defective adenovirus, preferably in integrated form in order to avoid the risks of recombination. As an example of a line, there may be mentioned the human embryonic kidney line 293 (Graham et al., J. Gen. Virol. 36 (1977) 59), which contains, in particular, integrated in its genome, the left-hand portion of the genome of an Ad5 adenovirus (12%), or lines capable of complementing the E1 and E4 functions, as described, in particular, in Applications Nos. WO94/26914 and WO95/02697.
Thereafter, the adenoviruses which have multiplied are recovered and purified according to standard techniques of molecular biology, as illustrated in the examples.
Regarding adeno-associated viruses (AAV), the latter are relatively small DNA viruses which integrate stably and site-specifically in the genome of the cells they infect. They are capable of infecting a broad spectrum of cells without inducing an effect on growth, morphology or cell differentiation. Moreover, they do not appear to be involved in pathologies in man. The AAV genome has been cloned, sequenced and characterized. It comprises approximately 4700 bases, and contains at each end an inverted repeat region (ITR) of approximately 145 bases serving as origin of replication for the virus. The remainder of the genome is divided into 2 essential regions carrying the encapsidation functions: the left-hand portion of the genome, which contains the rep gene involved in viral replication and expression of the viral genes; and the right-hand portion of the genome, which contains the cap gene coding for the capsid proteins of the virus.
The use of vectors derived from AAV for gene transfer in vitro and in vivo has been described in the literature (see, in particular, WO91/18088; WO93/09239; U.S. Pat. Nos. 4,797,368, 5,139,941, EP 488,528). These applications describe various constructions derived from AAV, in which the rep and/or cap genes are deleted and replaced by a gene of interest, and their use for transferring the said gene of interest in vitro (on cells in culture) or in vivo (directly into a body). The defective recombinant AAVs according to the invention may be prepared by cotransfection, into a cell line infected with a human helper virus (for example an adenovirus), of a plasmid containing a nucleic acid sequence of the invention of interest flanked by two AAV inverted repeat regions (ITR) and of a plasmid carrying the AAV encapsidation genes (rep and cap genes). A cell line which can be used is, for example, the 293 line. The recombinant AAVs produced are then purified by standard techniques.
Regarding herpesviruses and retroviruses, the construction of recombinant vectors has been amply described in the literature: see, in particular, Breakfield et al., New Biologist 3 (1991) 203; EP 453,242, EP 178,220, Bernstein et al., Genet, Eng. 7 (1985) 235; McCormick, BioTechnology 3 (1985) 689, and the like. In particular, retroviruses are integrative viruses that selectively infect dividing cells. Hence they constitute vectors of interest for cancer applications. The genome of retroviruses essentially comprises two LTRs, an encapsidation sequence and three coding regions (gag, pol and env). In the recombinant vectors derived from retroviruses, the gag, pol and env genes are generally deleted wholly or partially, and replaced by a heterologous nucleic acid sequence of interest. These vectors may be prepared from different types of retrovirus such as, in particular, MoMuLV (Murine moloney leukaemia virus, also designated MoMLV), MSV (Murine moloney sarcoma virus), HaSV (Harvey sarcoma virus), SNV (spleen necrosis virus), RSV (Rous sarcoma virus) or alternatively Friend virus.
To construct recombinant retroviruses according to the invention containing a nucleic acid according to the invention, a plasmid containing, in particular, the LTRs, the encapsidation sequence and the said nucleic acid is constructed, and is then used to transfect a so-called encapsidation cell line capable of supplying in trans the retroviral functions which are deficient in the plasmid. Generally, the encapsidation lines are hence capable of expressing the gag, pol and env genes. Such encapsidation lines have been described in the prior art, and in particular the PA317 line (U.S. Pat. No. 4,861,719), the PsiCRIP line (WO90/02806) and the GP+envAm-12 line (WO89/07150). Moreover, the recombinant retroviruses can contain modifications in the LTRs in order to abolish transcriptional activity, as well as extended encapsidation sequences containing a portion of the gag gene (Bender et al., J. Virol. 61 (1987) 1639). The recombinant retroviruses produced are then purified by standard techniques.
To carry out the present invention, it is most especially advantageous to use a defective recombinant adenovirus or retrovirus. These vectors possess, in effect, especially advantageous properties for the transfer of genes into tumour cells.
2.3. Chemical vector
Among the synthetic vectors developed, it is preferable to use, in the context of the invention, cationic polymers of polylysine, (LKLK) n , (LKKL) n , polyethylenimine and DEAE-dextran type, or alternatively cationic lipids or lipofectants. They possess the property of condensing DNA and of promoting its association with the cell membrane. Among these latter vectors, lipopolyamines (lipofectamine, transfectam, and the like) and various cationic or neutral lipids (DOTMA, DOGS, DOPE, and the like), as well as peptides of nuclear origin, may be mentioned. In addition, the concept of receptor-mediated targeted transfection has been developed, which turns to good account the principle of condensing DNA by means of the cationic polymer while directing the binding of the complex to the membrane by means of a chemical coupling between the cationic polymer and the ligand for a membrane receptor, present at the surface of the cell type. which it is desired to graft. The targeting of the transferrin or insulin receptor or of the asialoglycoprotein receptor of hepatocytes has thus been described. The preparation of a composition according to the invention using a chemical vector of this kind is carried out according to any technique known to a person skilled in the art, generally by simply bringing the different components into contact.
Example 3
Inhibition of the Transactivation of RRE (Ras Responsive Elements) Due to the Oncogenic Forms of Ras (FIG. 2)
NIH 3T3 fibroblasts were transfected with a reporter gene, that for chloramphenicol acetyltransferase, placed under the control of Ras responsive elements derived from the enhancer of polyoma virus. These elements are stimulated from 15- to 20-fold when the cells are cotransfected with an expression vector carrying the cDNA of the SV40 oncogene Middle T(MT). This stimulation is only slightly affected when a cotransfection supplies the vectors for the expression of p62-C and of Δp62 (see Example 2). When the cotransfection is carried out with the activated form of the oncogene Ha-ras (Val 12) instead of with MT, the CAT activity is stimulated from 30- to 40-fold above the baseline level. The expression of p62 has little effect on this stimulation, whereas p62-C and Δp62 inhibit almost completely all activity due to the oncogenic Ras. In the same way, the stimulation obtained by cotransfection with the oncogene v-src is strongly inhibited by the p62-C and Δp62 proteins, but not by p62.
These experiments were carried out with 0.5 μg of vector permitting the expression of MT or of Ras VAL 12 or of v-src, and 4 μg of expression vector carrying the p62-C or Δp62 cDNA. They demonstrate clearly the power of the proteins of the invention to interfere with the oncogenic ras signals.
Example 4
Demonstration of Δp62-induced Cell Death in NIH3T3 Fibroblasts (FIG. 3)
NIH3T3 fibroblasts were transfected with an efficiency of 60% with 5 μg of vector for the expression of Δp62 (Example 2).
24 hours after transfection, the cells display a considerable impairment of their viability with respect to the control. Analysis of their DNA reveals, after migration on agarose gel, scales of degradation characteristic of the phenomena of apoptosis. The same phenomena are observed when p62-C is transfected under the same conditions as Δp62.
Example 5
Demonstration of the Expression of Δp62 in Embryonic Fibroblasts Treated with Various Cytotoxic Agents and by Deprivation of Serum (FIG. 4)
Mouse embryonic fibroblasts were cultured (1), treated with 0.5 μg of okadaic acid (2), treated with 10 ng/ml of PMA and with 2 μg of ionomycin (3), subjected to 1 μM staurosporine (4) or to 2 μg/ml of camptothecin (5) and lastly deprived of serum.
The expression of the p62 and Δp62 messenger RNAs in these fibroblasts and during these various treatments was analysed. At each treatment, three points were analysed. These points correspond to three treatment times: 6, 12 and 24 hours.
5′ probe specific for Δp62 (SEQ ID No. 10): CTGTCMGCAGTATCCCAAGGAGG
5′ probe specific for p62 (SEQ ID No. 11): AAGGGCTCAATGAGAGACAAAGCC
3′ probe common to p62 and to Δp62 (SEQ ID No. 12): GTATGTATCATCATATCCATATTC
In the fibroblasts cultured in the presence of 10% foetal calf serum (FCS), p62 mRNA is revealed, whereas Δp62 mRNA is not detected even after 24 hours of culturing. The situation is the same during treatment with okadaic acid. In contrast, a strong induction of Δp62 mRNA is observed after 6 to 12 hours of treatment with PMA and ionomycin. This mRNA is also detectable after the addition of staurosporine, and is very strongly induced after 12 hours of treatment with camptothecin. When the embryonic fibroblasts are deprived of serum, a strong induction of Δp62 is observed at the same time as a disappearance of the p62 messenger.
Hence these results demonstrate that the expression of Δp62 mRNA is induced in the course of certain apoptotic situations in fibroblasts.
Example 6
Inhibition by Δp62 of Ras-induced Foci Formation
This example describes another study showing that Δp62 interferes with the oncogene-induced transformation process. More especially, this example demonstrates that Δp62 is capable of inhibiting the formation of foci induced by various oncogenes (oncogenic ras, v-src) in NIH-3T3 cells, whereas p62 does not affect this phenomenon.
NIH3T3 fibroblasts were cotransfected with 0.1 μg of vector for the expression of v-Src or Ha-Ras Val12 and with 4 mg of vector for the expression of p62 or of Δp62 or empty vector (Example 2). The cells were maintained in medium containing 10% of newborn calf serum, and the number of foci was determined after fixation and staining of the cells in the presence of phenol-fuchsin. The experiments were carried out in triplicate.
The results obtained are presented in FIG. 5 . They show that Δp62 decreases the number of foci induced by v-src and Ha-Ras Val12 by approximately 50%. This effect reflects a specific antagonist power with respect to transformation by v-src and oncogenic Ha-Ras, since Δp62 does not affect the formation of foci induced by v-Raf. In addition, the observed effect is not associated with a toxicity of the product, since the number of neomycin-resistant colonies after transfection with p62, Δp62 or an empty vector is comparable. Hence these results confirm the inhibitory role of the molecules of the invention in the oncogene-induced transformation process. These results thus confirm the usefulness of these products in approaches of correction of the processes of cell proliferation induced by oncogenes, and also as a tool for the identification of other active molecules and/or those involved in the pathways of signalling of these oncogenes.
Example 7
Demonstration of an Interaction with Src in vivo
This example describes a study of the interaction of Δp62 with other molecules. It demonstrates that p62 and Δp62 are capable of interacting in vivo with src.
NIH3T3 fibroblasts were transfected with a vector for the expression of p62 or of Δp62 comprising an myc marker (“myc teg”) (Example 2). The transfected cells were maintained In asynchronous growth or blocked in the mitotic phase by treatment with nocodazole. The cells were then cotransfected with a vector for the expression of v-Src or an empty vector. 48 hours later, the cells were lysed, and the complexes formed were immunodetected by means of anti-myc antibodies (9E10 antibodies) and anti-Src antibodies (N16 antibodies).
The results obtained show that p62 and Δp62 are capable of interacting in vivo with src. In addition, whereas the interaction between p62 and src appears to take place only in mitotic cells, Δp62 binds significantly to Src even in asynchronous cells. This interaction is strengthened in mitotic cells.
12
1332 base pairs
nucleic acid
single
linear
cDNA
CDS
1..1332
1
ATG CAG CGC CGG GAC GAC CCC GCC GCG CGC ATG AGC CGG TCT TCG GGC 48
Met Gln Arg Arg Asp Asp Pro Ala Ala Arg Met Ser Arg Ser Ser Gly
1 5 10 15
CGT AGC GGC TCC ATG GAC CCC TCC GGT GCC CAC CCC TCG GTG CGT CAG 96
Arg Ser Gly Ser Met Asp Pro Ser Gly Ala His Pro Ser Val Arg Gln
20 25 30
ACG CCG TCT CGG CAG CCG CCG CTG CCT CAC CGG TCC CGG GGA GGC GGA 144
Thr Pro Ser Arg Gln Pro Pro Leu Pro His Arg Ser Arg Gly Gly Gly
35 40 45
GGG GGA TCC CGC GGG GGC GCC CGG GCC TCG CCC GCC ACG CAG CCG CCA 192
Gly Gly Ser Arg Gly Gly Ala Arg Ala Ser Pro Ala Thr Gln Pro Pro
50 55 60
CCG CTG CTG CCG CCC TCG GCC ACG GGT CCC GAC GCG ACA GTG GGC GGG 240
Pro Leu Leu Pro Pro Ser Ala Thr Gly Pro Asp Ala Thr Val Gly Gly
65 70 75 80
CCA GCG CCG ACC CCG CTG CTG CCC CCC TCG GCC ACA GCC TCG GTC AAG 288
Pro Ala Pro Thr Pro Leu Leu Pro Pro Ser Ala Thr Ala Ser Val Lys
85 90 95
ATG GAG CCA GAG AAC AAG TAC CTG CCC GAA CTC ATG GCC GAG AAG GAC 336
Met Glu Pro Glu Asn Lys Tyr Leu Pro Glu Leu Met Ala Glu Lys Asp
100 105 110
TCG CTC GAC CCG TCC TTC ACT CAC GCC ATG CAG CTG CTG ACG GCA GAA 384
Ser Leu Asp Pro Ser Phe Thr His Ala Met Gln Leu Leu Thr Ala Glu
115 120 125
ATT GAG AAG ATT CAG AAA GGA GAC TCA AAA AAG GAT GAT GAG GAG AAT 432
Ile Glu Lys Ile Gln Lys Gly Asp Ser Lys Lys Asp Asp Glu Glu Asn
130 135 140
TAC TTG GAT TTA TTT TCT CAT AAG AAC ATG AAA CTG AAA GAG CGA GTG 480
Tyr Leu Asp Leu Phe Ser His Lys Asn Met Lys Leu Lys Glu Arg Val
145 150 155 160
CTG ATA CCT GTC AAG CAG TAT CCC AAG TTC AAT TTT GTG GGG AAG ATT 528
Leu Ile Pro Val Lys Gln Tyr Pro Lys Phe Asn Phe Val Gly Lys Ile
165 170 175
CTT GGA CCA CAA GGG AAT ACA ATC AAA AGA CTG CAG GAA GAG ACT GGT 576
Leu Gly Pro Gln Gly Asn Thr Ile Lys Arg Leu Gln Glu Glu Thr Gly
180 185 190
GCA AAG ATC TCT GTA TTG GGA AAG GGC TCA ATG AGA GAC AAA GCC AAG 624
Ala Lys Ile Ser Val Leu Gly Lys Gly Ser Met Arg Asp Lys Ala Lys
195 200 205
GAG GAA GAG CTG CGC AAA GGT GGA GAC CCC AAA TAT GCC CAC TTG AAT 672
Glu Glu Glu Leu Arg Lys Gly Gly Asp Pro Lys Tyr Ala His Leu Asn
210 215 220
ATG GAT CTG CAT GTC TTC ATT GAA GTC TTT GGA CCC CCA TGT GAG GCT 720
Met Asp Leu His Val Phe Ile Glu Val Phe Gly Pro Pro Cys Glu Ala
225 230 235 240
TAT GCT CTT ATG GCC CAT GCC ATG GAG GAA GTC AAG AAA TTT CTA GTA 768
Tyr Ala Leu Met Ala His Ala Met Glu Glu Val Lys Lys Phe Leu Val
245 250 255
CCG GAT ATG ATG GAT GAT ATC TGT CAG GAG CAA TTT CTA GAG CTG TCC 816
Pro Asp Met Met Asp Asp Ile Cys Gln Glu Gln Phe Leu Glu Leu Ser
260 265 270
TAC TTG AAT GGA GTA CCT GAA CCC TCT CGT GGA CGT GGG GTG CCA GTG 864
Tyr Leu Asn Gly Val Pro Glu Pro Ser Arg Gly Arg Gly Val Pro Val
275 280 285
AGA GGC CGG GGA GCT GCA CCT CCT CCA CCA CCT GTT CCC AGG GGC CGT 912
Arg Gly Arg Gly Ala Ala Pro Pro Pro Pro Pro Val Pro Arg Gly Arg
290 295 300
GGT GTT GGA CCA CCT CGG GGG GCT TTG GTA CGT GGT ACA CCA GTA AGG 960
Gly Val Gly Pro Pro Arg Gly Ala Leu Val Arg Gly Thr Pro Val Arg
305 310 315 320
GGA GCC ATC ACC AGA GGT GCC ACT GTG ACT CGA GGC GTG CCA CCC CCA 1008
Gly Ala Ile Thr Arg Gly Ala Thr Val Thr Arg Gly Val Pro Pro Pro
325 330 335
CCT ACT GTG AGG GGT GCT CCA GCA CCA AGA GCA CGG ACA GCG GGC ATC 1056
Pro Thr Val Arg Gly Ala Pro Ala Pro Arg Ala Arg Thr Ala Gly Ile
340 345 350
CAG AGG ATA CCT TTG CCT CCA CCT CCT GCA CCA GAA ACA TAT GAA GAA 1104
Gln Arg Ile Pro Leu Pro Pro Pro Pro Ala Pro Glu Thr Tyr Glu Glu
355 360 365
TAT GGA TAT GAT GAT ACA TAC GCA GAA CAA AGT TAC GAA GGC TAC GAA 1152
Tyr Gly Tyr Asp Asp Thr Tyr Ala Glu Gln Ser Tyr Glu Gly Tyr Glu
370 375 380
GGC TAT TAC AGC CAG AGT CAA GGG GAC TCA GAA TAT TAT GAC TAT GGA 1200
Gly Tyr Tyr Ser Gln Ser Gln Gly Asp Ser Glu Tyr Tyr Asp Tyr Gly
385 390 395 400
CAT GGG GAG GTT CAA GAT TCT TAT GAA GCT TAT GGC CAG GAC GAC TGG 1248
His Gly Glu Val Gln Asp Ser Tyr Glu Ala Tyr Gly Gln Asp Asp Trp
405 410 415
AAT GGG ACC AGG CCG TCG CTG AAG GCC CCT CCT GCT AGG CCA GTG AAG 1296
Asn Gly Thr Arg Pro Ser Leu Lys Ala Pro Pro Ala Arg Pro Val Lys
420 425 430
GGA GCA TAC AGA GAG CAC CCA TAT GGA CGT TAT TAA 1332
Gly Ala Tyr Arg Glu His Pro Tyr Gly Arg Tyr *
435 440
443 amino acids
amino acid
linear
protein
2
Met Gln Arg Arg Asp Asp Pro Ala Ala Arg Met Ser Arg Ser Ser Gly
1 5 10 15
Arg Ser Gly Ser Met Asp Pro Ser Gly Ala His Pro Ser Val Arg Gln
20 25 30
Thr Pro Ser Arg Gln Pro Pro Leu Pro His Arg Ser Arg Gly Gly Gly
35 40 45
Gly Gly Ser Arg Gly Gly Ala Arg Ala Ser Pro Ala Thr Gln Pro Pro
50 55 60
Pro Leu Leu Pro Pro Ser Ala Thr Gly Pro Asp Ala Thr Val Gly Gly
65 70 75 80
Pro Ala Pro Thr Pro Leu Leu Pro Pro Ser Ala Thr Ala Ser Val Lys
85 90 95
Met Glu Pro Glu Asn Lys Tyr Leu Pro Glu Leu Met Ala Glu Lys Asp
100 105 110
Ser Leu Asp Pro Ser Phe Thr His Ala Met Gln Leu Leu Thr Ala Glu
115 120 125
Ile Glu Lys Ile Gln Lys Gly Asp Ser Lys Lys Asp Asp Glu Glu Asn
130 135 140
Tyr Leu Asp Leu Phe Ser His Lys Asn Met Lys Leu Lys Glu Arg Val
145 150 155 160
Leu Ile Pro Val Lys Gln Tyr Pro Lys Phe Asn Phe Val Gly Lys Ile
165 170 175
Leu Gly Pro Gln Gly Asn Thr Ile Lys Arg Leu Gln Glu Glu Thr Gly
180 185 190
Ala Lys Ile Ser Val Leu Gly Lys Gly Ser Met Arg Asp Lys Ala Lys
195 200 205
Glu Glu Glu Leu Arg Lys Gly Gly Asp Pro Lys Tyr Ala His Leu Asn
210 215 220
Met Asp Leu His Val Phe Ile Glu Val Phe Gly Pro Pro Cys Glu Ala
225 230 235 240
Tyr Ala Leu Met Ala His Ala Met Glu Glu Val Lys Lys Phe Leu Val
245 250 255
Pro Asp Met Met Asp Asp Ile Cys Gln Glu Gln Phe Leu Glu Leu Ser
260 265 270
Tyr Leu Asn Gly Val Pro Glu Pro Ser Arg Gly Arg Gly Val Pro Val
275 280 285
Arg Gly Arg Gly Ala Ala Pro Pro Pro Pro Pro Val Pro Arg Gly Arg
290 295 300
Gly Val Gly Pro Pro Arg Gly Ala Leu Val Arg Gly Thr Pro Val Arg
305 310 315 320
Gly Ala Ile Thr Arg Gly Ala Thr Val Thr Arg Gly Val Pro Pro Pro
325 330 335
Pro Thr Val Arg Gly Ala Pro Ala Pro Arg Ala Arg Thr Ala Gly Ile
340 345 350
Gln Arg Ile Pro Leu Pro Pro Pro Pro Ala Pro Glu Thr Tyr Glu Glu
355 360 365
Tyr Gly Tyr Asp Asp Thr Tyr Ala Glu Gln Ser Tyr Glu Gly Tyr Glu
370 375 380
Gly Tyr Tyr Ser Gln Ser Gln Gly Asp Ser Glu Tyr Tyr Asp Tyr Gly
385 390 395 400
His Gly Glu Val Gln Asp Ser Tyr Glu Ala Tyr Gly Gln Asp Asp Trp
405 410 415
Asn Gly Thr Arg Pro Ser Leu Lys Ala Pro Pro Ala Arg Pro Val Lys
420 425 430
Gly Ala Tyr Arg Glu His Pro Tyr Gly Arg Tyr
435 440
1215 base pairs
nucleic acid
single
linear
cDNA
CDS
1..1215
3
ATG CAG CGC CGG GAC GAC CCC GCC GCG CGC ATG AGC CGG TCT TCG GGC 48
Met Gln Arg Arg Asp Asp Pro Ala Ala Arg Met Ser Arg Ser Ser Gly
445 450 455 460
CGT AGC GGC TCC ATG GAC CCC TCC GGT GCC CAC CCC TCG GTG CGT CAG 96
Arg Ser Gly Ser Met Asp Pro Ser Gly Ala His Pro Ser Val Arg Gln
465 470 475
ACG CCG TCT CGG CAG CCG CCG CTG CCT CAC CGG TCC CGG GGA GGC GGA 144
Thr Pro Ser Arg Gln Pro Pro Leu Pro His Arg Ser Arg Gly Gly Gly
480 485 490
GGG GGA TCC CGC GGG GGC GCC CGG GCC TCG CCC GCC ACG CAG CCG CCA 192
Gly Gly Ser Arg Gly Gly Ala Arg Ala Ser Pro Ala Thr Gln Pro Pro
495 500 505
CCG CTG CTG CCG CCC TCG GCC ACG GGT CCC GAC GCG ACA GTG GGC GGG 240
Pro Leu Leu Pro Pro Ser Ala Thr Gly Pro Asp Ala Thr Val Gly Gly
510 515 520
CCA GCG CCG ACC CCG CTG CTG CCC CCC TCG GCC ACA GCC TCG GTC AAG 288
Pro Ala Pro Thr Pro Leu Leu Pro Pro Ser Ala Thr Ala Ser Val Lys
525 530 535 540
ATG GAG CCA GAG AAC AAG TAC CTG CCC GAA CTC ATG GCC GAG AAG GAC 336
Met Glu Pro Glu Asn Lys Tyr Leu Pro Glu Leu Met Ala Glu Lys Asp
545 550 555
TCG CTC GAC CCG TCC TTC ACT CAC GCC ATG CAG CTG CTG ACG GCA GAA 384
Ser Leu Asp Pro Ser Phe Thr His Ala Met Gln Leu Leu Thr Ala Glu
560 565 570
ATT GAG AAG ATT CAG AAA GGA GAC TCA AAA AAG GAT GAT GAG GAG AAT 432
Ile Glu Lys Ile Gln Lys Gly Asp Ser Lys Lys Asp Asp Glu Glu Asn
575 580 585
TAC TTG GAT TTA TTT TCT CAT AAG AAC ATG AAA CTG AAA GAG CGA GTG 480
Tyr Leu Asp Leu Phe Ser His Lys Asn Met Lys Leu Lys Glu Arg Val
590 595 600
CTG ATA CCT GTC AAG CAG TAT CCC AAG GAG GAA GAG CTG CGC AAA GGT 528
Leu Ile Pro Val Lys Gln Tyr Pro Lys Glu Glu Glu Leu Arg Lys Gly
605 610 615 620
GGA GAC CCC AAA TAT GCC CAC TTG AAT ATG GAT CTG CAT GTC TTC ATT 576
Gly Asp Pro Lys Tyr Ala His Leu Asn Met Asp Leu His Val Phe Ile
625 630 635
GAA GTC TTT GGA CCC CCA TGT GAG GCT TAT GCT CTT ATG GCC CAT GCC 624
Glu Val Phe Gly Pro Pro Cys Glu Ala Tyr Ala Leu Met Ala His Ala
640 645 650
ATG GAG GAA GTC AAG AAA TTT CTA GTA CCG GAT ATG ATG GAT GAT ATC 672
Met Glu Glu Val Lys Lys Phe Leu Val Pro Asp Met Met Asp Asp Ile
655 660 665
TGT CAG GAG CAA TTT CTA GAG CTG TCC TAC TTG AAT GGA GTA CCT GAA 720
Cys Gln Glu Gln Phe Leu Glu Leu Ser Tyr Leu Asn Gly Val Pro Glu
670 675 680
CCC TCT CGT GGA CGT GGG GTG CCA GTG AGA GGC CGG GGA GCT GCA CCT 768
Pro Ser Arg Gly Arg Gly Val Pro Val Arg Gly Arg Gly Ala Ala Pro
685 690 695 700
CCT CCA CCA CCT GTT CCC AGG GGC CGT GGT GTT GGA CCA CCT CGG GGG 816
Pro Pro Pro Pro Val Pro Arg Gly Arg Gly Val Gly Pro Pro Arg Gly
705 710 715
GCT TTG GTA CGT GGT ACA CCA GTA AGG GGA GCC ATC ACC AGA GGT GCC 864
Ala Leu Val Arg Gly Thr Pro Val Arg Gly Ala Ile Thr Arg Gly Ala
720 725 730
ACT GTG ACT CGA GGC GTG CCA CCC CCA CCT ACT GTG AGG GGT GCT CCA 912
Thr Val Thr Arg Gly Val Pro Pro Pro Pro Thr Val Arg Gly Ala Pro
735 740 745
GCA CCA AGA GCA CGG ACA GCG GGC ATC CAG AGG ATA CCT TTG CCT CCA 960
Ala Pro Arg Ala Arg Thr Ala Gly Ile Gln Arg Ile Pro Leu Pro Pro
750 755 760
CCT CCT GCA CCA GAA ACA TAT GAA GAA TAT GGA TAT GAT GAT ACA TAC 1008
Pro Pro Ala Pro Glu Thr Tyr Glu Glu Tyr Gly Tyr Asp Asp Thr Tyr
765 770 775 780
GCA GAA CAA AGT TAC GAA GGC TAC GAA GGC TAT TAC AGC CAG AGT CAA 1056
Ala Glu Gln Ser Tyr Glu Gly Tyr Glu Gly Tyr Tyr Ser Gln Ser Gln
785 790 795
GGG GAC TCA GAA TAT TAT GAC TAT GGA CAT GGG GAG GTT CAA GAT TCT 1104
Gly Asp Ser Glu Tyr Tyr Asp Tyr Gly His Gly Glu Val Gln Asp Ser
800 805 810
TAT GAA GCT TAT GGC CAG GAC GAC TGG AAT GGG ACC AGG CCG TCG CTG 1152
Tyr Glu Ala Tyr Gly Gln Asp Asp Trp Asn Gly Thr Arg Pro Ser Leu
815 820 825
AAG GCC CCT CCT GCT AGG CCA GTG AAG GGA GCA TAC AGA GAG CAC CCA 1200
Lys Ala Pro Pro Ala Arg Pro Val Lys Gly Ala Tyr Arg Glu His Pro
830 835 840
TAT GGA CGT TAT TAA 1215
Tyr Gly Arg Tyr *
845
404 amino acids
amino acid
linear
protein
4
Met Gln Arg Arg Asp Asp Pro Ala Ala Arg Met Ser Arg Ser Ser Gly
1 5 10 15
Arg Ser Gly Ser Met Asp Pro Ser Gly Ala His Pro Ser Val Arg Gln
20 25 30
Thr Pro Ser Arg Gln Pro Pro Leu Pro His Arg Ser Arg Gly Gly Gly
35 40 45
Gly Gly Ser Arg Gly Gly Ala Arg Ala Ser Pro Ala Thr Gln Pro Pro
50 55 60
Pro Leu Leu Pro Pro Ser Ala Thr Gly Pro Asp Ala Thr Val Gly Gly
65 70 75 80
Pro Ala Pro Thr Pro Leu Leu Pro Pro Ser Ala Thr Ala Ser Val Lys
85 90 95
Met Glu Pro Glu Asn Lys Tyr Leu Pro Glu Leu Met Ala Glu Lys Asp
100 105 110
Ser Leu Asp Pro Ser Phe Thr His Ala Met Gln Leu Leu Thr Ala Glu
115 120 125
Ile Glu Lys Ile Gln Lys Gly Asp Ser Lys Lys Asp Asp Glu Glu Asn
130 135 140
Tyr Leu Asp Leu Phe Ser His Lys Asn Met Lys Leu Lys Glu Arg Val
145 150 155 160
Leu Ile Pro Val Lys Gln Tyr Pro Lys Glu Glu Glu Leu Arg Lys Gly
165 170 175
Gly Asp Pro Lys Tyr Ala His Leu Asn Met Asp Leu His Val Phe Ile
180 185 190
Glu Val Phe Gly Pro Pro Cys Glu Ala Tyr Ala Leu Met Ala His Ala
195 200 205
Met Glu Glu Val Lys Lys Phe Leu Val Pro Asp Met Met Asp Asp Ile
210 215 220
Cys Gln Glu Gln Phe Leu Glu Leu Ser Tyr Leu Asn Gly Val Pro Glu
225 230 235 240
Pro Ser Arg Gly Arg Gly Val Pro Val Arg Gly Arg Gly Ala Ala Pro
245 250 255
Pro Pro Pro Pro Val Pro Arg Gly Arg Gly Val Gly Pro Pro Arg Gly
260 265 270
Ala Leu Val Arg Gly Thr Pro Val Arg Gly Ala Ile Thr Arg Gly Ala
275 280 285
Thr Val Thr Arg Gly Val Pro Pro Pro Pro Thr Val Arg Gly Ala Pro
290 295 300
Ala Pro Arg Ala Arg Thr Ala Gly Ile Gln Arg Ile Pro Leu Pro Pro
305 310 315 320
Pro Pro Ala Pro Glu Thr Tyr Glu Glu Tyr Gly Tyr Asp Asp Thr Tyr
325 330 335
Ala Glu Gln Ser Tyr Glu Gly Tyr Glu Gly Tyr Tyr Ser Gln Ser Gln
340 345 350
Gly Asp Ser Glu Tyr Tyr Asp Tyr Gly His Gly Glu Val Gln Asp Ser
355 360 365
Tyr Glu Ala Tyr Gly Gln Asp Asp Trp Asn Gly Thr Arg Pro Ser Leu
370 375 380
Lys Ala Pro Pro Ala Arg Pro Val Lys Gly Ala Tyr Arg Glu His Pro
385 390 395 400
Tyr Gly Arg Tyr
726 base pairs
nucleic acid
single
linear
cDNA
CDS
1..726
5
ATG AGA GAC AAA GCC AAG GAG GAA GAG CTG CGC AAA GGT GGA GAC CCC 48
Met Arg Asp Lys Ala Lys Glu Glu Glu Leu Arg Lys Gly Gly Asp Pro
410 415 420
AAA TAT GCC CAC TTG AAT ATG GAT CTG CAT GTC TTC ATT GAA GTC TTT 96
Lys Tyr Ala His Leu Asn Met Asp Leu His Val Phe Ile Glu Val Phe
425 430 435
GGA CCC CCA TGT GAG GCT TAT GCT CTT ATG GCC CAT GCC ATG GAG GAA 144
Gly Pro Pro Cys Glu Ala Tyr Ala Leu Met Ala His Ala Met Glu Glu
440 445 450
GTC AAG AAA TTT CTA GTA CCG GAT ATG ATG GAT GAT ATC TGT CAG GAG 192
Val Lys Lys Phe Leu Val Pro Asp Met Met Asp Asp Ile Cys Gln Glu
455 460 465
CAA TTT CTA GAG CTG TCC TAC TTG AAT GGA GTA CCT GAA CCC TCT CGT 240
Gln Phe Leu Glu Leu Ser Tyr Leu Asn Gly Val Pro Glu Pro Ser Arg
470 475 480 485
GGA CGT GGG GTG CCA GTG AGA GGC CGG GGA GCT GCA CCT CCT CCA CCA 288
Gly Arg Gly Val Pro Val Arg Gly Arg Gly Ala Ala Pro Pro Pro Pro
490 495 500
CCT GTT CCC AGG GGC CGT GGT GTT GGA CCA CCT CGG GGG GCT TTG GTA 336
Pro Val Pro Arg Gly Arg Gly Val Gly Pro Pro Arg Gly Ala Leu Val
505 510 515
CGT GGT ACA CCA GTA AGG GGA GCC ATC ACC AGA GGT GCC ACT GTG ACT 384
Arg Gly Thr Pro Val Arg Gly Ala Ile Thr Arg Gly Ala Thr Val Thr
520 525 530
CGA GGC GTG CCA CCC CCA CCT ACT GTG AGG GGT GCT CCA GCA CCA AGA 432
Arg Gly Val Pro Pro Pro Pro Thr Val Arg Gly Ala Pro Ala Pro Arg
535 540 545
GCA CGG ACA GCG GGC ATC CAG AGG ATA CCT TTG CCT CCA CCT CCT GCA 480
Ala Arg Thr Ala Gly Ile Gln Arg Ile Pro Leu Pro Pro Pro Pro Ala
550 555 560 565
CCA GAA ACA TAT GAA GAA TAT GGA TAT GAT GAT ACA TAC GCA GAA CAA 528
Pro Glu Thr Tyr Glu Glu Tyr Gly Tyr Asp Asp Thr Tyr Ala Glu Gln
570 575 580
AGT TAC GAA GGC TAC GAA GGC TAT TAC AGC CAG AGT CAA GGG GAC TCA 576
Ser Tyr Glu Gly Tyr Glu Gly Tyr Tyr Ser Gln Ser Gln Gly Asp Ser
585 590 595
GAA TAT TAT GAC TAT GGA CAT GGG GAG GTT CAA GAT TCT TAT GAA GCT 624
Glu Tyr Tyr Asp Tyr Gly His Gly Glu Val Gln Asp Ser Tyr Glu Ala
600 605 610
TAT GGC CAG GAC GAC TGG AAT GGG ACC AGG CCG TCG CTG AAG GCC CCT 672
Tyr Gly Gln Asp Asp Trp Asn Gly Thr Arg Pro Ser Leu Lys Ala Pro
615 620 625
CCT GCT AGG CCA GTG AAG GGA GCA TAC AGA GAG CAC CCA TAT GGA CGT 720
Pro Ala Arg Pro Val Lys Gly Ala Tyr Arg Glu His Pro Tyr Gly Arg
630 635 640 645
TAT TAA 726
Tyr *
241 amino acids
amino acid
linear
protein
6
Met Arg Asp Lys Ala Lys Glu Glu Glu Leu Arg Lys Gly Gly Asp Pro
1 5 10 15
Lys Tyr Ala His Leu Asn Met Asp Leu His Val Phe Ile Glu Val Phe
20 25 30
Gly Pro Pro Cys Glu Ala Tyr Ala Leu Met Ala His Ala Met Glu Glu
35 40 45
Val Lys Lys Phe Leu Val Pro Asp Met Met Asp Asp Ile Cys Gln Glu
50 55 60
Gln Phe Leu Glu Leu Ser Tyr Leu Asn Gly Val Pro Glu Pro Ser Arg
65 70 75 80
Gly Arg Gly Val Pro Val Arg Gly Arg Gly Ala Ala Pro Pro Pro Pro
85 90 95
Pro Val Pro Arg Gly Arg Gly Val Gly Pro Pro Arg Gly Ala Leu Val
100 105 110
Arg Gly Thr Pro Val Arg Gly Ala Ile Thr Arg Gly Ala Thr Val Thr
115 120 125
Arg Gly Val Pro Pro Pro Pro Thr Val Arg Gly Ala Pro Ala Pro Arg
130 135 140
Ala Arg Thr Ala Gly Ile Gln Arg Ile Pro Leu Pro Pro Pro Pro Ala
145 150 155 160
Pro Glu Thr Tyr Glu Glu Tyr Gly Tyr Asp Asp Thr Tyr Ala Glu Gln
165 170 175
Ser Tyr Glu Gly Tyr Glu Gly Tyr Tyr Ser Gln Ser Gln Gly Asp Ser
180 185 190
Glu Tyr Tyr Asp Tyr Gly His Gly Glu Val Gln Asp Ser Tyr Glu Ala
195 200 205
Tyr Gly Gln Asp Asp Trp Asn Gly Thr Arg Pro Ser Leu Lys Ala Pro
210 215 220
Pro Ala Arg Pro Val Lys Gly Ala Tyr Arg Glu His Pro Tyr Gly Arg
225 230 235 240
Tyr
24 base pairs
nucleic acid
single
linear
other nucleic acid
/desc = “Oligonucleotide”
7
CAGCTGCTGA CGGCAGAAAT TGAG 24
24 base pairs
nucleic acid
single
linear
other nucleic acid
/desc = “Oligonucleotide”
8
TTAATAACGT CCATATGGGT GCTC 24
24 base pairs
nucleic acid
single
linear
other nucleic acid
/desc = “Oligonucleotide”
9
CAGTATCCCA AGGAGGAAGA GCTG 24
24 base pairs
nucleic acid
single
linear
other nucleic acid
/desc = “Oligonucleotide”
10
CTGTCAAGCA GTATCCCAAG GAGG 24
24 base pairs
nucleic acid
single
linear
other nucleic acid
/desc = “Oligonucleotide”
11
AAGGGCTCAA TGAGAGACAA AGCC 24
24 base pairs
nucleic acid
single
linear
other nucleic acid
/desc = “Oligonucleotide”
12
GTATGTATCA TCATATCCAT ATTC 24
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A polypeptide derivative of p62 having at least one deletion of at least one amino acid between amino acids 145 to 247 of p62, where the derivative inhibits signals transduced by ras.
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TECHNICAL FIELD
[0001] The present invention relates to a method of creating a textured nonwoven fabric for apparel and home fashions applications, and more specifically, a nonwoven fabric comprising a permanent distressed texture upon laundering of the nonwoven fabric.
BACKGROUND OF THE INVENTION
[0002] It has become desirable and considered stylish in the clothing and home fashions industries to impart an aesthetically pleasing pattern, texture, and/or color to a fabric. Traditionally, woven fabrics have been handled in this manner to provide the clothing and home fashions industries with such enhanced aesthetic-quality fabrics, however the production of conventional textile fabrics is known to be a complex, multi-step process. The production of fabrics from staple fibers begins with the carding process where the fibers are opened and aligned into a feedstock known as sliver. Several strands of sliver are then drawn multiple times on drawing frames to further align the fibers, blend, improve uniformity as well as reduce the diameter of the sliver. The drawn sliver is then fed into a roving frame to produce roving by further reducing its diameter as well as imparting a slight false twist. The roving is then fed into the spinning frame where it is spun into yarn. The yarns are next placed onto a winder where they are transferred into larger packages. The yarn is then ready to be used to create a fabric.
[0003] For a woven fabric, the yarns are designated for specific use as warp or fill yarns. The fill yarn or fiber packages (which run in the cross direction and are known as picks) are taken straight to the loom for weaving. The warp yarns (which run on in the machine direction and are known as ends) must be further processed. The packages of warp yarns are used to build a warp beam. Here the packages are placed onto a warper, which feeds multiple yarn ends onto the beam in a parallel array. The warp beam yarns are then run through a slasher where a water-soluble sizing is applied to the yarns to stiffen them and improve abrasion resistance during the remainder of the weaving process. The yarns are wound onto a loom beam as they exit the slasher, which is then mounted onto the back of the loom. Here the warp and fill yarns are interwoven in a complex process to produce yardage of cloth.
[0004] In contrast, the production of nonwoven fabrics from staple fibers is known to be more efficient than traditional textile processes as the fabrics are produced directly from the carding process. Nonwoven fabrics are suitable for use in a wide variety of applications where the efficiency with which the fabrics can be manufactured provides a significant economic advantage for these fabrics versus traditional textiles.
[0005] A review of prior art indicates wrinkles have been introduced into woven fabrics for aesthetic as well as functional reasons. U.S. Pat. No. 6,025,284 discloses a sun protective fabric that is a permanently wrinkled polyester fabric with UV absorbers. Incorporating wrinkles into the fabric functionally serves as an additional barrier to provide protection from UV light. The wrinkles are permanently fixed into the fabric by stuffing a jet-dyeing machine with an excessive amount of fabric and then heat setting the resultant wrinkles into the fabric.
[0006] U.S. Pat. No. 5,679,438 discloses a method of decorating woven fabrics by imparting wrinkles into the fabric and then heat setting the wrinkles. In one embodiment, the wrinkles are imparted by a wrinkler, in which the conventional printing apparatus is modified by the addition of a wrinkler.
[0007] Fulfilling a need for a more efficient mode of producing fashionable, innovative fabrics, it is in accordance with the present invention to provide an aesthetically appealing and durable hydroentangled nonwoven fabric suitable for the apparel and home fashions industries, which resembles that of a woven fabric. The said nonwoven fabric takes on a permanent wrinkled appearance once laundered.
SUMMARY ON THE INVENTION
[0008] The present invention relates to a method of creating a textured nonwoven fabric for apparel and home fashions applications, wherein the nonwoven fabric becomes aesthetically altered upon laundering. Once laundered during manufacture, the nonwoven fabric exhibits a permanent distressed appearance that becomes an integral part of the fabric. Subsequent to laundering, the fabric can be formed into a roll for shipment and storage. The distressed appearance of the nonwoven fabric is best described by comparing the laundered fabric to an elephant's skin.
[0009] The disclosed nonwoven fabric is characterized as unique since it is first textured with an image on an image-transfer device, then the imaged fabric is given a second distressed texture without being subsequently chemically treated, compoundly imaged on an image-transfer device, or embossed by a roll. The resultant hydroentangled nonwoven fabric of the present invention has a distress-free appearance until laundered, after which a controlled amount of wrinkling is imparted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a diagrammatic view of the apparatus for forming the nonwoven fabric.
[0011] [0011]FIG. 2 shows the fabric before and after laundering.
DETAILED DESCRIPTION OF THE INVENTION
[0012] While the present invention is susceptible of embodiment in various forms, hereinafter is described a presently preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated.
[0013] With particular reference to FIG. 1, therein is illustrated an apparatus for practicing the method of the present invention for forming a nonwoven fabric. The fabric is formed from a fibrous matrix, which comprises fibers selected to promote economical manufacture. The fibrous matrix is preferably carded and subsequently cross-lapped to form a precursor web, designated P.
[0014] [0014]FIG. 1 illustrates a hydroentangling apparatus for forming nonwoven fabrics in accordance with the present invention. The apparatus includes a foraminous-forming surface in the form of a flat bed entangler 12 upon which the precursor web P is positioned for pre-entangling. Precursor web P is then sequentially passed under entangling manifolds 14 , whereby the precursor web is subjected to high-pressure water jets 16 . This process is well known to those skilled in the art and is generally taught by U.S. Pat. No. 3,485,706, to Evans, hereby incorporated by reference.
[0015] The entangling apparatus of FIG. 1 further includes an imaging and patterning drum 18 comprising a three-dimensional image transfer device for effecting imaging and patterning of the now-entangled precursor web. After pre-entangling, the precursor web is trained over a guide roller 20 and directed to the image transfer device 18 , where a three-dimensional image is imparted into the fabric on the foraminous-forming surface of the device. The web of fibers is juxtaposed to the image transfer device 18 , and high pressure water from manifolds 22 is directed against the outwardly facing surface from jet spaced radially outwardly of the image transfer device 18 . The image transfer device 18 , and manifolds 22 , may be formed and operated in accordance with the teachings of commonly assigned U.S. Pat. No. 4,098,764, No. 5,244,711, No. 5,822,823, and No. 5,827,597, the disclosures of which are hereby incorporated by reference. It is presently preferred that the precursor web P be given a three-dimensional image suitable to provide fluid management, as will be further described, to promote use of the present nonwoven fabric in apparel and home fashions. The entangled fabric can be vacuum dewatered at 24 , and dries at an elevated temperature on drying cans 26 .
[0016] Hydroentanglement results in portions of the precursor web being displaced from on top of the three-dimensional surface elements of the imaging surface to form an imaged and patterned nonwoven fabric. Following the imaging station in FIG. 1, the imaged nonwoven layer is dyed by any commonly known practice such as a jet dying or stock dying. In an alternate process of the invention, the imaged nonwoven fabric is wound into a roll and transferred to a separate practicable printing means.
[0017] Depending on the amount of hydroentangling performed on the nonwoven fabric, the laundered end product will have more or less of a distressed texture. It is believed that the nonwoven fabric has a small degree of fiber movement occurring and the movement of the fiber in a wet environment (under relaxed conditions) allows the fibers to move relative to the planar construction of the nonwoven fabric causing the fabric to “pucker” and appear distressed. The more the nonwoven fabric is hydroentangled, the more restricted in movement the fibers are and therefore, the fabric appears less distressed.
[0018] Coloration of the fabric will affect the amount of texture since colors can obfuscate or accentuate the wrinkles due to light refraction. The amount of texture in the fabric is also affected by the fiber type or fiber blend that makes up the fabric. Dissimilar fibers react or behave differently to hydroentanglement and therefore the laundered end product will have more or less texture depending on the fiber type.
[0019] It is known to one skilled in the art that polyester fibers entangle better than lyocell, cotton, or rayon fibers, therefore the resultant laundered end-products comprised of 100% polyester have less of a distressed texture compared to a fabric comprised of 100% lyocell fabric. It can also be concluded that fabrics comprised of polyester blends would be more entangled and have less fiber movement when laundered than a fabric comprised of 100% cotton. Due to the limited fiber movement, the fabrics comprised of polyester blends would have less texture after laundered.
[0020] It is believed that the laundered nonwoven of the present invention becomes textured due to differential shrinkage of the different fiber types during the wetting process, home laundering, or commercial laundering of a garment or roll good. It is also believed that a nonwoven fabric of a single fiber composition, such as cotton, or fibrous blends, become textured due to several zones of micro-delaminations that does not have an deleterious effect on the overall integrity of the fabric. It is believed that slippage between fibers creates the permanently distressed appearance of the present fabric when it is subjected to laundering during fabric manufacture. Such slippage can be increased when there is a lack of compatibility of the fibers, such as by use of fibers having differing surface characteristics for fabric formation. This can include fibers having differing compositions, or fibers having differing surface finishes.
[0021] The nonwoven fabric utilized in the present invention may be a composite or laminate comprised of fibers selected from either synthetic or natural fibers or a combination thereof. Synthetic fibers may be selected from a group of thermoplastic polymers such as polyesters, polyamides, polyolefins, such as polyethylene or polypropylene, their derivatives and combinations thereof. The fibers may also be cellulosic in nature such as cotton, wood pulp, or rayon. The nonwoven fabric may also be a blend of said synthetic and natural fibers. The fibers may be splittable fibers or fibers of differing geometric configurations. Preferred fibrous blends of the present invention include the combinations of cotton, rayon, polyester, and lyocell fibers; Lyocell fibers are man-made fibers made of wood pulp and available commercially under the name Tencel® as a registered to Courtaulds PLC Corporation of London, England.
[0022] The combination of fibers mentioned above can result in both heavier and lighter fabrics. The resultant heavier fabrics have a preferred basis weight range from about 3.0-8.0 ounces per square yard and a more preferred weight range from 5.0-6.0 ounces per square yard. The resultant lighter fabrics have a basis weight range from about 1.0-3.0 ounces per square yard and a more preferred basis weight range from 1.5-2.5 ounces per square yard.
[0023] It is also in the purview of the present invention that the nonwoven fabric comprises a chemical or mechanical finish or a combination of the two finishes. Such finishes can be a jet dye finish or one that affects the fabric's drape or hand. Softening agents may also be used to impart a better hand and provide a nonwoven fabric with better conformability.
[0024] Due to specific attributes of fibers such as strength, drapeability, and hand, specific fibrous blends are preferred depending on whether the fabric of the present invention is to be utilized in the apparel or home fashions industry. The preferred fibrous blend for the home fashions industry includes polyester and lyocell fiber blends or polyester and rayon fibrous blends. For the apparel industry, a fibrous blend of cotton and polyester is preferred.
[0025] Test Procedures
[0026] Strip Tensile Test (D 5035)
[0027] This test is meant to measure the breaking strength of the fabric in units of either grams or pounds as well as measure the elongation of the fabric.
[0028] Crockfastness (AATCC TM8-1988)
[0029] This test may be preformed with a wet or dry sample. The sample is rubbed against a testing surface for a designated number of passes. Test results are rated on a scale of 1-5, where a rating of 5 indicates the lack of color transfer.
[0030] The test results, as provided in Table 1, reflect a sample that is a hydroentangled fibrous blend of 60% cotton and 40% polyester. Test results indicate that the sample remains unchanged after three home launderings. The sample has comparable strength and elongation in both the machine and cross direction. The data table indicates the multiple home launderings of the fabric do not have any negative affects on the fabric. In one embodiment of the present invention, the disclosed nonwoven fabric is suitable for the apparel industry. The imaged nonwoven fabric is utilized in a bottom weight article for men or women, such as pants or shorts, wherein the bottom weight article takes on a distressed appearance once laundered.
[0031] In another embodiment, the nonwoven fabric of the present invention is suitable for the home fashions industry. The imaged nonwoven fabric is utilized in window coverings, bed applications, such as duvet covers, bedspreads, or comforters, and furniture coverings, such couch, love seat, or arm chair covers, wherein the previously mentioned home fashions would also take on a distressed appearance after laundering.
TABLE 1 Sample 1 Sample 1 Jet Dyed after Test Units Jet Dyed 3 home launders Basis Weight (oz/yd2) 5.6 5.9 Thickness (mils) 29 32 Tensile - MD (lb/in) 85.2 88.3 Tensile - CD (lb/in) 99.1 98.0 Elongation-MD (%) 41.5 43.9 Elongation - CD (%) 65.6 70.9 Crockfastness - Wet ranked 1-5 5 5 Crockfastness - Dry ranked 1-5 5 5
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The present invention relates to a method of creating a textured nonwoven fabric for apparel and home fashions applications, wherein the nonwoven fabric becomes aesthetically altered upon laundering. Once laundered during manufacture, the nonwoven fabric exhibits a permanent distressed appearance that becomes an integral part of the fabric. Subsequent to laundering, the fabric can be formed into a roll for shipment and storage. The distressed appearance of the nonwoven fabric is best described by comparing the laundered fabric to an elephant's skin.
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BACKGROUND OF THE INVENTION
The expansive data transmission capabilities of optical fiber technology have made practical the operation of digital telecommunication systems at rates well into the gigabit per second (Gbit/s) range. The advantages to be realized in this technology are apparent, and development of such systems has proceeded on numerous fronts worldwide. Unfortunately, these contemporaneous developments have resulted in a number of independently-devised signal architectures which lack the compatibility necessary for effective global, or even regional, communications networks.
With a view toward establishing and maintaining such compatibility, standards bodies have endorsed basic structures of optical system transmission rates and interfaces, not the least among which are those incorporated into the Synchronous Optical Network (SONET) hierarchy concept. This important advancement operates upon a base level digital signal framing format, namely the Synchronous Transport Signal level 1 (STS-1) frame, which consists of 810 8-bit bytes of data, and which therefore provides a serial bit transmission rate of 51.84 Mbit/s at the basic 8000 per second frame transmission rate.
Under this concept, signal transmissions of higher rate are achieved by interleaving bytes of any desired number of STS-1 frames in a prescribed sequence to form the correspondingly higher signal levels, e.g. STS-3, STS-4, STS-6, . . ., STS-24, etc. The STS-24 signal thus consists of the interleaved bytes of 24 STS-1 signals, and has a resulting transmission rate of 1244 Mbit/s, or 1.244 Gbit/s, i.e. 24 times the rate of the basic 51.84 Mbit/s of the STS-1 signal. For the transmission of such a signal, a multiplexed serial bit stream is assembled by interleaving repeated sequential extractions of one byte from each of the component STS-1 frames. It is necessary, therefore, that the signal receiver reconstruct from this serial bit stream the original base frame, or some frame multiple thereof, in order that the correct substance of the transmitted signal may be recovered.
While with current technology the serial bit stream may be assembled into fundamental 8-bit byte structures, it is essential to the proper recovery of the original SONET frames that the byte assembly be correctly synchronized and the boundaries of each such frame be identified in the bit stream transmission in order that the reconstructed bytes will duplicate each of the bytes which were interleaved to produce that serial transmission signal. The present invention provides method and apparatus to ensure that such proper synchronization and frame identification are established and maintained throughout such a signal transmission.
SUMMARY OF THE INVENTION
The basic SONET frame prescribed for the first transport level (STS-1) consists of nine rows of ninety 8-bit bytes each. Of these bytes, the first three in each row constitute the frame transport overhead containing framing, identification, error checking, and like information, while the remaining eighty-seven bytes make up the "payload" of the frame, i.e. the transport medium for the substance of the message or data transmission.
With a transmission rate of 51.84 Mbit/s, the STS-1 frame establishes the SONET frame period of 125 microseconds. This frame period is maintained throughout the hierarchy of increasing transport level frames by interleaving the respective bytes from each row of the component lower level frames, thereby deriving a transmission rate of N×51.84 Mbit/s for the STS-N frame. Utilizing available gallium arsenide (GaAs) enhancement-depletion mode metal semiconductor field effect transistor (MESFET) technology, integrated circuits for accomplishing such byte interleaf multiplexing have become practicable to the N=24 range of an STS-24 frame having a transmission rate of 1.244 Gbit/s.
Transmission of the STS-N frame is effected in a row-by-row manner, beginning with the first framing byte in the transport overhead and proceeding through the final N×87th payload byte of the first row before continuing on to the first overhead byte of the second frame row for transmission of each subsequent row of the frame in like manner. Following transmission of the last payload data byte of the ninth frame row at the end of the 125 microsecond frame period, the first framing byte of the next STS-N frame is transmitted, and the process continues in this manner throughout the transmission.
The bit stream of the transmission proceeds in the noted byte-interleaved succession at the rate, assuming the STS-24 frame, of 1.244 Gbits/s to the receiving station where that stream must be reformatted into the original bytes and frames in order for the receiver processing circuitry to properly extract the transmitted data and messages. Within this serial transmission of the data bit stream, however, there are no distinctly highlighted boundaries between the respective bytes and frames. It is necessary, therefore, that there be a capability in the receiving system by which these boundaries may be recognized so that synchronous byte structuring and frame formatting may be established.
The circuitry of the invention utilizes the two prescribed SONET framing byte bit patterns as bases for timing the initiation of byte structuring, as well as designating and confirming the boundaries of the frame format within such byte sequences. These framing bytes reside in the transport overhead and occupy the initial two positions in the STS-1 frame, or N-multiples thereof in a transmitted STS-N frame, and their respective unique bit patterns distinguish between them in all circumstances of bit pattern rotation.
During the demultiplexing of bits from the high-speed serial transmission of a frame, a characteristic bit pattern from one of the framing bytes is eventually recognized in comparator circuitry which signals the proper synchronization of byte formation and sets the clock controlling that operation. Other comparator means are provided which recognize the transition from the first to the second of the framing byte patterns to enable this occurrence to be utilized to denote the boundary between demultiplexed frames.
The present capabilities of GaAs enhancement-depletion mode and CMOS technologies are such as to provide maximum functionality of the former up to the STS-24 transmission rate of 1.244 Gbit/s, and of the latter at the 1:8 demultiplexed STS-3 rate of 155.5 Mbit/s. Although the reframing and demultiplexing of the high-speed serial data bit stream can be effected at the receiver in the GaAs MESFET circuitry, the requisite cost and power consumption make it desirable to reduce the signal transmission rate as soon as possible in the demultiplexing and signal processing operations in order to take advantage of the more economical low-power CMOS VLSI circuits. By limiting the operations of the high-speed GaAs circuits to the initial frame formatting and synchronization, and relegating to available CMOS chips the in-depth frame demultiplexing and signal processing, an effective and economical use is made of the capabilities of both these technologies.
In the general application of the present invention, the high-speed serial bit stream of the STS-N level, e.g. STS-24, transmission is demultiplexed to the basic SONET 8-bit byte-parallel format in the GaAs circuitry either at the STS-N clock rate or, preferably, at half that clock rate in order to provide a less restrictive time span for the implementation of the synchronizing gating functions. The resulting parallel byte stream is made available to companion CMOS circuitry for signal processing, while the high-speed GaAs chip, in addition to its byte-formatting function, is required only to recover framing synchronization. In the event of a loss of such frame synchronization, the CMOS processing circuit reinstitutes in the GaAs circuits the reframing process which normally will be accomplished within the period of two frames.
THE DRAWING
The present invention may be readily seen in the accompanying drawing of which:
FIG. 1 is the representation of an N-level frame of the Synchronous Optical Network (SONET) signal hierarchy;
FIG. 2 is the representation of the transmitted byte stream format of the first row of a SONET N-level frame;
FIG. 3 is a block diagram of an embodiment of the framer-demultiplexer circuit of the present invention;
FIG. 4 is a block diagram of a preferred embodiment of the framer-demultiplexer circuit of the present invention;
FIG. 5 is a block diagram of a shift register and latch arrangement utilized in the embodiment of the circuit of FIG. 4;
FIG. 6 is a block diagram of a shift register and 3-bit comparator arrangement utilized in the embodiment of the circuit of FIG. 4; and
FIG. 7 is a block diagram of an 8-bit comparator and frame boundary detector arrangement utilized in the framer-demultiplexer circuit of the present invention.
DESCRIPTION OF THE INVENTION
The Synchronous Optical Network (SONET) signal hierarchy is based upon the signal frame format generally represented in FIG. 1. The base, N=1 signal frame of STS-1 (Synchronous Transport Signal level 1) consists of the nine rows of ninety bytes in which the first two bytes of 8-bits are the SONET framing bytes, F1 and F2, having the prescribed bit patterns, 11110110 and 00101000, respectively. The third byte of the first frame row, designated generally as I, along with the remaining first three bytes in each of the remaining eight rows of the frame make up the balance of the transport overhead which provides frame identification, error checking information, message pointers, and the like.
The body of functional data, designated as the "payload", transmitted in each frame is located in the remaining 87 data bytes, D, in each of the nine frame rows to yield 783 bytes of such functional data. Each SONET frame is transmitted row-by-row at the rate of 8000 frames per second, thus producing, for the basic STS-1 signal, a serial bit stream of 51.84 Mbits/s. Successive levels of signal in the hierarchy are formed by interleaving the respective bytes of the basic STS-1 signals within the frame format to obtain the STS-N frame, where N=2, 3, 4, . . . The basic 125 microsecond frame period is retained, however, thereby yielding increasing bit transmission rates to N×51.84 Mbits/s.
In each such frame, the similarly positioned bytes from each STS-1 signal are assembled sequentially in a string in the like position of that frame, thus locating a byte, B, from the ith position of the jth STS-1 frame at the Bij position in the STS-N frame. This SONET multiplexing arrangement may be seen from FIG. 2 in which there is depicted a representative serial transmission of the first row of an STS-N frame. The transmitted byte stream is headed by F1 framing bytes, F11, F12, . . . , F1N, from each of the N interleaved STS-1 frames, followed by the F2 framing bytes, F21, F22, . . . , and the remaining bytes of the row down to the final 87th data byte of the Nth STS-1 frame.
The following rows of the STS-N frame and subsequent such frames are similarly transmitted in the continuing serial bit stream to their destined terminating SONET receiver where the frames must be reformatted by reconstructing and demultiplexing the transmitted bytes in original order and sequence. It is necessary, however, in order to effect such byte and frame structuring that the beginning of each STS-N frame, as embedded in the serial transmission, be identified as such, and that byte formation be synchronized with that benchmark.
As noted, the serial transmission rate of the SONET frame is determined by the number of STS-1 signals multiplexed into the STS-N frame. It is, of course, desirable that this transmission rate be as great as possible in order to best exploit the extensive bandwidth available in today's fiber optic transmission facilities. At present, GaAs enhancement-depletion mode MESFET technology provides the capability of multiplexing/demultiplexing SONET frames up to the STS-24 signal level of 1.244 Gbits/s. However, in practice, the signal receiver requires complex circuitry to carry out the overhead processing and payload extraction on incoming signals. It is for this reason that it is desirable for the maximum amount of receiver processing to be accomplished in widely available lower speed, low-power CMOS VLSI circuits in order to avoid the substantial cost and power requirements of high-speed GaAs chip processing.
In accordance with the present invention, the byte formatting and frame definition are accomplished in a high-speed GaAs MESFET device receiver arrangement generally shown in FIG. 3. In this embodiment, the transmitted serial data bit stream of the STS-N signal, which for purposes of this description will be assumed to be at the STS-24 level, is input to an 8-bit shift register (SR) 31 where it is clocked through to the Q-outputs at the STS-24 rate of 1.244 Gbit/s. These outputs of SR 31 are connected in parallel to the inputs of 8-bit latch 33 from which the data will be appear as 8-bit bytes at outputs L1 . . . L8. Although depicted here simply as separate devices, the shift register and latch may be combined in any known manner into a single device.
The STS-24 clock signal which is synchronized to the bit stream transmission, and which controls the sequencing of data bits through SR 31, is directed to clock divider 32 where it is reduced to one-eighth, C/8, of the STS-24 rate, i.e. to 155.5 Mbit/s. This C/8 clock signal output from divider 32, with usual appropriate timing and delay adjustments, is input to latch 33 to thereby trigger the output of each byte of 8-bits newly accumulated in SR 31. Without further control, however, the byte formatting at this point is subject to the arbitrary phase of the counter of divider 32. The correct sequence of bits in any byte output from latch 33 can therefore not be assured, since, depending upon the set of the divider counter, the bits of such byte may be distributed in any fashion between two consecutive latched-out bytes. The known sequence of the prescribed F1 framing byte, 11110110, may, for example, appear in any of eight such distributions, such as xxxxx111, 10110xxx, or xx111101, 10xxxxxx.
In order to set the byte-latching clock signal from divider 32 to the proper phase to ensure synchronization of byte formatting with the original bytes of the frame, comparator 39 is used to monitor the progressing states of the outputs of SR 31 as the incoming serial data stream containing the bits of the F1 framing byte are shifted through. The 8-bit comparator 39, which may be an OR gate configuration such as that of F1 comparator 34 shown in FIG. 7, or any equivalent combination of other types of gate elements, such as AND gates for example, is connected by means of individual input conductor leads to the appropriate Q and Q outputs of SR 31 in order that each such input will have a "0" state when SR 31 is loaded with the F1 framing byte, 11110110.
The "0" state output from comparator 39 will then set the counter of clock divider 32 to trigger the output of the matched F1 framing byte, and to begin clocking reconstructed, properly-phased 8-bit bytes out of latch 33 from that time on until some extraneous error occurs in the transmission. An enable/disable input to comparator 39, of which more will be described later, ensures that the resetting of clock divider 32 takes place only when its counter is out of synchronization with the F1 framing bytes.
Upon completion of the formatting of the high-speed input serial data stream to a low-speed, properly synchronized byte-parallel data stream, there remains the problem of identifying the boundaries of each frame of the original transmission in order that the payload, as well as the relevant overhead information bytes, may be demultiplexed to the basic STS-1 level. For this purpose, the present invention relies upon the prescribed bit sequences of both the F1 and F2 framing bytes, of which each frame above STS-1 will have at least two, the F2 bytes following immediately upon the final F1 framing byte as depicted in FIG. 2.
This transition from the F1 to the F2 framing bytes repeats once each frame, N bytes after the beginning of the frame, and therefore serves as the benchmark from which may be determined the boundaries of the frame to be processed in the receiver circuitry. To recognize this transition, occurrence of the unique byte pattern sequence, FIF2F2, that is 11110110, 00101000, 00101000, is detected in the combination of 8-bit comparators 34, 35, and FIF2F2 detector 36, an embodiment of which is shown in greater detail in FIG. 7.
As earlier noted, the inputs to the OR gate combination of F1 comparator 34 are attached to those respective L or L outputs of 8-bit latch 33, or of the two 4-bit latches 45, 46 used in the embodiment of FIG. 4, which will present "0" states to each of OR gates 71, 73 when an F1 framing byte, 1110110, is latched to the byte-parallel output line in synchrony with the C/8 clock signal from divider 32. The like "0" state outputs from gates 71, 73 will then carry through gate 72 as the output from F1 comparator 34. Passing sequentially through flip-flop (F/F) devices 75, 76, this "0" state output will appear at OR gate 79 two C/8 clock pulses later.
In similar manner, a following F2 framing byte, 00101000, will appear at comparator 35, which has the same device component structure, but different input lead arrangement, as comparator 34, one C/8 clock signal state change, or pulse, after the F1 byte appearance at comparator 34, and will provide a "0" state output to F/F 78. This state will appear at gate 79 one clock pulse later along with the second "0" state from comparator 35 signifying the occurrence of the second F2 byte in the FIF2F2 sequence. The three simultaneous "0" states thus appearing at gate 79 from comparator 35 and F/Fs 76 and 78 confirm detection of the unique FIF2F2 byte sequence by output of a framing pulse, FP, from detector 36.
This framing pulse, FP, will occur once in each synchronous frame of the byte-parallel transmission and is sent from the GaAs chip to a byte counter 37 associated with processing CMOS circuitry to reset that counter when the transmission remains "in frame". In the event of any error which causes loss of byte synchronization, F1 and F2 comparisons and FIF2F2 detection will fail, resulting in loss of the framing pulse, FP. After two frame cycles of such an "out-of-frame" condition, the CMOS byte counter 37 will have accumulated a preselected count and will overflow an out-of-frame pulse, OOF, which is directed back to toggle 38 in the GaAs circuitry to create an "enable" condition in comparator 39.
Thus activated, comparator 39 will initiate the reframing procedure with a search of SR 31 output conditions until the F1 framing byte appears. The phase of divider 32 is thereupon reset to establish, once again, correct frame synchronization. The first FIF2F2 sequence detected thereafter will generate an initial framing pulse, FP, which, in addition to resetting CMOS counter 37, will trip toggle 38 to disable comparator 39 and allow divider 32 to remain set at its present phase for as long as the transmission remains in frame.
The foregoing embodiment, although effective in its implementation, does exhibit somewhat less than optimal performance in that the initial operations for resetting the framing clock are carried out at the STS-N clock rate. Where, as in the current example, transmission is at the STS-24 signal level, these operations not only require the use of excessive power in the necessary high-speed devices, but they also establish a rather restricted clock-setting "window" which extends for only about 800 picoseconds. In order to effect an improvement in these areas, the split-register embodiment of the invention depicted in FIG. 4 is preferred over the single-register implementation of FIG. 3 in that it utilizes high-speed devices only in a simple free-running clock divider, and it expands the framing clock window to a more comfortable 1.6 nanoseconds.
As shown in FIG. 4, this preferred embodiment of the invention employs a high-speed clock divider 41 which need only reduce the STS-N, i.e. STS-24, clock rate of 1.244 Gbit/s to one-half that rate. Utilizing both the Q and Q outputs of divider 41, there are made available two 622 Mbit/s clock signals, C/2 and C/2 that are in 180° phase opposition. One or the other of these clock signals may be put into use by means of 2:1 selector 42 which is set by toggle 47. This toggle is in turn controlled by 3-bit comparator 62 and activated when it is determined, as will later be described, that the byte formatting is out of frame and in need of the opposite phase of the C/2 clock. The selected clock signal is employed to load and shift the STS-24 signal serial data in paired bits into and through the two shift registers 43 and 44, and serves also as a basis for four-fold rate reduction in clock divider 48 to obtain the 155.5 Mbit/s byte clock signal.
Shift registers 43 (SR1) and 44 (SR2) are basically constructed of master/slave-type flip-flop devices which load input data on one phase, e.g. the rise, of the triggering clock, and latch that loaded data to the Q outputs on the opposite, i.e. falling, phase. Register 44, however, comprises as an additional first element a slave latch which operates, in this example, on the falling clock phase to trap a current bit for use as input to the following first stage of that register on the next rising load phase of the clock. In this manner, the trapped bit and the following bit in the serial transmission are loaded as a pair into the respective first stages of the SR2 and SR1 registers at each pulse of the C/2 clock, the SR2 bit lagging the SR1 bit due to the delay imparted by the trap latch element. Thus, although this clock signal is running at only half the rate of the serial data transmission, each STS-24 data bit is nonetheless clocked into the respective registers.
Latching out of the eight bits accumulated in registers 43, 44 is effected, as in the previous embodiment, upon a C/8 clock signal derived from the STS-24 clock of the incoming serial data stream. In this instance, this latching clock signal is obtained from a four-fold division, in clock divider 48, of the C/2 signal from selector 42. It should be understood here that although there are depicted a pair of 4-bit latches 45, 46 in use for this purpose a single 8-bit latch might be employed as in the single stage embodiment of FIG. 3. In any event, in order to obtain the correct sequence of bits at the latch outputs L1 . . . L8, the arrangement of conductor leads between the Q1 . . . Q8 outputs of registers 43, 44 and the inputs to latches 45, 46 is selected to be as shown in FIG. 5.
Since the first bits input to registers 43, 44 will have shifted to their respective Q4 and Q8 output positions during the accumulation of the remaining six bits of a given byte, the lead pattern between registers 43, 44 and latches 45, 46 appears as Q8-D1, Q4-D2, Q7-D3, . . . This chosen arrangement will, of course, be valid for only one of the two possible opposed clock phases deriving from selector 42; however, as noted, the clock phase may readily be reversed to match the indicated connector arrangement. Upon each pulse of a properly-phased C/8 clock signal, then, the eight bits accumulated in registers 43, 44 in frame synchronization will be latched out to the byte-parallel output line in a correctly ordered, i.e. b1 . . . b8, byte.
As previously indicated, the extra trap latch stage in register 44 imparts a one-bit delay in the loading of its first stage, thereby causing the SR2 bit to lag its companion SR1 bit during each clocked step in the register-loading process. As a result, the first bit of a given byte will, depending upon the phase of the C/2 clock, be loaded into SR1 register 43 or SR2 register 44. In the former event, the lagging SR2 bit will be the last bit of the previous byte, and the ultimately loaded byte will be out of byte synchronization. In the latter condition, the SR2 bit, i.e. the first bit of the loading byte, will lag the more recently arrived second bit of that byte which will be loaded simultaneously into the first stage of register 43 as the SR1 bit, thereby establishing the byte-synchronous condition wherein all bits of the given byte will reside in the registers at one time during the loading progression. Thus, in the present example, the byte-synchronous condition exists when the odd bits, i.e. the first, third, fifth, and seventh, of the given frame are trapped at SR2 register 44, and the even bits are loaded into SRI register 43.
Since the beginning of a framing procedure is subject to an arbitrary phase of the STS-N clock, and its dependent loading clock signal, C/2, one cannot be assured of the accumulation of bits in a byte-synchronous fashion, i.e. synchronized in accordance with the above-described loading preference upon which the noted conductor arrangement was chosen for transmitting staged bits to the byte-parallel output latch(es). There is thus a 50% chance that first bit of the 8-bit sequence of a given byte will be input to register 43 on the rising clock, rather than being, as desired, trapped at the slave latch of register 44 on the falling clock pulse. The clocking of bits in this out-of-phase manner will in effect retard the formatting of the byte by one bit and cause the latched-out byte to be out of phase, with the resultant loss of frame as well as all substantial meaning of the content of the transmission. The F1 framing byte, for instance, assuming a properly phased latching clock, C/8, would not appear in a fully-loaded register pair as its prescribed 11110110, but as an out-of-phase pattern, x1111011.
Upon analysis it will be seen, however, that during the progressive loading of registers 43, 44 under an out-of-phase clock signal a unique pattern of bits from an F1 framing byte will appear at the Q-outputs of those registers; specifically, the 010 pattern will appear at the Q7, Q2, Q1 outputs. The unique character of this pattern lies in the fact that it will not thus appear during any progressive loading of an in-phase sequence of any number, i.e. from any STS-N frame, of F1 and F2 framing bytes. The appearance of the 010 pattern may be relied upon, therefore, to signal the existence of an out-of-phase loading clock signal at the beginning of a framing procedure, since it will be encountered during receipt of the first F1 framing byte of the STS-N frame, and may be used to trigger a change in the output of selector 42 to the phase-opposed C/2 loading clock signal.
This phase-change operation is controlled in 3-bit (010) comparator 62, which is shown in FIG. 6 as being implemented in OR gate 62 to output a "0" state which will activate toggle 47 to effect the clock phase change in selector 42, as previously noted. To achieve the required 000 input to gate 62, the Q7, Q2, Q1 outputs from registers 43, 44 are employed, along with the "0" input "enable" state from toggle 38 which, as will be recalled, is in that state as a result of a failure of the detection of the FIF2F2 frame sequence, i.e. the indication of the existence of some out-of-frame condition. As a matter of convention, the three bit leads are simply indicated in FIG. 4 by the character "/3", in the same manner as the respective leads for 4-bit and 8-bit data lines bear the notations, "/4" and "/8". Once the loading clock signal has been thus set to the proper phase, comparator 62 will not again see the occurrence of the 010 bit pattern in subsequent F1 and F2 framing bytes, and will be disabled at the FIF2F2 transition; thereby allowing the clock signal to remain in the selected phase even in the event that bits of an actual data byte match the 010 pattern. If, however, a transmission error occurs which disrupts the established framing, comparator 62 will be re-enabled by the resulting F1F2F2 failure at the beginning of the next frame, and will again initiate proper loading clock phasing at the start of the following frame.
With the loading clock signal, C/2, in the correct phase to ensure the loading of proper bytes from the STS-N frame, there remains the necessity to set the latching clock signal, C/8, to the correct phase to properly formatted bytes, rather than some intermediate rotation or progression in the bit accumulation. Once again, an analysis of the progressing in-phase bit patterns at the Q-outputs of registers 43, 44 reveals that there appears at the noted Q7, Q2, Q1 outputs the 110 bit pattern only when a complete F1 framing byte is fully-loaded and ready to be latched to the 8-bit byte-parallel output line. In the manner previously described with respect to comparator 62, a second 3-bit (110) comparator 64, more specifically shown in OR gate implementation in FIG. 6, employs the outputs from Q7, Q2 and Q1 to obtain, with the enabling state from toggle 38, to set the counter of clock divider 48 to trigger at this byte-synchronized stage for all subsequent framed bytes in the transmission. The disabling and re-enabling of comparator 64 is effected in the same manner as, and coincides with, that of comparator 62.
After frame synchronization has been established in the foregoing manner for the preferred embodiment of FIG. 4, the procedure for frame boundary definition is carried out as previously described with respect to the single-register embodiment of FIG. 3, namely by passing the synchronous framing bytes on to 8-bit comparators 34, 35 to initiate the confirming framing pulse, FP, from FIF2F2 detector 36 during the subsequent in-frame condition. The enable/disable signal from toggle 38, which is conditioned by the framing pulse, is likewise employed similarly in both embodiments to activate the clock-phasing comparators. Although not specifically shown in the drawing, this signal may be used in comparator 39 in the same manner as that employed with 3-bit comparators 62, 64 (FIG. 6) to supply the additional control input state. For example, this control signal may be input to a final stage of 8-bit comparator 39, which could be similar to that shown as a gate 72 in comparator 34 (FIG. 7).
The present invention thus provides for the maximum utilization of available technologies for optimum economies of power and time in the demultiplexing of high-speed serial bit data transmissions to low-speed byte-parallel format within the Synchronous Optical Network (SONET) signal hierarchy. It is anticipated that other embodiments of the invention will be apparent from the foregoing description to those of ordinary skill in the art, and such embodiments are likewise to be considered within the scope of the invention as set out in the appended claims.
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A framer-demultiplexer circuit provides means for reducing the high serial bit-stream rate of byte-interleaved low level signal frame structures proposed by the Synchronous Optical Network (SONET) signal hierarchy to speeds which can be processed with low-power low-cost CMOS VLSI technology, while establishing and maintaining basic byte integrity. In this circuitry the incoming high-rate serial bit stream is divided alternately between shift registers 43, 44 under the control of a single high-precision clock-division circuit to provide a multi-bit formatting that enables parallel delivery of stage bytes with the multifold reduction in transmission to a rate within the processing capabilities of CMOs devices. Necessary synchronization of the register and latching elements of the circuit with the incoming bit stream is effected through use of comparator means 62, 64 which detect key bit patterns within the standard framing bytes for controlling the phases of the bit-distribution and byte out-latch clocks 41, 48. Additional comparator circuitry 34, 35, 36 employs framing byte sequences established during synchronous byte output to detect and signal the occurrence of frame structure benchmarks from which data-processing CMOS circuitry can determine the boundaries of data bytes within the parallel byte output from the demultiplexed frame. The phase-control bit sequence comparator circuitry 62, 64 is disabled during periods of satisfactory frame processing, but is reactivated upon the detection of framing sequence error to provide resynchronization in order to ensure recovery of properly restaged data bytes.
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RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/176,108, filed Feb. 9, 2015.
GOVERNMENT RIGHTS IN THE INVENTION
[0002] This invention was made with government support under National Science Foundation No. CNS-1149611. The government has certain rights in this invention.
BACKGROUND OF THE INVENTION
[0003] Many smart building applications require indoor identification of individuals for personalized tracking and monitoring services. For example, in a nursing home, identifying monitored patients and tracking individual activity range helps nurses understand the condition of patients. Similarly, such identification information can also be used in smart stores/malls to analyze shopping patterns of customers.
[0004] Various methods and apparatuses have been explored for identification of individuals. These methods and apparatuses utilize biometrics (face, iris, fingerprints, hand geometry, gait, etc.) and sensing technologies (vision, sound, force, etc.). Some biometrics, such as iris, fingerprints and hand geometry achieve relatively high identification accuracy and are widely used for access control. However, they often require human interactions, and, as such, they have limited usefulness for ubiquitous smart building applications. With other methods, such as facial and gait recognition, it is often difficult to get enough sensing resolution required for recognition from a distance, particularly when used in surveillance applications. Numerous sensing technologies have been explored and proven useful and efficient, but all have limitations. Vision-based methods often require line-of-sight, with performance dependent upon lighting conditions, and may require high computational costs, which limits their viability. Likewise, sound-based methods have limitations when deployed in conversation sensitive areas, as they are prone to be affected by ambient audio. Force-based methods typically utilize specialized floor tile sensors for footstep detection, resulting is the requirement for dense deployment at a high installation cost.
SUMMARY OF THE INVENTION
[0005] This invention performs identification of individuals via footstep induced structural vibration analysis. People walk differently, and therefore their footsteps result in unique structural vibrations. The invention measures these vibrations, detects signals induced by footsteps, extracts features from these signals, and applies a hierarchical classifier to these features to identify each registered user with a high confidence level.
[0006] Due to better wave attenuation properties in solids, with proper amplification, the invention can detect individuals at a relatively large range. As a result, the invention has a sensing density that is low compared to known force-based methods. Compared to vision-based and sound-based methods, the invention measurement suffers less interference from obstacles that move around, because the vibrations travel in the structure itself. Furthermore, the installation of the invention is non-intrusive, consisting of one or more geophones installed on or near the floor surface, which can be accomplished without alteration the structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 shows recorded step events from three different people wearing soft-soled shoes, with each row showing a different person. The left column shows the time domain of the step event, while the right column shows the frequency domain of the same step event.
[0008] FIG. 2 shows three separate recordings of step events from the same person. The left column shows the time domain of the step event, while the right column shows the frequency domain of the same step event.
[0009] FIG. 3 presents the schematic overview of the components of the invention, highlighting the required functional modules.
DETAILED DESCRIPTION OF THE INVENTION
[0010] Each person has a unique walking pattern due to many factors, including, for example, individual physical characteristics, the center of gravity position during the walk, the way feet contact the ground, etc. Due to each person's unique walking pattern, there is a uniqueness and consistency of the footstep induced floor vibration for each person.
[0011] The floor vibration signal induced by a footstep is referred to herein as a step event. A sequence of step events from a continuous walk is referred to herein as a trace.
[0012] The floor vibration signal is captured by one or more sensing modules, each of which consists of three major parts: a geo-phone, an amplifier, and an analog-to-digital converter. The geophone is set on the floor of the structure to capture floor vibration signals. The analog signal is then amplified. In the preferred embodiment, the amplification is performed by connecting the geophone to an op-amp with an empirical amplification gain of approximately 1000, which allows approximately a sensing range of about 10 m for particular factors including floor type, shoe type, etc., however, as would be realized by one of skill in the art, many methods of amplification could be used. A sampling rate of 25 kHz allows the capture of a wide frequency range of signal characteristics, but other sampling rates could be used.
[0013] In tests of the system using this sensor module, step events from different people were recorded, showing distinguishable variations in both time and frequency domains. FIG. 1 shows step events from three people, labelled (a), (b) and (c). The left and right columns show corresponding time and frequency domain signals from the same step event for each person, respectively. In addition, dotted lines and dashed/dotted lines indicate locations of peaks and valleys in the frequency domain, respectively. As shown in FIG. 1 , the locations of peaks and valleys vary among different people, which can be used as features to identify them.
[0014] Step events from one person bear resemblance between each other. FIG. 2 shows three step events from one trace (i.e., from a series of steps by the same person). The left and right columns show corresponding time and frequency domain signals, respectively. Note that the step events span similar time duration with nearly identical velocity profiles in the time domain. The frequency domain patterns are well aligned across the three step events. This data demonstrates that a step event is a feasible metric for identification of individuals.
[0015] As shown in FIG. 3 , the identification system of the present invention contains three modules: sensing 10 , footstep analysis 20 , and decision-making 30 . FIG. 3 displays the relations of these modules.
[0016] Sensing module 10 (described above) performs floor vibration sensing 12 . The vibrations sensed are those that are induced by a person walking across a floor surface Sensing hardware 10 amplifies the signal received from the sensor and outputs a digital signal derived from the amplified analog output of the sensor. As discussed above, in a preferred embodiment of the invention, the sensor is a geophone of a type that is well known and commercially available, however, other types of sensors may be used. The system may use multiple sensing modules 10 , depending upon the desired area of coverage.
[0017] Footstep analysis module 20 takes a trace of step events and extracts individual step events therefrom. Features representing characteristics of each step event are then extracted.
[0018] The key to identification of individuals is to extract and analyze the characteristics of step events. There are two major components in the footstep analysis module. The first is step extraction 22 to obtain step events, and the second is feature extraction 24 , which characterizes step events via feature extraction.
[0019] Step events contain a person's identity information, while the interval between step events is mainly noise. Therefore, to identify people, step events need to be extracted from the trace containing the entire vibration signal by step extraction module 22 . The noise is modeled as a Gaussian distribution, and then an anomaly detection method is used to extract step events. The threshold value to detect a step event is determined by an allowable false alarm rate.
[0020] Two detection algorithms have been developed for extracting step events from the trace containing the entire vibration signal. The first detection algorithm is threshold-based method and uses the time representation of the signal. This method finds the threshold using the background noise distribution and a footstep event is indicated whenever the energy of signal exceeds a defined threshold. The second detection algorithm uses the time-frequency representation of the signal. This approach is able to deal with signals with very low signal-to-noise ratio where it is difficult to differentiate between the background noise and footstep-induced vibrations and improves the accuracy by distinguishing between footsteps and other sources of non-stationary excitation. Some examples of such sources include vibrations induced by dropping an object and shutting a door. This algorithm uses the characteristics of structure to find the frequency components of the signal which are more robust to background noise. Furthermore, it includes a classification algorithm which distinguishes between footstep-induced vibrations and vibrations induced by non-stationary signals.
[0021] Feature extraction module 24 , extracts features from selected step events. The events from which to the features are extracted are selected based on their signal to noise ratio. Features can be more efficiently extracted from step events in a trace having a high signal-to-noise ratio. Features of the selected steps are then extracted to characterize the footsteps.
[0022] Step events in one trace may have different signal-to-noise ratios depending on the relative distance of the location of each step event to a sensor. This leads to a variation in classification performance. A small number of step events closest to the sensor, and consequently with the highest signal-to-noise ratio, are selected for classification.
[0023] Once the step events are selected, they are normalized to remove effects of the distance between the footstep location and the sensor, and for different types of floor surfaces, for example, a hard floor versus a carpeted floor. Step events closer to the sensor have a higher signal energy, which is calculated as the sum of squared signal values. Each selected step event is divided by its signal energy to normalize for differences in the distance of each step event from the sensor, thereby removing the distance effect, the distance of each step event from the sensor is irrelevant to characterizing the step event for a particular person and contains no identify information.
[0024] After normalization, features are computed in both time and frequency domains to present different characteristics of step events for each person. Time domain features may include, but are not limited to standard deviation, entropy, peak values, partial signal before and after the maximum peak, etc. In the frequency domain, features may include, but are not limited to spectrum centroid, locations and amplitudes of peaks, power spectrum density, etc.
[0025] Once these features are extracted, decision-making module 30 takes the features and runs through a hierarchical classifier, which includes both step level classification 32 and trace level classification 34 . The identification individuals is modeled as a hierarchical classification problem in the invention. A hierarchical classifier includes step level classifications 32 and trace level classifications 34 . Identification accuracy is increased by utilizing the fact that steps from the same trace belong to the same person. The classified step events are compared against a database 36 of previous step events from identified individuals to accurately identify the individual.
[0026] The system takes features of step events from different people's traces to generate a classification model using a Support Vector Machine, which maximizes the distance between data points and the separating hyper-plane. The step level classification 32 returns both the identification label and the confidence level from testing the step event.
[0027] By classifying identity at trace level 34 , classification uncertainty is reduced by eliminating outlier step events from the step level classification 32 , thereby enhancing the overall identification accuracy of the system.
[0028] Each step event classified obtains an identification label and a confidence level as the result of the step level classification 32 . Since multiple steps events with the highest signal-to-ratio are referenced a confidence matrix P s×n is created, where n is the number of people to be classified, and s is the number of step events selected from the trace. The identity of the step event with highest confidence level is selected to be the identity of the entire trace.
[0029] Achieving high accuracy for the classified step events is important. When a new person's trace is detected, it is possible that step events in the new trace are not similar to any of the footsteps in database 36 . In this case, the confidence levels of all steps in a trace are equally low, and the system detects such situations. The confidence level threshold CL threshold is set to determine a reliable classification result. The trace is considered to be identifiable when the confidence level is higher than the confidence level threshold. Otherwise, the trace is determined to be unclassifiable (i.e., the trace of a previously un-identified person). The system can adjust this threshold to obtain different identification accuracy based on the application.
[0030] In tests of the system, various numbers of persons, and various types of structures were used, and the system was found to provide a high identification accuracy.
[0031] Many applications of the system have been identified in the areas of individual monitoring, analysis of group behavior and security.
[0032] Individual identification and monitoring can be used to detect children or elderly patients in an in-home setting, where the system can detect and identify individuals and respond accordingly, for example, if they appear alone in designated area (e.g., the kitchen or bathroom), or if they leave the premises. For elderly subjects, the system can be used to analyze walking patterns to predict fatigue level, which may be useful in and prevent fall events from occurring. Finally, individual identification can be used to identify individuals in a smart space, and personalize the environmental settings, for example, by detecting the identity of an individual as they walk through the front door, the smart system can start their computer before their arrival, then, by tracking the individual to the elevator, the smart system can play their favorite songs in the elevator. Likewise, the system could also set customized temperature, turn on lights, unlock doors, etc.
[0033] The system may also be applied to monitor and analyze group behavior. In a supermarket, shopping mall or airport environment, the system may recognize individual shopping patterns and understand the group shopping pattern based on the characterization from the footstep induced vibration signals (e.g., height, weight, gender, etc.). In a smart office type environment, the system could recognize the activity range of each individual and assign resources/space and manage energy consumption based on the optimized convenience.
[0034] Lastly, there are security applications for the system. For example, the system may be used to authorize access to a particular area by determining if the detected footsteps fit the profile of an authorized individual. The system may also be useful in theft detection, by detecting changes in the pattern of individual footsteps due to hidden objects on the body of the individual. Lastly, the system may be able to detect specific gait patterns due to individuals carrying weapons on their body.
[0035] Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limiting to the details shown. Rather, various modifications may be made in the details without departing from the invention.
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This invention introduces an indoor person identification system that utilizes the capture and analysis of footstep induced structural vibrations. The system senses floor vibration and detects the signal induced by footsteps. Then the system then extracts features from the signal that represent characteristics of each person's unique gait pattern. With these extracted features, the system conducts hierarchical classification at an individual step level and at a collection of consecutive steps level, achieving high degree of accuracy in the identification of individuals.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is generally directed to portable dispensers for selectively dispensing sheet-like articles and particularly to a portable business or calling card dispenser which is of a size to be carried in a person's pocket and which includes a housing having a slideable cover by way of which cards may be inserted therein. The case of the dispenser includes generally continuous upper and lower planar surfaces which may be utilized to display various advertising or identification indicia. The ejector mechanism for the dispenser is uniquely designed to cooperate with the internal portion of the case so that the dimension of the case is just slightly larger than the dimension of the cards carried therein. The cards are positively biased toward the ejector in a vertical array by way of a generally continuous plate having a plurality of integrally formed spring-like portions that are generally equally or uniformly oriented along the undersurface thereof. The ejector mechanism includes portions which extend through a side wall of the housing in order to allow the ejector to be selectively operated and is resiliently returned to a seated position within the housing after a card has been urged from the case.
2. History of the Related Art
Heretofore, there have been many inventive efforts directed to providing dispensers for sheet-like materials or articles including cards, tickets, chewing gum, razor blades and the like. Most of these dispensers have been designed to be portable and carried in a person's pocket and include a housing in which the articles to be dispensed are housed in stacked relationship. Most of the prior art dispensers further include an ejector which is slideably carried by a portion of the case or housing and which acts to urge a single article from the housing by being manipulated toward one end thereof.
Many such prior art dispensers have not proven to be reliable or effective for continuously dispensing a single article at a time from the housing or case in which the articles are stored. In other such portable dispensers, the size of the housings or cases are necessarily enlarged in order to provide operative clearance for the ejection mechanisms incorporated therewith. In addition, prior art portable dispensers of the type for dispensing small articles have generally not been designed to simultaneously function as a means of identification or as an advertising display case.
Many prior art small portable article dispensers include an enclosed housing having upper and lower and side surfaces which substantially enclose the articles to be dispensed. The ejector mechanism is mounted within the housing and includes one end portion which engages an end of the upper article in a stack of articles in such a manner that the ejector will urge the article outwardly through an opening in the case when operated by an appropriate push button or lever which extends outwardly of the case. In order to insure that the articles contained within the various cases are continuously or sequentially presented to the ejector mechanism, use is traditionally made of a separate spring member which is mounted in the housing and which engages the lower article in a stack of articles and which is utilized to force the stack of articles toward the ejector.
Many portable prior art dispensers include an operating mechanism which extends through the upper surface of the case or housing and which is reciprocally movable with respect thereto. When being transported, it is possible for the operating mechanism to be accidentally moved forwardly or shifted thereby discharging or partially discharging an article from the case as the case is being carried or being placed into or removed from a person's pocket. Such premature ejection of an article not only is undesirable but creates problems with having to reinsert the article for future dispensing or will result in an article, such as a flexible card, being damaged.
In prior art portable pocket dispensers which are designed so that the operating mechanism extends from the upper surface thereof, the operating mechanisms prevent the use of the upper surface for displaying advertising or identification which could otherwise be associated with the dispenser housing or case. Some examples of such dispensers are disclosed in U.S. Pat. Nos. 1,503,144 to Warwick, 1,697,366 to Opfergelt, 2,152,174 to Brunetti, 2,591,855 to Nicholson, 2,973,882 to Jeffus, 3,308,989 to Alltop et al. and 3,393,831 to Stewart.
In an effort to overcome the accidental discharge of small articles from portable article dispensers, some prior art dispensers have been provided with return springs which will operatively retain the ejector control mechanism in a relatively fixed position within the dispenser case or housing. Movement of the ejector mechanism is then only possible if a sufficient force is provided to move the mechanism against the tension of the spring. In this manner, such ejectors will be retained in a non-dispensing position when being transported or carried. An example of such a resiliently biased dispensing mechanism is disclosed in U.S. Pat. No. 2,803,378 to Gundling.
As previously mentioned, many prior art portable article dispensers generally have been designed to be of a large enough size to allow substantial clearance from the injector mechanism relative to a stack of articles contained within the dispenser case or housing thereby permitting the ejector mechanisms to be aligned with the rear of the uppermost article to be dispensed. Unfortunately, the need for clearance has required that most prior art dispensers be manufactured of a size which is significantly greater than the article to be dispensed thereby making the dispensers more difficult to handle and expensive to manufacture.
Other prior art portable dispensers are disclosed in U.S. Pat. Nos. 909,110 to O'Neil, 1,244,338 to Johnson and 3,131,806 to Tait et al.
SUMMARY OF THE INVENTION
This invention is directed to a portable article dispenser of the type which is specifically designed to dispense business or calling cards and which includes a case having generally continuous upper and lower walls which are oriented generally parallel with respect to the cards which are to be carried therein and which also includes substantially closed side and end wall portions. An opening is provided along one end portion through which cards may be selectively dispensed by means of an ejector mechanism which is slideably mounted within the casing. The ejector mechanism includes a body portion which extends generally parallel to one of the side walls and adjacent thereto and from which a pair of push button mounting flanges are integrally formed so as to be disposed outwardly through a slot formed in the adjacent side wall. The ejector mechanism also includes a card engaging depending flange which extends generally perpendicularly with respect to the main body portion and which is reinforced and integrally connected thereto by means of a generally triangular flange element which is beveled along its front edge so as to not interfere with the movement of cards which are stacked within the casing. An elongated recess is provided in the end wall of the dispenser case opposite the end wall having the opening therein in which the card engaging flange is selectively seated when the ejector mechanism is fully retracted within the housing. A mounting stud extends inwardly of the side wall of the case having the opening therein and which stud also extends through an elongated opening in the main body portion of the ejector mechanism whereby the ejector element may be movable with respect thereto. An elastic member is mounted around the fixed stud and extends forwardly and around one of the mounting flanges for the push button. The cards are positively biased within the case toward the ejector mechanism by a movable card support plate which is resiliently biased upwardly away from the bottom wall of the casing by a plurality of integrally formed spring elements which extend downwardly therefrom into engagement with the bottom wall. The card support plate includes a plurality of outwardly extending flanges which are guidingly engaged in cooperative slots or grooves which are provided in the side and end walls of the dispenser case. Each of the slots or grooves is terminated at a point below the upper edge of the walls so that the movable card support plate is positively retained within the case when in its uppermost position. The upper surface of the case or lid is frictionally secured and normally closed with respect to the side and end walls but may be raised and slidingly urged rearwardly with respect to the dispensing slot in one end wall so that cards may be introduced into the dispenser.
It is a primary object of the present invention to provide a dispenser for business cards and the like wherein the cards are retained within a relatively compact portable casing which is generally of a size which is only slightly larger than the size of the business cards so as to be as compact as possible.
It is another object of the present invention to provide a dispenser for housing a plurality of business cards wherein the upper and lower surfaces of the dispenser are generally continuous and unobstructed so that advertising or identification indicia may be selectively carried along either of the lower or upper surfaces to either identify the company or organization to which a business person belongs or to advertise goods or services which may be of interest to the business person.
It is another object of the present invention to provide a dispensing apparatus which may be easily transported in a person's pocket and which is designed to selectively dispense business or calling type cards wherein the ejector mechanism is operative through the side wall of the casing of the dispenser and is resiliently urged toward a normally fully retracted rest position when not being manually operated to dispense a card therefrom.
It is also an object of the present invention to provide a low cost and yet durable dispenser for business and calling cards wherein the cards are uniformly urged toward an ejector mechanism mounted within the dispenser by a support plate of a size generally equal to the size of the cards so that the pressure being applied to the cards is uniformly distributed throughout the length of the cards thereby preventing any bending or twisting of the cards when being dispensed.
Another object of the present invention is to provide a portable dispenser for business or calling cards wherein the dispensing case is locked into an assembled configuration so that the cards carried therein may not be accidentally discharged therefrom by portions of the case being accidentally opened yet wherein access may be obtained by specifically urging the lid portion of the case relative to an end wall thereof to dislodge the same for limited sliding or reciprocal movement with respect thereto.
It is also an object of the present invention to provide an ejector mechanism for use with portable pocket dispensers for dispensing generally flat articles which are oriented in stacked relationship such as business or calling cards wherein the ejector mechanism includes an enlarged reinforcing flange member which is perpendicularly oriented with respect to the cards so as to engage the upper card over an extended portion thereof to thereby insure that the rear edge is appropriately aligned for proper dispensing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective illustrational view taken from the forward end of the business card dispenser of the present invention showing a business card being dispensed therefrom in dotted line.
FIG. 1A is a perspective view taken from the back side of the business card dispenser shown in FIG. 1.
FIG. 2 is an enlarged top plan view of the business card dispenser of FIG. 1 having the lid of the dispenser removed so as to expose the ejector mechanism and card support plate of the present invention.
FIG. 2A is an enlarged right side view of the business card dispenser as shown in FIG. 1.
FIGS. 2B and 2C are enlarged partial cross sectional views taken along lines 2--2 of FIG. 1 showing in FIG. 2B the position of the inner card support plate when a plurality of cards are placed within the dispenser and FIG. 2C indicates the position of the card support plate when no cards are retained within the dispenser.
FIG. 3 is an enlarged side elevational view of the ejector mechanism of the present invention.
FIG. 4 is a top plan view of the ejector mechanism of FIG. 3 showing the relationship of a card to be ejected in dotted line and showing a portion of the resilient return member which is associated therewith.
FIG. 5 is an enlarged side elevational view taken in the area of circle 5--5 in FIG. 4 and showing the movement of the card ejector mechanism in full and dotted line position.
FIG. 6 is an enlarged rear elevational view of the card dispenser of the present invention.
FIG. 7 is an enlarged left side view of the card dispenser of the present invention as shown in FIG. 1.
FIG. 8 is an enlarged partial cross sectional view showing the relationship between the card support plate and the bottom wall of the card dispenser of the present invention.
FIG. 9 is an enlarged top plan view of the lid of the present invention.
FIG. 10 is a side elevational view of the lid of FIG. 9.
FIG. 11 is an enlarged top plan view of the base portion of the card dispenser of the present invention having portions broken away showing a recessed area along one side wall of the base.
FIG. 12 is a cross sectional view taken along lines 12--12 of FIG. 11.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With continued reference to the drawings, the business card dispenser of the present invention is shown in FIGS. 1 and 1A in perspective view. The business card dispenser is specifically designed to be compact and of a size which is just slightly larger than a conventional business or calling card C. The size of the business card dispenser will therefore facilitate the carrying of the dispenser in a person's coat or pants pocket or purse.
The business card dispenser includes a case 20 having a slideable lid portion 21 which is selectively movable with respect to a base portion 22. The base portion has forward and rear ends 23 and 24, respectively, which are integrally joined on either side by elongated side walls 25 and 26. The front, rear and side walls are joined by a common bottom wall 27 so as to form a substantially enclosed chamber 28 in which the business or other types of cards are retained for selective dispensing.
The lid is generally rectangular in configuration and includes a generally continuous and planar upper surface 29 and a front edge 30. The front edge extends slightly outwardly from longitudinally extending side flanges 31 and 32 which generally terminate in line with a slightly depending rear wall 33. The lid 21 is designed to cooperatively seat and be engaged with the body portion 22 of the dispenser and to this extent, the body portion includes a pair of opposing and spaced elongated recesses formed along the upper and inner portion of each of the side walls 25 and 26. The opposing recesses are generally indicated at 34 and 35. When the lid is slidingly engaged with the body portion of the dispenser, the flanges will ride within the opposing recesses 34 and 35 until the rear wall 33 comes into engagement in vertical alignment with the rear wall 24 of the body portion of the dispenser. In this position, the front or leading edge 30 of the lid 21 will be spaced a slight vertical distance above the upper portion of the front wall 23 so as to create an elongated slot 36 through which the cards are dispensed from the body portion of the dispenser. The tolerances between the flange portions of the lid and the opposing recesses in the side walls of the body portion of the dispenser are such that a lid will be substantially locked into place when in the position shown in FIGS. 1 and 1A. In order to effectuate the movement of the lid relative to the body portion of the dispenser to load additional cards therein, a small keyed recess 38 is provided in the uppermost portion of the rear wall 24 for purposes of permitting a small tool or key to be inserted therein in order to pry the lid upwardly relative to the rear wall to permit a selective sliding movement of the lid relative to the body portion.
As previously discussed, the upper surface 29 of the lid is specifically designed to be free of any obstructions or openings so that a portion thereof may be used to selectively display advertising or identification indicia such as shown at 29'. The available advertising space will enable the dispenser of the present invention to be used by corporations and/or businesses as effective promotional sources or materials
Mounted within the body portion of the dispenser is a positively biased inner bottom wall or card support plate 39 which is of a size which is substantially equal to the inner dimensions of the body portion as defined by the front, rear and side walls thereof. The card support plate is preferably formed of a plastic material having a plurality of integrally formed depending resilient leg or spring members 40 formed therein. The card support plate is shown in top plan view in FIG. 2 with portions of the spring biasing members or legs 40 being shown in compressed and extended position in FIGS. 2B and 2C, respectively. As shown in FIG. 2, six such resilient leg portions are shown as being in generally symmetric relationship with respect to one another. In this manner, tee force applied by the legs in elevating the card support plate is generally consistent throughout the total area thereof. Due to the equal application of pressure on the card elevating plate, any cards carried thereby will be raised in a uniform and parallel manner relative to the lid of the dispenser. Although six such legs are shown in the drawings, it is believed that four or more even numbers of geometrically spaced spring members would be appropriate.
In order to retain the card support plate 39 within the body portion of the dispenser, the plate is provided with a plurality of outwardly extending guide flanges designated at 41. Each of the guide flanges is guidingly received within vertical slots 42 formed in the side wall 26 and front wall 27. It is noted that the slots 42 extend from the bottom wall 27 of the body portion and terminate at a point below the upper edge of the front and side wall. Therefore, the upper portion of the side and front walls provide a stop to insure that the resiliently urged card support plate cannot be dislodged from the body portion of the dispenser. Additionally, although four such flanges and slots are shown in the drawings, it is envisioned that the number of such guide flanges and cooperating slots could be varied so long as sufficient members and slots are provided to positively retain the card elevating member in proper position within the body portion of the dispenser.
To insure a compact size of card dispenser and also to insure that the dispenser has generally continuous and uninterrupted upper and lower surfaces, the card dispenser of the present invention includes a specially designed ejector mechanism that is generally indicated at 45. The ejector mechanism 45 includes an elongated and generally planar body portion 46 which is of a height to extend between the inner surface of the lower wall 27 and the bottom surface of the lid 21 as shown in FIGS. 2B and 2C. The body portion is vertically oriented and in sliding engagement with the inner surface of side wall 25. The length of the body 46 is less than the length of the side wall so that the body portion may move longitudinally relative thereto. An elongated slot 47 is provided through the rear end portion 48 of the ejector mechanism 45 for purposes of allowing clearance for an inwardly extending mounting stud or member 49 which is integrally molded and extends inwardly from the inner surface of the side wall 25 for purposes of which will be described in greater detail hereinafter.
The ejector mechanism is provided with a perpendicularly oriented and depending ejection flange 50 which extends outwardly from the rear portion 48 thereof. The flange 50 is reinforced by an integrally formed triangular web 51 which extends from the upper surface 52 of the body portion of the ejector mechanism to the upper portion of the ejector flange 50. The ejector flange 50 and web 51 extend outwardly from the body portion of the ejector mechanism a distance equal to approximately half the width of the body portion of the dispenser. The front or leading wall 53 of the reinforcing web 51 is tapered as shown in detail in FIG. 5 of the drawings In this manner, the leading edge of the web will not interfere with the operation of the ejector mechanism as it is moved relative to a stack of cards being carried within the dispenser but will cause the web to ride over any cards in its path. However, the depending flange 50 is of a size to engage the rear end of the vertically adjacent card in a stack of cards contained within the dispenser. By way of example, the typical business card may have a thickness of approximately 0.010 to 0.012 inch. Therefore, the depending flange 50 will extend downwardly below the reinforcing flange 51 by a distance of approximately 0.006 to 0.008 inch. The reinforcing flange 51 will also act as an alignment surface for assuring that the uppermost card is generally horizontally aligned in planar relationship with respect to the flange element 50 thereby facilitating the ejection of cards by the movement of the ejector mechanism within the body portion thereof.
The ejector mechanism also includes a pair of spaced flange elements 55 and 56 which extend outwardly from a middle portion of one of the side walls of the body portion 46. The elements 55 and 56 extend through an opening 60 which is provided in the side wall portion 25 of the body of the dispenser. Each of the elements 55 and 56 include outwardly biased leg portions 61 and 62 as shown in FIGS. 2B and 2C which are selectively and resiliently engaged within the recess 63 of an operating or push button 64 which is frictionally secured thereto. The push button 64 is shown as being mounted on the exterior of the dispenser case along the side wall 25 and is of a size to overly the opening or slot 61 therein.
The ejector mechanism of the present mechanism is positively biased to a rearward or fully retracted position interiorly of the case by a resilient member or rubberband 65 which is disposed about the mounting flange 49 and the flange element 56 carried by the ejector mechanism. Once the resilient band has been installed, the ejector is oriented so that the elements 55 and 56 extend through the slot or opening 60 in the side wall 25 and thereafter the push button 64 is frictionally secured so as to retain the elastic band in locked position relative to the ejector mechanism.
To provide clearance and to further provide for a compact structure for the dispenser, the inner surface of the side wall 25 includes a recessed area 70 which provides clearance for the elastic band. The recessed area 70 extends from one side of the stud 49 to adjacent the remote end of the slot 60 and thereby provides sufficient clearance for the elastic band either when extended or retracted. In addition, to provide clearance for the flange 50 of the ejector mechanism so that the flange will be seated rearwardly of the uppermost card in the stack of cards within the dispenser, a recess 72 is formed in the inner surface of the end wall 24 adjacent the upper edge thereof. The recess will permit the depending flange 50 to be seated within the wall portion 24 and just rearwardly of the stack of cards when the ejector is in its fully retracted position within the dispenser.
In the use of the card dispenser of the present invention, the lid 21 of the dispenser may be slideably oriented with respect to the body portion so as to create an opening into which business, calling or other types of personalized cards may be inserted in stacked vertical relationship with respect to one another. As the cards are loaded within the dispenser, the card support plate 39 will be urged into a position adjacent the bottom wall 27 thereof In this position, the integral spring legs 40 of the plate will be under maximum tension forcing the cards upwardly against the lid 21. When the lid is secured in its locked relationship as shown in FIG. 1 and FIG. 1A with respect to the body portion of the dispenser, the ejector mechanism will be located in its fully seated position as reflected by the position of a push button 64 in FIG. 1.
To dispense a card from the dispenser, the push or thumb button 64 is merely urged forwardly within the slot 60 thereby causing the ejector flange 50 to engage the rear of the uppermost card contained within the dispenser case as shown in FIG. 5. As the ejector moves forward, the card is forced outwardly of the opening 36 in the front end portion of the dispenser by a distance sufficient for the card to be engaged and pulled outwardly by the person utilizing the dispenser. Thereafter, the push button is released and the ejector mechanism is automatically returned under the influence of the rubberband or resilient member 65 which pulls the ejector back into its fully seated or retracted position wherein the flange 50 is seated within the slot 72 in the rear wall of the case. As the cards are dispensed, the card support plate will continue to raise the stack of cards relative to the ejector mechanism applying sufficient and uniform pressure so as to insure that the cards are appropriately and horizontally aligned with the ejector flange so that the cards may be uniformly urged from the dispenser without causing any bending or tearing of the cards as they are moved through the opening 36 therein.
In construction, it is preferred that each of the elements of the dispenser of the present invention, with the exception of the resilient band, be molded from a fairly rigid plastic material although metallic materials could be used in some instances.
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A pocket-sized dispenser for business or calling cards which includes a case having generally continuous upper and lower surfaces upon which advertising or identification indicia may be displayed and in which the cards are protectively housed for selective dispensing utilizing a reinforced and automatically retracted ejector mechanism which is compactly oriented within the case and is operable through a side wall thereof.
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TECHNICAL FIELD
[0001] The invention relates to devices and methods for placing sutures.
BACKGROUND INFORMATION
[0002] Suturing of body tissue is a time consuming aspect of many surgical procedures. For many surgical procedures, it is necessary to make a large opening in the human body to expose the area that requires surgical repair. There are instruments available that allow for viewing of certain areas of the human body through a small puncture wound without exposing the entire body cavity. These instruments, called endoscopes, can be used in conjunction with specialized surgical instruments to detect, diagnose, and repair areas of the body that previously required open surgery to access.
[0003] Some surgical instruments used in endoscopic procedures are limited by the manner in which they access the areas of the human body in need of repair. In particular, the instruments may not be able to access tissue or organs located deep within the body or that are in some way obstructed. Also, many of the instruments are limited by the way they grasp tissue, apply a suture, or recapture the needle and suture. In addition, the needle can become separated from the needle-driving device and lost within a patient. Furthermore, many of the instruments are complicated and expensive to use due to the numerous parts and/or subassemblies required to make them function properly.
SUMMARY OF THE INVENTION
[0004] The suture passer of the present invention eliminates the need for a preassembled needle and suture and eliminates the possibility of needle loss during suturing. This is accomplished by eliminating the use of a loose needle or any needle at all. Specifically, the suture passer uses a suture with a formed tip that engages a suture carrier. The suture carrier is coupled to the suture passer and has a sharpened end for piercing tissue. The suture carrier also has a notch for carrying the formed tip of the suture. When the device is actuated, the suture carrier pierces the tissue and carries the formed tip through the tissue and into a formed tip catch. The suture carrier is then retracted leaving the suture intact.
[0005] In one aspect, the invention relates to a suturing instrument. The suturing instrument includes an elongate body member, a suture deployment system disposed at a distal portion of the elongate body member, and a catch to receive and retain a formed suture tip. The suture deployment system includes a suture carrier having a sharpened distal end for tissue penetration and a notch for holding the formed suture tip.
[0006] In some embodiments, the suturing instrument may include a deployment controller having a proximal end and a distal end. The deployment controller extends substantially along a longitudinal axis of the elongate body member to the distal portion of the elongate body member, where the distal end of the deployment controller is coupled to the suture carrier and moves the suture carrier between a retracted position and a deployed position. The proximal end of the deployment controller may be coupled to an actuator. In some embodiments, the deployment controller guides the suture carrier along a path that includes a proximal curved path segment such that the suture carrier initially travels away from the elongate body member and then towards the elongate body member.
[0007] In another aspect, the invention relates to a suturing instrument including a suture carrier and a body member defining a suture exit port and a suture carrier channel. The suture carrier includes a sharpened distal end for tissue penetration and a notch for holding a formed suture tip. The suture carrier is movably positioned in the suture carrier channel between a retracted position within an interior region of the body member and a deployed position exterior to the body member. The suture carrier is configured within the suture carrier channel such that the suture carrier exits the interior region of the body member through the suture exit port.
[0008] In yet another aspect, the invention relates to a suturing instrument including an elongate body member having a longitudinal axis and a distal tip suture deployment assembly joined with a distal end of the elongate body member such that the distal tip assembly is free to rotate axially about the longitudinal axis of the elongate body member. The distal tip suture deployment assembly includes a suture exit port and a curved suture carrier channel formed in the distal tip suture deployment assembly, a curved suture carrier movably positioned in the curved suture carrier channel, a suture with a formed tip coupled to the suture carrier, and a deployment controller including a proximal end and a distal end. The deployment controller extends substantially along the longitudinal axis of the elongate body member to the distal end of the elongate body member, where the distal end of the deployment controller is coupled to the distal tip suture deployment assembly and moves the curved suture carrier through the curved suture carrier channel as the deployment controller moves between a retracted position and a deployed position. Additionally, the proximal end of the deployment controller may be coupled to an actuator.
[0009] In still another aspect, the invention relates to a suturing instrument including a body member defining an exit port and a carrier channel, a carrier movably positioned in the carrier channel, and a surgical needle permanently fixed on a distal end of the carrier. The carrier has a retracted position within an interior region of the body member and a deployed position exterior to the body member. The carrier is configured within the carrier channel such that the carrier exits the interior region of the body member through the exit port. The permanently fixed needle may include a notch for holding a formed suture tip. In addition, the exit port, suture carrier channel, and suture carrier can be located in a distal tip assembly coupled to the body member, and the distal tip assembly can be coupled to the body member such that the distal tip assembly is free to rotate axially about a longitudinal axis of the body member.
[0010] Various embodiments according to any of the foregoing aspects of the invention can include the following features. A suture can include a formed tip, which may be permanently fixed to an end of the suture. The formed tip of the suture can insert into the suture carrier notch. Also, the formed tip can be plastic, metal, or polymer compound. In addition, the suturing instrument can include a catch to receive and retain the formed suture tip, where the catch is positioned on the body member such that a distal segment of the suture carrier's path is intercepted by the catch. Additionally, the suturing instrument may include a second suture carrier and a second exit port. Further, the deployment controller may be coupled to the suture carrier with a flexible driver member. The flexible driver member may be manufactured of an alloy that includes at least or exclusively nickel and titanium.
[0011] An additional aspect of the invention relates to a method for placing a suture in tissue. In accordance with the method, inserting a suturing instrument enclosing a suture carrier having a sharpened end for tissue penetration and a notch for holding a formed suture tip, deploying the suture carrier out of the suturing instrument through an exit port such that the suture carrier exits an interior region of the suturing instrument through the exit port along a path which approaches being substantially tangential to an outer surface of the suturing instrument surrounding the exit port, and capturing a suture carried by the suture carrier in a catch that receives and retains the formed suture tip. The suture carrier is movably positioned within a suture carrier channel adjacent the tissue to be sutured.
[0012] These and other objects, along with advantages and features of the present invention herein disclosed, will become apparent through reference to the following description, the accompanying drawings, and the claims. Furthermore, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and permutations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the following description, various embodiments of the present invention are described with reference to the following drawings.
[0014] FIGS. 1A-1H are cutaway views illustrating the general structure and operation of one embodiment of the present invention.
[0015] FIGS. 2A-2D and 2 F are perspective views of various embodiments of sutures and formed suture tips.
[0016] FIG. 2E is a cross-sectional view of one embodiment of a suture and formed tip.
[0017] FIGS. 2G and 2H are end views of the embodiment of a suture and formed tip shown in FIG. 2F .
[0018] FIG. 3A is a partial-cutaway view of a suture carrier.
[0019] FIG. 3B is an enlarged perspective view of the suture carrier of FIG. 3 .
[0020] FIG. 4 is a perspective view of a catch and a suture with a formed suture tip.
[0021] FIG. 5 is a perspective view of an alternate catch mechanism with a suture carrier.
[0022] FIGS. 6A and 6B are partial cutaway views illustrating the general structure and operation of one embodiment of a suture delivery and capture system.
[0023] FIGS. 6C and 6D are partial cutaway views illustrating the general structure and operation of an alternate embodiment of a suture delivery and capture system.
[0024] FIG. 7 is a partial side view taken along line 7 - 7 of FIG. 6A and illustrating the formed suture tip catch.
[0025] FIG. 8 is a cross-sectional view taken along line 8 - 8 of FIG. 7 .
[0026] FIG. 9A is an exploded illustrating the general structure of an alternate embodiment of the suture carrier and guide track.
[0027] FIG. 9B is a perspective view illustrating the general structure of an alternate embodiment of the suture carrier of FIG. 9A .
[0028] FIG. 10 is a cross-sectional view illustrating the relationship between the suture carrier and guide track.
[0029] FIGS. 11A and 11B are cross-sectional views of two alternate designs of the suture carrier taken along line 11 - 11 of FIG. 9A .
[0030] FIG. 12 is a cross-sectional view of the suture carrier and guide track taken along line 12 - 12 of FIG. 10 .
[0031] FIG. 13 is a cross-sectional view of the suture carrier and guide track taken along line 13 - 13 of FIG. 10 .
[0032] FIG. 14 is an elevation of another embodiment of the present invention.
[0033] FIG. 15 is a cutaway view illustrating the general internal structure of the embodiment shown in FIG. 14 .
[0034] FIG. 16 is a cutaway view of the head of the embodiment shown in FIGS. 14 and 15 .
[0035] FIGS. 17A-17D are cutaway views illustrating the operation of the embodiment shown in FIGS. 14-16 .
[0036] FIGS. 18A-18B are partial-cutaway views of the distal tip of one embodiment of a suturing device and illustrating the general structure and operation of the axial articulation of the suture driver head.
[0037] FIGS. 19A-19C are perspective views of one embodiment of a suturing instrument of the invention featuring an elbow-shaped, elongated body member with a rotatable head shown in various rotated positions.
[0038] FIGS. 19D-19F are partial-cutaway views illustrating some details of the rotatable head shown in FIGS. 19A-19C and featuring a suture carrier, a catch, and engaging elements.
DESCRIPTION
[0039] Embodiments of the present invention are described below. It is, however, expressly noted that the present invention is not limited to these embodiments, but rather the intention is that modifications that are apparent to the person skilled in the art are also included.
[0040] FIGS. 1A-1H illustrate the general structure and operation of one embodiment of the present invention. A device 2 according to the present invention incorporates a length of suture material 4 with a formed tip 6 on each end. Suture carriers 10 hold the formed tips 6 . The suture carriers 10 and formed tips 6 are deployable out of a housing 12 and into tissue surrounding a puncture wound 14 . Deployment is via an actuator, such as a plunger 3 , coupled to a pair of rigid driving members 5 , which are suitably attached to the suture carriers 10 . In this disclosed embodiment, the plunger 3 is pushed, simultaneously driving the suture carriers 10 and formed tips 6 into a catch mechanism 16 . The suture carriers 10 are then retracted back into the housing 12 . The housing 12 (now containing only the suture carriers 10 without the formed tips 6 ) and the catch mechanism 16 with the captured formed tips 6 are retracted as shown in FIGS. 1G and 1H . With a loop of suture 4 having thus been placed in the tissue surrounding the puncture wound 14 , the suture device 2 is removed from the wound 14 , thereby pulling the ends of the suture 4 with it ( FIG. 1H ). Closure of the puncture wound 14 is accomplished by cutting the suture 4 to disconnect the formed tips 6 from the installed suture 4 , tying a knot with the now-free ends of the installed suture 4 , and pushing into the wound 14 the knot and any suture 4 extending out of the wound 14 . Superficial closure is then performed by normal means according to a surgeon's preference.
[0041] The suture carrier path shown in FIGS. 1A-1H is generally circular; however, it is contemplated that the above embodiment may be modified to include suture carrier paths other than circular, such as helical, elliptical, or straight, by modification of the suture carriers and/or the suture carrier guides defined by the housing 12 . It is also possible to adapt the above configuration to allow each of the suture carriers to be actuated and driven independently by dividing the deployment controls and the suture carrier drivers into separate left and right hand members. Further, it is possible to utilize a tool that uses only a single suture carrier and guides the carrier through both sides of the wound as opposed to the double suture carrier configuration described above.
[0042] Referring to FIG. 2A , a formed tip 234 (such as the formed tip 6 described above and the one described hereinafter) comprises a body 236 having a shoulder 238 . The shoulder 238 is the rear surface of the formed tip body 236 that engages a catch. A length of suture material 242 is inserted into a hole 244 located on the shoulder 238 and attached to the formed tip 234 thereby. The suturing material 242 is attached to the body 236 by any suitable means, such as crimping or adhesive bonding. The rectangular shaped body 236 is merely illustrative, and the shape may be varied to fit a particular application. For example, a simple elongated cylinder or a triangular block may be used, as shown in FIGS. 2B-2E . The formed tip 234 can be manufactured from a plastic, metal, or polymer compound and can be formed by, for example, extrusion, molding, or machining. Furthermore, the type of material(s) used to form the suture is not critical to the present invention, as long as the material(s) used is/are biocompatible. The formed tip 234 of the present invention may be used with any type or size (length, cross-sectional shape) of suture material. The surgeon will select the length, diameter, and characteristics of the suture to suit a particular application.
[0043] Various possible formed tips according to the invention are now described with reference to FIGS. 2B-2H .
[0044] In FIG. 2B , the suture 242 is shown attached to an elongated cylindrically-shaped body 235 , which may illustratively be somewhat rigid, at least as compared to the suture 242 , to facilitate capture by a catch. As illustrated in FIG. 2C , an end portion of the suture 242 may be molded or otherwise formed within the body 235 of the formed tip.
[0045] In FIGS. 2D and 2E , the body 237 has a generally triangular cross-sectional shape and is shown attached to the suture 242 . It will be appreciated that the suture 242 may be inserted into a mold in which a plastic or plastic-like material of the body 237 is injected. Alternatively, the suture 242 may be held within a hole 245 within the body 237 by adhesive bonding.
[0046] FIGS. 2F-2H show how a body 239 may be clamped downwardly on a suture 242 and welded or otherwise pressure formed and closed to capture the suture 242 . The body 239 is an elongated member having a C-shaped cross-section, as shown in FIG. 2F , to receive the suture 242 . The body 239 may have a plurality of ridges 241 as shown to grip the suture 242 when the C-shaped body 239 is clamped with forces F as shown in FIG. 2G to produce the cross sectional shape shown in FIG. 2H . Techniques for welding or joining plastic by the application of pressure and energy to capture another material, such as a suture, are well known.
[0047] Referring now to FIG. 3A , a suture carrier 246 (such as the suture carriers described above and the one described hereinafter) comprises a body 248 defining a lumen 259 , a notch 250 to receive a formed tip 234 , and a sharpened end 252 for tissue penetration. Forming or machining may be used to fabricate the sharpened end 252 . The lumen 259 is in communication with the notch 250 at one end and with an aperture 258 at the other end. The notch 250 is sized and shaped to releasably engage the formed tip 234 . A length of suture material 242 attached to the formed suture tip 234 is inserted into the notch 250 , through the lumen 259 , and out the aperture 258 . The attached formed tip 234 is then releasably engaged with the notch 250 . Alternatively, the suture carrier 246 can be a solid piece with the suture 242 disposed in a groove in the outer surface of the suture carrier 246 .
[0048] FIG. 3B depicts an enlarged view of the tip of the suture carrier 246 . The formed tip 234 is releasably engaged with the notch 250 so that the body 236 protrudes slightly from the notch 250 . The rear surface of the body 236 , which forms the shoulder 238 , faces away from the sharpened tip 252 . The formed tip 234 is engaged with the notch 250 such that the body 234 is held in place by frictional forces when the suture carrier 246 is extended forward. The body 236 is released from the notch 250 when the suture carrier 246 is retracted from a catch. The shoulder 238 is dimensioned so as to be retained by the catch when the suture carrier 246 exits the catch. The interaction of the suture carrier 246 and various catches is described in greater detail with respect to FIGS. 4 and 5 .
[0049] FIGS. 4 and 5 depict alternate catches and illustrate their operation. Referring to FIG. 4 , the catch 260 includes openings 262 defined by successive ribs 264 . The catch 260 receives a suture carrier 246 (not shown) and a suture 242 with a formed tip 234 through opening 262 , the ribs 264 deflect slightly to allow the suture carrier 246 and formed tip 236 to pass through. After the formed tip shoulder 238 has passed the ribs 264 and the suture carrier 246 has been withdrawn, thereby releasing the formed tip 234 , the ribs 264 spring back to their original position defining the openings 262 . The openings 262 are chosen to be smaller in dimension than the formed tip shoulder 238 . This causes the catch 260 to retain the formed tip 234 , because due to the flat rear surface of the shoulder 238 , the formed tip 236 cannot pass back through an opening 262 . When it is necessary to remove the formed tip 234 from the catch 260 , it may be moved toward an enlarged portion 265 of opening 262 . The enlarged portion 265 is sized to allow the formed tip shoulder 238 to pass through without resistance. The catch 260 is preferably constructed of thin stainless steel of high temper, such as ANSI 301 full hard. The catch 260 may be fabricated by means of stamping, laser machining, or chemical etching.
[0050] Referring now to FIG. 5 , a catch 266 includes a frame 268 to which is attached a woven mesh 270 . Threads 272 creating the woven mesh 270 may be nylon, polyester, or the like woven in a common over/under pattern. The weaving of the threads 272 creates windows 274 in the mesh through which a suture carrier 246 may be passed. The suture carrier 246 is constructed such that the shoulder 238 of the formed tip 234 is larger than the windows 274 , or conversely, the windows 274 are chosen to be smaller than the shoulder 238 . The sharpened end 252 of the suture carrier 246 pushes the threads 272 aside creating room for the shoulder 238 to pass through the windows 274 . Upon withdrawal of the suture carrier 246 , the threads 272 return to their original positions and the catch 266 retains the formed tip 234 (once again due to the flat rear surface of the shoulder 238 , which is larger than the windows 274 ).
[0051] FIGS. 6A and 6B depict one embodiment of a suture carrier and catch system. Referring to FIG. 6A , an elongate body member 718 is formed of two complementary housing halves 720 a,b . It is to be understood that for clarity only one of the housing halves 720 a of the elongate body member 718 is shown in FIGS. 6A and 6B . The housing halves 720 a,b are configured to create a guided pathway 722 that includes a suture carrier channel 724 and a flexible carrier driver guide track 726 . A suture carrier 728 and flexible carrier driver 730 are joined at an end 732 of the suture carrier 728 . Crimping, welding, adhesive bonding, or various other techniques can accomplish the attachment between the suture carrier 728 and the flexible carrier driver 730 at the end 732 . A formed tip 734 and a length of suture material 742 are attached to the suture carrier 728 . Further incorporated in the housing halves 720 are a pair of catch pockets 746 a,b , which position and retain a catch 748 . Referring to FIG. 7 , the catch 748 includes openings 750 defined by ribs 752 . The configuration and function of the formed tip catch 748 is similar to that described earlier with respect to FIG. 4 . When the catch 748 is fabricated by means of chemical etching, the preferred method is to etch from a single side, known in the art as single sided etching. When the catch 748 is etched from a single side, the ribs 752 have a tapered cross-section 753 as shown in FIG. 8 . The tapered cross section 753 helps to guide the sharpened end of the suture carrier 728 into the catch openings 750 , thereby minimizing the chance of the sharpened end of the suture carrier 728 hitting the top of the ribs 752 .
[0052] With renewed reference to FIGS. 6A and 6B , the operation of this embodiment will be described. FIG. 6A shows the formed tip 734 loaded into the suture carrier 728 , which is depicted in the retracted position. In this position, the body 718 may be passed through a surgical trocar and into a body cavity for operation of the device. As shown in FIG. 6B , as the flexible carrier driver 730 is advanced into the suture carrier channel 724 , the suture carrier 728 , holding the formed tip 734 and trailing the suture 742 , is driven in a semi-circular path that intersects the catch 748 . The formed tip 734 is received and retained by the catch 748 in a manner previously described with respect to FIG. 4 . The flexible carrier driver 730 may be retracted back into the flexible carrier driver guide track 726 , causing the suture carrier 728 to rotate back into the suture carrier channel 724 . The instrument may be removed from the surgical trocar, and the process repeated on the other side of the wound.
[0053] FIGS. 6C and 6D depict an alternate suture carrier and catch system. Referring to FIG. 6C , an elongate body member 770 is comprised of a pair of complementary housing halves 772 a,b . It is to be understood that for clarity only one of the housing halves 772 a of the body 770 is shown in FIGS. 6C and 6D . The housing halves 772 a,b are configured to create a guided pathway 774 that defines a suture carrier channel 776 and a flexible carrier driver guide track 778 . A suture carrier 780 and flexible carrier driver 782 are joined at a saddle 784 of the suture carrier 780 . The saddle 784 comprises a channel, groove, or opening formed in the proximate end of the suture carrier 780 into which the flexible carrier driver 782 may enter. Crimping, welding, adhesive bonding, or various other techniques can accomplish the attachment between the suture carrier 780 and the flexible carrier driver 782 at the saddle 784 . A formed tip 790 and a length of suture material 794 are attached to the suture carrier 780 . Further incorporated in the housing halves 772 a,b are a pair of catch pockets 798 a,b that position and retain a catch 800 . The configuration and function of the catch 800 is similar to that described earlier with respect to FIG. 4 . The suture carrier 780 carries the formed tip 790 of the suture through the tissue and into the catch 800 as previously described.
[0054] Although the operation of this embodiment is similar to that described in FIGS. 6A and 6B , there are some differences. Referring back to FIGS. 6A and 6B , as the suture carrier 728 approaches the end of its stroke, as illustrated in FIG. 6B , the circumferential length of the suture carrier 728 left inside the suture carrier channel 724 is minimal. This may allow the suture carrier 728 holding the formed tip 734 to drift off of the prescribed arcuate path that terminates in the formed tip catch 748 . This drift may allow the sharpened end of the suture carrier 728 to miss the catch 748 , causing an incomplete suturing cycle. Therefore, it is desirable to increase the circumferential length of the suture carrier left inside the guide track in order to improve the guidance of the suture carrier.
[0055] Accordingly, the embodiment illustrated in FIGS. 6C and 6D equips the suture carrier 780 with the saddle 784 . The saddle 784 allows the flexible carrier driver 782 to exit from the suture carrier 780 at a point along the circumference, rather than at a distal end 804 . This may be seen to increase the overall arc length of the suture carrier 780 when compared with the suture carrier 728 shown in FIG. 6A . As a result, when the flexible carrier driver 782 is slidably moved in the guided pathway 774 , the suture carrier 780 rotates within the suture carrier channel 776 such that when the formed tip 790 enters the catch 800 , a significantly larger portion of the suture carrier 780 is still captured within the suture carrier channel 776 . This may provide additional guidance to the suture carrier 780 as it penetrates tissue. This geometry may also allow for a longer stroke length and greater tissue bite.
[0056] Referring to FIG. 9A , the distal end of an elongate body 858 is comprised of a pair of complementary housing halves 860 a,b . It is to be understood that for clarity only one of the housing halves 860 a of the body 858 is shown in FIG. 9A . The housing halves 860 a,b are configured to create a guided pathway 862 that defines a suture carrier channel 864 and a flexible carrier driver guide track 866 . A suture carrier 868 includes a saddle 872 , to which is attached a carrier bearing 874 . The saddle 872 comprises a channel, groove, or opening formed in the proximate end of the suture carrier 868 into which the flexible carrier driver 870 may enter.
[0057] The construction of the suture carrier may be best understood by referring to FIG. 11A , where a cross-sectional view shows the suture carrier 868 and the carrier bearing 874 . The carrier bearing 874 further includes bearing wings 876 a,b . The carrier bearing 874 may be joined by welding, adhesive bonding, or the like to the suture carrier 868 .
[0058] The suture carrier 868 may also be formed by another method. FIG. 11B shows a cross-sectional view of a suture carrier 878 that has been formed out of, for example a 17-4 stainless steel alloy by a process called metal injection molding. This process allows the suture carrier 878 to be formed in a monolithic fashion such that the suture carrier 878 , bearing wings 880 a,b , and saddle are formed as one piece. Other processes such as die casting, investment casting, or powdered metal could also be used to create a monolithic suture carrier 878 .
[0059] Another embodiment of the suture carrier, indicated generally at 885 in FIG. 9B , includes a sharpened end 886 at the distal end adapted to penetrate tissue and a groove 887 at the proximal end adapted to contain a flexible suture driver 888 as previously described. A series of pins 889 a,b, c, d are attached to the sides of the suture carrier 885 . The pins 889 a,b, c, d are dimensioned to be slidably disposed within the groove 884 in the suture carrier channel 864 , and to provide guidance and stability to the suture carrier 885 in a fashion similar to that described with reference to FIG. 9A below.
[0060] Referring again to FIG. 9A , the suture carrier 868 and flexible carrier driver 870 are joined as previously described at saddle 872 of the suture carrier 868 , which incorporates bearing wings 876 . The suture carrier 868 has a sharpened distal end 882 adapted to penetrate tissue as previously described in other embodiments. Alternatively, the suture carrier 868 may include an aperture located at its distal end for receiving a surgical needle, the needle being permanently attached to the suture carrier 868 . The needle includes a sharpened distal tip and a notch for holding a formed suture tip. The surgical needle can be permanently attached to the suture carrier 868 by welding, chemical bonding, or similar technique. In this embodiment, the suture carrier guide track 864 further incorporates a groove 884 adapted to receive the bearing wings 876 a,b . FIG. 12 depicts a detailed cross-sectional view of the groove 884 and the bearing wings 876 . FIG. 13 depicts a detailed cross-sectional view of the suture carrier guide track 864 and illustrates an area of the suture carrier 868 and of the suture carrier guide track 864 where there are no bearing wings 876 . It should be understood that the cross-section shown in FIG. 13 of the suture carrier 868 could be of solid material instead of tubular material if the cross-section were illustrating a monolithic part, such as suture carrier 878 . It may also be understood from the foregoing illustrations, that the width and depth of the bearing wings 876 a,b shown in FIG. 11A and the bearing wings 880 a,b shown in FIG. 11B are not to be taken as literal illustrations of the physical dimensions of those features, as the width and depth may be varied in order to achieve more or less guidance and bearing surface area as the designer deems appropriate.
[0061] The operation of the embodiment described in FIGS. 9A through 13 is identical to that previously described in FIGS. 6C and 6D , with the exception that the bearing wings 876 a,b are adapted to rotationally slide in the grooves 884 a,b of the housing halves 860 a,b . This provides axial and torsional guidance and resistance to deflection of the suture carrier 868 from the anticipated path. Performance improvements over the embodiment described in FIGS. 6C and 6D relate primarily to an increased ability to torque and/or lift the device while the suture carrier is exposed to the tissue to be sutured.
[0062] The preferred material for the flexible carrier driver 870 is an alloy of nickel and titanium known in the art as nitinol. This material has both austenitic and martensitic forms, and can be alloyed to exhibit properties of both forms as the material moves through a transition temperature that can be varied. The martensitic form of the alloy, when processed into, for example wire, has a lead-solder like consistency and easily deflects plastically to a certain point, beyond which a considerable amount of force is necessary to cause further deflection. This elastic behavior is what allows the material to be both flexible and exhibit high column strength when properly constrained. Thus, the flexible carrier driver 870 is constrained in a track that allows it to be moved axially, but constrains its deflection off-axis.
[0063] Another embodiment of the invention is shown in FIGS. 14-18 . This embodiment of the present invention is particularly well suited for, e.g., the fixation of sutures to the Cooper's ligament during the performance of a Burch bladder neck suspension via a transvaginal approach. As will become apparent, this embodiment includes features for limiting the depth of the sharpened end penetration for placing sutures in, for example, ligaments lying directly on bone, and for accommodating the anatomy of, for example, the female pelvis.
[0064] FIG. 14 depicts a suturing instrument 300 including a pair of handles 302 a,b , an elongate body 304 , distal tips 306 a,b , and an actuator button 308 . FIG. 15 depicts the suturing instrument 300 , the handle 302 a , the elongate body 304 , the distal tip 306 a , and the actuator button 308 in cross-section. The actuator button 308 includes a button head 310 , a button shaft 312 , a series of button bearing surfaces 314 a,b, c, d , a button end 316 , and a hole 318 . The button bearing surfaces 314 a,b,c,d ride along a cylindrical surface 320 that is formed by the inside diameter of the elongate body 304 . A wireform 322 is inserted into the hole 318 , coupling it to the actuator button 308 . A spring 324 encircles the wireform 322 , abuts the button end 316 , and is compressed between the button end 316 and a spring washer 326 . The spring washer 326 is seated upon a center tube 328 . The center tube 328 is housed by the cylindrical surface 320 and is constrained at the distal end by the distal tip 306 . A pusher wire 330 is attached to the wireform 322 by means of a weld, a coupling, adhesive, or other means, and is slidably disposed within a proximal guidance sleeve 332 and a distal guidance sleeve 334 , said sleeves 332 , 334 being disposed within a cylindrical surface 336 formed by the inside diameter of the center tube 328 .
[0065] The pusher wire 330 is preferably constructed of nitinol wire, so chosen as previously discussed for its combination of properties that allow for bendability and high column strength when constrained. The constraints in this construction are provided by the proximal guidance sleeve 332 and the distal guidance sleeve 334 .
[0066] FIG. 16 depicts the distal end of the suturing device 300 . For the purposes of clarity, only one of the distal tips 306 a is shown and cross-sectional representations of the center tube 328 , the distal guide tube 334 , and the elongate outer tube 304 are shown. The pusher wire 330 is attached by welding or other means to a coupling 338 , which is slidably disposed within a track 340 . The coupling 338 is also attached to a carrier wire 342 , which by virtue of its attachment to the coupling 338 , is also slidably disposed within the track 340 . The carrier wire 342 is attached to a suture carrier 344 by welding or other means. The carrier 344 is rotatably and slidably disposed within a suture carrier channel 346 molded into the distal tip 306 . The relationship between the carrier wire 342 , the carrier 344 , and the channel 346 is similar to that previously described in FIGS. 9-13 . The coupling 338 abuts a backstop washer 348 that is slidably disposed about the pusher wire 330 , and constrained within a pocket 350 . The pocket 350 includes a back wall 352 , against which the backstop washer 348 rests.
[0067] The track 340 terminates distally in a pocket 354 that includes a wall 356 . A downstop washer 358 is slidably disposed about the carrier wire 342 and constrained within the pocket 354 . Positioned at the terminus of the path of the carrier 344 is a catch 360 that is held distally in a pocket 362 and proximally in a pocket 364 . The catch 360 is similar in construction and function to the catch described with respect to FIGS. 4, 7 , and 8 . The distal tips 306 a,b are held together by rivets placed in rivet holes 366 a,b,c,d and by tip shafts 368 a,b being inserted into the cylindrical surface 320 , which is the inside diameter of the elongate body 304 . A depression 370 in the elongate body 304 may be formed by mechanical means such as striking with a pin or forming with a die. The depression 370 is engaged in a rotation pocket 372 a,b that is formed as a feature of the distal tips 306 a,b , and will be further described with respect to FIGS. 18A-18B .
[0068] FIGS. 17A-17D depict a sequence of operation of the suturing instrument shown in FIGS. 14-16 . Although this description relates to a specific application, i.e., the performance of a Modified Burch bladder neck suspension via a transvaginal approach, it is to be understood that the principles and construction herein described may be applied to other areas of the human body, and for other procedures requiring suturing body structures, such as ligaments that are in direct communication with bone. FIG. 17A depicts a cross-sectional view of the distal tip of the suturing device 300 . The suturing device 300 is shown with a suture 374 attached to a suture formed tip 376 in a manner similar to that described with respect to FIG. 2 and is shown loaded into the suture carrier 344 in preparation for actuation. The suturing device 300 has been placed against a ligament 378 that lies directly on a bone 380 . Referring to FIGS. 15 and 17 A, it may be seen that the pusher wire 330 is held in tension by the spring 324 , as the coupling 338 shown in FIG. 17A abuts the backstop washer 348 that is held against the back wall 352 , positioning the suture carrier 344 in its retracted position.
[0069] As those skilled in the art will appreciate, it can be quite difficult to drive a suture through a ligament that lies directly on bone, as the bone's density typically does not allow a suture needle to penetrate it. Thus a skimming path should be taken to avoid hitting bone, but ensuring good penetration of the ligament and a subsequent “good bite” of tissue. In the case of the Cooper's ligament that is the focus of the anterior fixation point for the Modified Burch bladder neck suspension procedure, the difficulty in placing those sutures is directly attributable to the ligament lying on the bone and the problems with exposure of the ligament to the surgeon.
[0070] Again referring to FIG. 15 , and now FIG. 17B , the actuator button 308 is depressed by pushing on button head 310 , which via attachment to the wireform 322 is attached to pusher wire 330 , which moves coupling 338 along track 340 while concomitantly moving the carrier wire 342 , which slidably and rotatably moves the suture carrier 344 in the channel 346 and drives the sharpened end of the suture carrier 344 into the ligament 378 . The suture carrier 344 skims or slides along the surface of the bone 380 , maximizing the depth of penetration, but not digging in or penetrating the bone surface.
[0071] Referring now to FIG. 17C , the coupling 338 reaches a point in its travel along the track 340 where it pushes the downstop washer 358 against the wall 356 of the pocket 354 . This action limits the outward travel of the suture carrier 344 to prevent overdriving and reduces or eliminates the possibility of expelling the suture carrier 344 from the distal tip 306 . The suture carrier 344 drives the formed tip 376 and attached suture 374 through ligament 378 and into the catch 360 , where it is received and retained in a manner previously described. As the button 308 is released, the spring 324 urges the button 308 proximally, moving the pusher wire 330 , the coupling 338 , the carrier wire 342 , and the suture carrier 344 along with it to the position shown in FIG. 17D , where the backstop washer 348 arrests the proximal movement in a manner previously described, leaving the formed tip 376 in the catch 360 and the suture 374 driven through the ligament 378 .
[0072] A variation of this embodiment can be seen with respect to FIGS. 10 and 16 . In the embodiment shown in FIG. 10 , the path of the suture carrier 868 , illustrated by a phantom line in FIG. 10 , exits the housing 860 in a direction that is substantially perpendicular to the surface of the housing 860 and presents an opportunity for the suture carrier 868 to be driven directly into the tissue surface placed against the exit port. Thus, if there were bone immediately underlying that tissue, this would allow the sharpened end of the suture carrier 868 to be driven directly into bone. In the embodiment shown in FIG. 16 , a phantom line illustrates a different type of carrier path. In this embodiment, the carrier path exits the distal tip 306 in a direction that approaches being substantially tangential to the surface of the distal tip 306 . This substantially tangential exit path allows this instrument to achieve the skimming tissue bite referred to earlier. As shown in FIGS. 17A-17D , when the surface surrounding the exit port of this device is placed next to a tissue surface, the sharpened end of the suture carrier 344 takes a skimming tissue bite, thereby minimizing any possible penetration of bone underlying the tissue.
[0073] Another aspect of this embodiment which is advantageous to the function of the device is the ability to rotate the distal tip 306 of the instrument relative to the elongate body 304 , thereby allowing the instrument to conform to the contours of, for example, the pelvic brim. This is accomplished by incorporating the construction illustrated in FIGS. 18A and 18B . For clarity, the elongate body 304 has been shown in partial cross-section so that the depression 370 may be seen to engage the rotation pockets 372 a,b . This engagement couples the distal tips 306 a,b to the elongate body 304 , as previously described, and also allows the assembly of the distal tips 306 a,b to be rotated axially along the cylindrical surface 320 .
[0074] In yet another embodiment, the instrument can be adapted to facilitate access into the abdominal cavity and the placement of suture(s) radially in a body lumen. Such instrument may be particularly useful where anastomosis is required such as urethral anastomosis following radical prostatectomy or in blood vessel or bowel anastomosis. Referring to FIGS. 19A-19C , the suturing instrument 66 includes an elongated body member 82 and a rotatable head 124 . The elongated body member 82 can include an elbow 122 (or bend). The head 124 rotates by angular increments. The elongated body member 82 includes an engaging element located at its distal end 128 . The head 124 includes an engaging element located at its proximal end 126 for mating with the engaging element of the elongated body member 82 . The head 124 includes a dilator cap or a bullet-shaped end at the distal end 130 of the head 124 to maintain the urethra or any other body lumen in a dilated configuration. The rotation of the head 124 is performed manually between each application of a suture in a body lumen and before reloading with the needle and suture to permit application of a series of sutures along the circumference of the lumen, at incremental angular positions that can be as small as 10°. The embodiment of the suturing instrument featuring an elbow and rotatable head is particularly adapted to perform suturing after removal of the prostate to connect the bladder to the urethra or generally following any other type of resection.
[0075] In one embodiment, the rotatability of the head 124 is accomplished with the structure depicted in FIGS. 19D-19F . The head 124 includes an engaging element with a male configuration 123 . The male configuration 123 includes a series of fluted cuts 133 located along 330° of its perimeter. The male configuration 123 includes a stop to prevent the head 124 from rotating 360°. The elongated body member 82 includes an engaging element with a female configuration 125 and a flexible detent 131 . The female configuration 125 is a substantially circular recess with the flexible detent 131 mounted within the elongated body member 82 and protruding into the substantially circular recess. The flexible detent 131 can be a length of spring wire or a pin and can be made of nitinol. The head 124 can be positioned by rotating the male configuration 123 engaging element with respect to the female configuration 125 engaging element, deflecting the flexible detent 131 , and then allowing the flexible detent 131 to mechanically engage the fluted cut 133 which corresponds to the desired angular orientation. The head can be positioned in angular increments of 30°. In addition, the head 124 depicted in FIGS. 19D-19F includes a suture carrier 127 and a catch mechanism 129 , which perform substantially the same and are constructed substantially the same as the prior-described suture carriers and catches.
[0076] Having described certain embodiments of the invention, it will be apparent to those of ordinary skill in the art that other embodiments incorporating the concepts disclosed herein can be used without departing from the spirit and the scope of the invention. Accordingly, the described embodiments are to be considered in all respects only as illustrative and not restrictive.
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Sutures can be placed in difficult to access areas of the human body with devices, and related methods, utilizing a suture carrier with a sharpened tip and a notch for holding a formed suture tip. The devices and methods can be used in conjunction with both endosurgical and traditional open surgery
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BACKGROUND OF THE INVENTION
1. Field of the Invention
Embodiments of the present invention generally relate to methods for estimating efficiency and controlling the operation of a downhole pump. More particularly, embodiments of the present invention generally relate to methods for estimating efficiency and controlling the operation of a conventional sucker-rod pump.
2. Description of the Related Art
The production of oil with a sucker-rod pump such as that depicted in FIG. 1 is common practice in the oil and gas industry. The sucker-rod pump 100 is driven by a motor 110 that turns a crank arm 120 . Attached to the crank arm 120 is a walking beam 130 and a Horsehead 140 . A cable 150 hangs off the Horsehead 140 and is attached to a sucker-rod 155 . The sucker-rod 155 is attached to a downhole pump 160 located within the wellbore 165 . A portion of the sucker-rod 155 passes through a stuffing box 170 at the surface. That portion of the sucker-rod is called the polished rod 175 . In operation, the motor 110 turns the crank arm 120 which reciprocates the walking beam 130 which reciprocates the sucker-rod 155 .
The downhole pump 160 includes a barrel 180 that can be attached to or part of the production tubing 185 within the wellbore 165 . A plunger 187 is attached to the end of the sucker-rod 155 and reciprocates in the barrel 180 . The barrel 180 includes a standing valve 190 . The plunger 187 is provided with a traveling valve 195 . On the up stroke of the plunger 187 , the traveling valve 195 closes and the fluid is lifted above the plunger 187 to the top of the well, and the standing valve 190 opens to allow additional fluid from the wellbore 165 into the barrel 180 . On the down stroke of the plunger 187 , the traveling valve 195 opens and the standing valve 190 closes, allowing the plunger 187 to pass through the fluid which is being held in the barrel 180 by the standing valve 190 .
Typically, the pumping system is designed with the capacity to remove liquid from the wellbore 165 faster than the reservoir can supply liquid into the wellbore 165 . As a result, the downhole pump does not completely fill with fluid on every stroke. The well is said to be “pumped-off” when the pump barrel 180 does not completely fill with fluid on the upstroke of the plunger 187 . The term “pump fillage” is used to describe the percentage of the pump stroke which actually contains liquid.
Varying degrees of mechanical damage can occur to the pumping system if the pump is operated with substantially less than 100% pump fillage for extended periods of time (i.e. when the well is pumped-off). During pumped-off conditions, the plunger contacts the fluid in an incompletely filled barrel at which point the traveling valve will open. The impact between the plunger 187 and fluid known as “fluid pound” will cause a sudden shock to travel through the sucker-rod 155 and the pumping unit 100 which can cause damage to the sucker-rod 155 and other pumping components. Thus, an effort is made to shut down the pumping unit when the well reaches a pumped-off condition to prevent damage to the equipment as well as to save power.
Automation devices have been used with sucker-rod pumping systems to monitor and temporarily discontinue pumping operations to protect the pump. Surface dynamometer data have long been used as a basis for controlling sucker-rod pumping systems. Historically, measured operating characteristics of the pumping unit have been used to derive a data set representing load (force) on the polished rod vs. displacement of the polished rod (known as a “surface dynamometer card”). Various algorithms have subsequently been applied to these data sets to identify a “pump-off” condition.
However, the surface dynamometer card does not supply an accurate depiction of the operation of the downhole pump due to the elasticity of the sucker-rod string and viscous damping effects among other operating conditions. With longer sucker-rods and larger pump sizes (higher stress) and even revolutionary new sucker-rod materials, the differences between the displacement versus time at the surface and the displacement versus time at the downhole pump can be quite dramatic. Therefore, methods of controlling sucker rod pumping units based upon surface dynamometer cards can be prone to error. In addition, the elasticity of the sucker rod string causes the stroke length of the downhole pump to differ from the stroke length of the polished rod. This introduces further error into production volume estimates.
Therefore, measurements taken at the pump are more reliable and less prone to error. Since direct measurement of the load and displacement at the pump in the wellbore is cost prohibitive in most production operations, attempts have been made to mathematically model or infer “downhole dynamometer cards” (load vs displacement at the downhole pump) from the surface dynamometer card and other static data. Those models are capable of providing an approximation of the actual downhole dynamometer card. However, the execution of those models in a remote setting (i.e. at the well site) requires considerable computing capacity. Additional logic must also still be applied to make a pump-off determination once the downhole dynamometer card has been mathematically simulated. Furthermore, existing methods including downhole dynamometer cards provide no direct means of estimating pump fillage. As a result, still more computational effort is required to derive the information needed to support reliable estimates of pump production.
There is a need, therefore, for a method for determining pump fillage and a method for controlling pump operations without deriving a downhole dynamometer card.
SUMMARY OF THE INVENTION
Methods for estimating pump efficiency of a rod pumped well are provided. In at least one embodiment, the method provides a rod within the well where the rod is connected to a pumping unit at a first end thereof and a pump at a second end thereof. The pumping unit is located at the surface. The rod reciprocates within the well by the pumping unit. A load on the polished rod and displacement of the polished rod are determined at a plurality of times during a single stroke of the pumping unit. The rod loads and displacement at the plurality of times are utilized to calculate at least one displacement and time near the pump. The calculated displacement and time near the pump are utilized to determine a minimum stroke (NS, feet) and maximum stroke (XS, feet). The calculated displacement and time near the pump are also used to calculate a transfer point (TP). From the minimum stroke (NS, feet), maximum stroke (XS, feet), and transfer point (TP), the pump efficiency (PEFF) can be calculated according to the following equation: PEFF=100%*(TP−NS)/(XS−NS).
In at least one other embodiment, the method provides a rod within the well where the rod is connected to a pumping unit at a first end thereof and a pump at a second end thereof. The pumping unit is located at the surface. The rod reciprocates within the well by the pumping unit. A load on the polished rod and displacement of the polished rod are determined at a plurality of times during a single stroke of the pumping unit. The rod loads and displacements at the plurality of times are used to determine a minimum stroke (NS, feet) and maximum stroke (XS, feet) near the pump. The rod loads and displacements at the plurality of times are also used to calculate a change in rod displacement versus change in time near the pump and a change in rod displacement versus change in depth near the pump. The calculated change in rod displacement versus change in time near the pump and the change in rod displacement versus change in depth near the pump are used to calculate a transfer point (TP). From the calculated minimum stroke (NS, feet), maximum stroke (XS, feet), and transfer point (TP), a pump efficiency (PEFF) can be calculated according to the following Equation: PEFF=100%*(TP−NS)/(XS−NS).
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is schematic depiction of an illustrative sucker-rod pumping unit.
FIG. 2 is a graphical illustration of a matrix of displacement versus time and depth.
DETAILED DESCRIPTION
Methods are provided that utilize a more direct approach to determining pump fillage which reduces processing requirements for wellsite devices and provides more precise estimates of pump fillage. In one or more embodiments, the methods calculate pump fillage directly from load and displacement data measured at the surface or determined from other measurements at the surface, rendering the calculation of load (i.e. force) at the pump unnecessary. In one or more embodiments, a finite-difference algorithm can be used to calculate rod displacement vs. time at the pump and rod displacement vs. depth at the pump. That information can be used to identify the minimum and maximum displacement at the pump as well as the pump displacement at precisely the time when load transfers from the traveling valve to the standing valve. The result is an accurate estimate of rod pump production and pump “fillage,” without the time and expense required to calculate a traditional downhole card. The term “pump fillage” as used herein refers to the ratio of the net fluid stroke to downhole stroke expressed in percent.
The term “pump” as used herein refers to any downhole reciprocating pump. Preferably, the term “pump” refers to a sucker-rod pump such as the pump shown in FIG. 1 . While a conventional beam pumping unit is shown in FIG. 1 , the method is applicable to any system that reciprocates a rod string including tower type units which involve cables, belts, chains, and hydraulic and pneumatic power systems.
The term “net fluid stroke” as used herein refers to the measure of the portion of the downhole stroke during which the fluid load is supported by the standing valve. The net fluid stroke can be expressed in feet.
The term “downhole stroke” as used herein refers to the measure of extreme travel of the rod derived at the location of the pump. In other words, the term “downhole stroke” refers to the maximum displacement minus the minimum displacement, and corresponds to the horizontal span of a downhole card.
The method can function in a “closed loop” automated environment with no human interaction. Preferably, the method can be incorporated in a wellsite Rod Pump Controller (RPC) to control (e.g. stop or change the speed of) the pumping unit and accurately estimate fluid production from the well using rigorous (stroke-by stroke) analysis of the net fluid stroke. For example, the speed of the pumping unit can be varied when the pump efficiency falls below a preset amount. Particularly, the uphole stroke speed of the pumping unit can be varied when the pump efficiency falls below a preset amount. Additionally, a tubing leak can be detected when the average production rate exceeds a preset amount.
In one or more embodiments, the displacement and load data can be used to determine one or more characteristics of the downhole pump operation, such as the minimum pump stroke, maximum pump stroke, and transfer point in the downhole stroke. The “transfer point” for the downhole stroke is the displacement in the downhole stroke where load is transferred from the traveling valve to the standing valve. This transfer occurs because the pressure in the pump barrel has exceeded the pressure in the plunger. The portion of the stroke below (with lower displacement than) the transfer point can be interpreted as the percentage of the pump stroke which contains liquid.
In one or more embodiments, the displacement and load data can be measured (or determined) at the surface. For example, the motor speed and the displacement of the polished rod can provide a series of motor speed and displacement data pairs at a plurality of displacements along the polished rod. That displacement data which represents a complete stroke of the pumping unit can then be converted to load on the rod string and displacement of the rod string at a plurality of displacements along the polished rod, as described in U.S. Pat. No. 4,490,094.
In one or more embodiments above or elsewhere herein, the degree of rotation of the pumping unit crank arm can provide displacement data. For example, a sensor can determine when the pumping unit crank arm passes a specific location, and a pattern of simulated polished rod displacement versus time can be adjusted to provide an estimate of polished rod positions at times between these crank arm indications.
In one or more embodiments above or elsewhere herein, the degree of inclination of the pumping unit can provide displacement data. For example, a device can be attached to the pumping unit walking beam to measure the degree of inclination of the pumping unit.
In one or more embodiments above or elsewhere herein, the load data can be directly measured. For example, a load cell can be inserted between the polished rod clamp and the pumping unit carrier bar.
In one or more embodiments above or elsewhere herein, the strain on the pumping unit walking beam can provide load data. In one or more embodiments above or elsewhere herein, the amplitude and frequency of the electrical power signal applied to the motor can be used to determine motor rotation (i.e. displacement data) and motor torque (i.e. load data).
The polished rod loads and displacement data can then be used to calculate at least one displacement and time near the pump. In one or more embodiments, a finite-difference method for solving a one dimensional wave equation can be used to determine the displacements at time near the pump. An illustrative wave equation can be represented by Equation (1) as follows:
v
2
∂
2
u
∂
x
2
=
∂
2
u
∂
t
2
+
c
∂
u
∂
t
,
(
1
)
where v=√{square root over (144Eg c /ρ)}
Equation 1 assumes a rod with a constant diameter. Multiplying Equation (1) by (ρA/44g c ) modifies the wave equation to account for variable rod diameters, and provides a modified wave equation (Equation (2)) as follows:
EA
∂
2
u
∂
x
2
=
ρ
A
144
g
c
∂
2
u
∂
t
2
+
c
ρ
A
144
g
c
∂
u
∂
t
(
2
)
Finite differences can then be used to obtain a numerical solution for the wave equations. For example, the sucker-rod string can be divided into “finite elements,” and Taylor series approximations can be used to generate finite-difference analogs for the derivatives of displacement that appear in the wave equation. Substituting the Taylor series approximations into Equation (2) gives Equation (3) as follows:
u
i
+
1
,
j
=
{
[
α
{
1
+
c
Δ
t
)
]
u
i
,
j
+
1
-
[
α
(
2
+
c
Δ
t
)
-
(
EA
/
Δ
x
)
+
-
(
EA
/
Δ
x
)
-
]
u
i
,
j
+
α
u
i
,
j
-
1
-
(
EA
/
Δ
x
)
-
u
i
-
1
,
j
}
/
(
EA
/
Δ
x
)
+
where
α
=
Δ
x
_
Δ
t
2
[
(
ρ
A
/
144
g
c
)
+
+
(
ρ
A
/
144
g
c
)
-
2
]
(
3
)
Equation (3) transmits the surface displacement downhole by calculating displacements at each node along the rod string until the last node just above the pump is reached. The polished rod loads at each displacement (u 0,j ) can be used to start the solution. The displacements at u 1,j can be calculated using Hooke's law in the form of Equation (4) as follows:
F=EA (∂ u/∂x ) (4)
FIG. 2 is a graphical illustration that shows a matrix of displacement versus time and depth. FIG. 2 shows the displacements at each node along the rod string until the last node just above the pump (i.e. “the last rod section”). “Node 0” represents the displacement versus time data at the surface and “Node m” represents the displacement versus time data of the section just above the pump. The displacement limits of the last rod section (U MIN and U MAX ) can be determined from the matrix. The displacement limit U MIN is the smallest displacement in the array (i.e. bottom of stroke). The displacement limit U MAX is the largest displacement in the array (i.e. top of stroke).
Next, the displacement, depth and time matrix of FIG. 2 can be used to calculate a “strain quotient.” The strain quotient can be used to determine the exact location in the downhole stroke where the transfer of the fluid load occurs (i.e. the “transfer point”). As mentioned above, the “transfer point” for the downhole stroke is the displacement in the downstroke where load is transferred from the traveling valve to the standing valve. During the period of time when load transfers from the traveling valve to the standing valve, the pump plunger is not moving. However, the sucker-rod is compressing to relieve the stretch in the rod. Therefore, the change in displacement versus change in time (i.e. rod velocity) is zero or essentially zero, but the change in displacement versus change in depth is not zero. In mathematical terms, this can be represented by the following equations (5) and (6):
∂u/∂t→0 (5); and
∂ u/∂x not= 0 (6).
The (∂u/∂x) term describes the change in the length of the finite element section of the rod string just above the pump. This term is used to represent or otherwise describe the stretch or compression on the rod finite element. The (∂u/∂t) term describes the motion of the bottom edge of the finite element section of the rod string just above the pump. This term is used to represent or otherwise describe the “net” motion of the rod finite element.
The strain quotient is the ratio of the change in displacement versus change in depth (∂u/∂x) to the change in displacement versus change in time (au/at). The strain quotient can be represented by Equation (7) as follows:
(∂ u/∂x )/(∂ u/∂t ) (7).
As seen in Equation (7), the strain quotient approaches infinity at the bottom of the stroke and at the top of the stroke because (∂u/∂t) approaches zero or becomes zero. In other words, the bottom end of the rod stops moving at or near those positions, which can indicate a transfer point. Mathematically, this condition (i.e. division by zero) rarely occurs at the discrete points represented by the finite element calculations because zero is not obtained although the rod has stopped moving. Instead, the strain quotient experiences a sign reversal (i.e. goes from positive to negative or negative to positive) between consecutive finite element time steps. The sign reversal indicates that the strain quotient has effectively passed through infinity, which indicates that a transfer point lies between the adjacent steps in time where the sign reversal occurs, and indicates that the rod stopped moving somewhere between those two times.
The displacement in the downhole stroke where the strain quotient experiences a “sign reversal” indicates a transfer point (“TP”). The downhole stroke is the displacement of the stroke where the general trend of displacement versus time data near the pump is decreasing. As discussed above, the downhole stroke is the maximum displacement minus the minimum displacement derived at the location near the pump. The strain quotient also experiences a sign reversal at these maximum and minimum displacements.
In one or more embodiments above or elsewhere herein, the two-dimensional displacement matrix of FIG. 2 can serve as input to a finite-difference calculation to obtain the strain quotient at the pump ((∂u/∂x)/(∂u/∂t) pump,j ). Using a Taylor series expansion, the strain quotient can be approximated as:
(∂ u/∂x )/(∂ u/∂t ) pump,j ={( u pump,j −u pump−1,j )/Δ x }/{( u pumpj+1 −u pump,j−1 )/2Δ t} (8).
The consecutive points where a sign reversal occurs can be represented by:
{(∂ u/∂x )/(∂ u/∂t ) pump,j }*{(∂ u/∂x )/(∂ u/∂t ) pump,j+1 }<0 (9).
Using substitution and ignoring the Δx and 2Δt terms which are constant and positive, a direct calculation at any time j can be provided by:
{( u pump,j −u pump−1,j )/( u pump,j+1 −u pump,j−1 )}*
{( u pump,j+1 −u pump−1,j+1 )/( u pump,j+2 −u pump,j )}<0 (10).
Beginning at or near the index (j) in the matrix representing the maximum downhole stroke, the relationship in Equation (10) can be applied to a plurality of points representing all or part of the downhole stroke. The first index at which the relationship is satisfied will reveal the location of the transfer point. When Equation 10 is satisfied, the transfer point lies between u pump,j and u pump,j−1 .
The complete set of displacements at the pump is examined to determine a minimum value of displacement at the pump. That minimum value represents the minimum stroke (NS). Similarly, the complete set of displacements at the pump is examined to determine a maximum value of displacement at the pump. That maximum value represents the maximum stroke (XS).
In one or more embodiments above or elsewhere herein, the pump efficiency (P eff ) can be calculated from the minimum stroke (NS), maximum stroke (XS), and transfer point (TP). The pump efficiency can be represented according to Equation (11):
P eff =100%*( TP−NS )/( XS−NS ) (11).
In one or more embodiments above or elsewhere herein, a pump-off condition can be detected when the pump efficiency falls below a preset amount. For example, the RPC can be programmed to shut off when the pump efficiency falls below 95% of a selected amount. In one or more embodiments, the pump can be programmed to shut off when the pump efficiency falls below 50% or 60% or 70% or 80% or 90% of the selected amount.
In one or more embodiments above or elsewhere herein, the amount of produced volume (“PV”) for a stroke can be determined from the minimum stroke (NS) and transfer point (TP). The amount of produced volume (“PV”) in Barrels can be calculated according to Equation (12):
PV= 0.0009714( TP−NS )( D 2 ) (12).
TP is the transfer point in feet, NS is the minimum stroke in feet, and D is the pump diameter. Specifically, D is the inside diameter of the pump barrel in inches.
In one or more embodiments above or elsewhere herein, an average production rate can be calculated according to Equation (13):
APR= 24.0 APV /( T 2− T 1) (13).
APR is average production rate in Barrels per day. APV is accumulated volume in Barrels for strokes which the pump made between times T1 and T2 in hours.
In one or more embodiments above or elsewhere herein, a tubing leak or other malfunction can be detected when the average production rate exceeds the production volume known to be reaching the surface by a preset amount. For example, if a routine measurement of the well production via a production separation test determines the production to be 100 barrels per day, that value can be programmed into the RPC. For example, when the average production (calculated by the present method) exceeds that 100 barrel per day value by 20% or 30% or 40% or 50%, it can be inferred that the pump is pumping more fluid that is reaching the surface facilities. Therefore a tubing leak or other mechanical malfunction is indicated.
As discussed above, the transfer of load from the traveling valve to the standing valve (“transfer point”) does not occur at the extreme “top” end of the stroke when the pump is not full. Accordingly, the strain quotient provides a valuable tool for identifying the precise location in the downhole stroke where the transfer of fluid load occurs.
All numerical values are “about” or “approximately” the indicated value, and take into account experimental error and variations that would be expected by a person having ordinary skill in the art. All patents, test procedures, and other documents cited in this application are fully incorporated by reference to the extent such disclosure is not inconsistent with this application and for all jurisdictions in which such incorporation is permitted.
Furthermore, various terms have been defined above. To the extent a term used in a claim is not defined above, it should be given the broadest definition persons in the pertinent art have given that term as reflected in at least one printed publication or issued patent.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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The present invention provides highly accurate methods for directly calculating pump fillage which avoid the need and expense of a pump dynamometer card and subsequent calculations.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation Application of PCT International Application No. PCT/JP2014/081730 filed on Dec. 1, 2014, which designated the United States. This application claims priority to Japanese Patent Application No. 2013-254967 filed on Dec. 10, 2013, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a receiver, and more particularly to a receiver having a resistance to burst interference.
BACKGROUND OF THE INVENTION
[0003] A configuration of a conventional receiver will be described with reference to FIG. 6 .
[0004] An orthogonal frequency-division multiplexing (OFDM) modulation signal received by an antenna 601 is inputted to an automatic gain control (AGC) unit 602 and gain-adjusted based on a gain control signal from a loop filter 606 such that an output signal level becomes a predetermined value. The level-adjusted received signal which is an output of the AGC unit 602 is outputted to a frequency converter 603 and a detector 604 .
[0005] The detector 604 detects the level of the input signal and outputs the signal to a target comparator 605 . This signal is hereinafter referred to as a detection signal.
[0006] The target comparator 605 compares the input value with a preset target value, generates a gain control signal based on the comparison result to make the detection signal close to the target value, and outputs the gain control signal to the loop filter 606 . The loop filter 606 extracts a low frequency component of the input signal and outputs the low frequency component to the AGC unit 602 . The loop filter is used for the purpose of suppressing oscillation.
[0007] The frequency converter 603 converts the frequency of the input signal into an intermediate frequency (IF) band, performs channel selection filtering to pass the frequency band of one channel, and outputs the filtered signal to an analog-to-digital converter (ADC) unit 607 . The ADC unit 607 converts the signal inputted from the frequency converter 603 into a digital signal and outputs the digital signal to a fast Fourier transform (FFT) unit 608 . In this case, a sampling rate is determined by OFDM parameters (the number of FFT points and an effective symbol length).
[0008] The FFT unit 608 converts the input signal into a signal of a frequency domain and outputs the converted signal to an equalizer 609 . The equalizer 609 performs equalization processing for correcting the amplitude and phase of the input signal, and outputs the equalization result to a determination unit 610 . The determination unit 610 determines the input signal, associates the determination result with an error correction likelihood, and outputs the resultant signal to a forward error correction (FEC) unit 611 . The FEC unit 611 performs de-interleaving processing on the input signal, and performs error correction of the signal based on the error correction likelihood for the determination result.
[0009] As another related art, for example, in Patent Document 1, each system for received signal processing includes an amplifier, an AGC circuit for automatic gain control having a different response speed, and an ADC. A digital signal processor which receives the signals having passed through the systems selects digital data having the lowest error rate from among the systems. Thus, it is possible to obtain the received signal data having the lowest error rate. For example, it discloses a technique for selecting an output of the system having the AGC circuit with a fast response speed when the received signal undergoes interference of fast level variations such as fading, and selecting an output of the system having the AGC circuit with a slow response speed when the received signal uses a modulation scheme with an amplitude component.
Patent Document 1: Japanese Patent Application Publication No. 2004-201066 Patent Document 2: Japanese Patent Application Publication No. 2010-130630 Patent Document 3: Japanese Patent Application Publication No. 2010-45706 Patent Document 4: Japanese Patent Application Publication No. 2006-319608
[0014] The problems in the above-mentioned related art will be described with reference to FIGS. 7A to 7E . FIGS. 7A to 7E are diagrams for explaining the adverse effects of interferences in the receiver.
[0015] In FIG. 7A shows the power spectrum when large-level interference due to, e.g., a radar appears in the same band as the desired wave. Further, FIG. 7B represents the reception level when the interference is mixed repeatedly and intermittently. In the conventional receiver of FIG. 6 , it is difficult for the gain control signal to follow the level variation at a high speed.
[0016] In FIG. 7C shows a graph of an ideal gain control signal and a conventional gain control signal. The ideal gain control signal controls the gain so as not to cause intermodulation distortion of an analog element by lowering the gain control signal immediately even when interference is mixed, and returns the gain control signal to an original state immediately even when interference is no longer mixed to prevent desensitization in the analog element.
[0017] However in a feasible receiver, if a time constant of the loop filter is shortened by allowing the gain control signal to follow at a high speed, oscillation may occur. Accordingly, the time constant cannot be shortened. Thus, as shown by a dotted line in FIG. 7C , both when the interference is mixed and when the interference is no longer mixed, the gain control signal deviates from the ideal value. Thus, since the gain control cannot follow at a high speed, the level of the received signal when the interference is mixed reaches a nonlinear region of the analog element to cause intermodulation distortion in the frequency converter 603 , thereby resulting in deterioration of the transmission quality.
SUMMARY OF THE INVENTION
[0018] In view of the above, the present invention provides a receiver configured to perform error correction using a received signal which is adjusted to an optimum gain both when interference is mixed and when interference is not mixed.
[0019] In accordance with an aspect of the present invention, there is provided a receiver including: one or more antenna units configured to receive modulated signals; a first and a second amplification unit configured to respectively amplify a first and a second received signal, which are received by the one or more antenna units, with a variable gain; a level variation detection unit configured to perform gain control of the first amplification unit; a maximum received signal level extraction unit configured to perform gain control of the second amplification unit; a first and a second frequency conversion unit configured to frequency-convert the amplified first received signal and the amplified second received signal, respectively; an interference frequency detection unit configured to detect a frequency of interference included in the second received signal; an interference frequency cut-off unit configured to cut off the frequency of the interference from the second received signal; a first and a second demodulation unit configured to demodulate the first and the second received signal, respectively; a first and a second noise amplitude calculation unit configured to calculate noise amplitudes from the first and the second received signal, respectively; a first and a second equalizing unit configured to correct amplitudes and phases of the first and the second received signal, respectively, in a frequency domain; a combining unit configured to combine demodulation results of the first and the second received signal based on the noise amplitudes calculated by the first and the second noise amplitude calculation unit; an error correction likelihood modifying unit configured to reduce an error correction likelihood of a frequency signal into which the interference is mixed based on a frequency detection result of the interference, with regard to a combination result of the combining unit; and an error correction unit configured to perform error correction decoding using the likelihood modified by the error correction likelihood modifying unit.
[0020] Further, in the above-described receiver, the level variation detection unit includes a holding unit to hold levels of the first received signal, and detects a level variation of a received signal by comparing a level of a newly received signal with an average value of the levels of the first received signal held by the holding unit. The first amplification unit uses the level of the newly received signal for the gain control if the level variation detected by the level variation detection unit is equal to or less than a predetermined value, and uses a level of a received signal immediately before the level variation exceeds the predetermined value for the gain control if there is a sudden level variation exceeding the predetermined value.
[0021] Further, in the above-described receiver, the maximum received signal level extraction unit may include a holding unit to hold levels of the second received signal, and extracts a maximum level of a received signal from levels of a previously received signal held by the holding unit and a level of a newly received signal. The second amplification unit may use a result of the maximum received signal level extraction unit for the gain control.
[0022] Further, the above-described receiver may further include a first and a second fast Fourier transform (FFT) unit, which are respectively provided before the first and the second equalizing unit, for respectively converting the first and the second received signal into frequency domain signals. The interference frequency cut-off unit may cut off the frequency of the interference at a stage prior to the second FFT unit.
[0023] According to the present invention, it is possible to perform error correction using a received signal which is adjusted to an optimum gain both when interference is mixed and when interference is not mixed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a block diagram of a receiver according to a first embodiment of the present invention.
[0025] FIG. 2 is a block diagram of a nonlinear filter A of the receiver of the first embodiment.
[0026] FIG. 3 is a block diagram of a nonlinear filter B of the receiver of the first embodiment.
[0027] FIG. 4 is a block diagram of a receiver according to a second embodiment.
[0028] FIG. 5 is a block diagram of a receiver according to a third embodiment.
[0029] FIG. 6 is a block diagram of a receiver according to the related art.
[0030] FIGS. 7A to 7E are timing charts for explaining the gain control of the receiver of the present invention and the related art.
[0031] FIG. 8 is a block diagram of a nonlinear filter 550 of a receiver according to a fourth embodiment.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0032] Hereinafter, various embodiments of the present invention will be described in detail with reference to accompanying drawings.
First Embodiment
[0033] FIG. 1 is a block diagram for explaining a receiver according to a first embodiment of the present invention. The receiver includes a reception system A 11 , a reception system B 12 , analog-to-digital converters (ADCs) 111 and 116 , fast Fourier transform (FFT) units (demodulation units) 112 and 119 , equalizers 113 and 121 , noise calculating units 114 and 120 , a combining unit 115 , a band-stop filter (interference frequency cut-off unit) 117 , an interference frequency detector 118 , a determination unit 122 , a elimination unit 123 , and a forward error correction (FEC) unit 124 .
[0034] First, the reception system A 11 will be described in detail.
[0035] A signal received by a reception antenna 101 of the reception system A 11 is inputted to an automatic gain control (AGC) unit (amplification unit) 102 . The AGC unit 102 adjusts the gain of the input signal such that a level of the received signal becomes a predetermined level based on a gain control signal inputted from a nonlinear filter A 105 . Then, the gain-adjusted received signal is inputted to a frequency converter 103 and a detector 104 . The detector 104 detects the level of the input signal, and outputs the detection result to the nonlinear filter A 105 . The frequency converter 103 performs down-converting into an intermediate frequency (IF) band and channel selection filtering. Here, the detector 104 and the nonlinear filter A 105 constitute a level variation detection unit.
[0036] Next, the reception system B 12 will be described in detail.
[0037] Similarly to the reception antenna 101 of the reception system A 11 , a signal received by a reception antenna 106 of the reception system B 12 is inputted to an automatic gain control (AGC) unit (amplification unit) 107 . The AGC unit 107 adjusts the gain of the input signal such that a level of the received signal becomes a predetermined level based on a gain control signal inputted from a nonlinear filter B 110 , and outputs the gain-adjusted received signal to a frequency converter 108 and a detector 109 . The detector 109 detects the level of the input signal and outputs a signal to the nonlinear filter B 110 . Here, the detector 109 and the nonlinear filter B 110 constitute a maximum received signal level extraction unit.
[0038] In the reception system B 12 , the gain control is performed to allow the gain to follow only the level of the interference which is intermittently mixed. Thus, by using a detection signal when the interference is mixed, in the gain control signal outputted from the nonlinear filter B 110 , intermodulation distortion caused by an analog element does not occur even when the interference is mixed.
[0039] If the reception antenna 106 knows the direction of an interference source, a null point of sensitivity directivity may be directed toward the interference source. In this case, although the gain is not a maximum with respect to a signal source of a desired wave, a ratio of the level of the interference to the level of the desired wave is compressed, thereby improving a carrier-to-noise ratio (hereinafter, simply referred to as “C/N”).
[0040] The configurations of the frequency converters 103 and 108 are the same, and the same local signal may be applied in common to the frequency converters 103 and 108 . Each of the detector 104 and the detector 109 is a root mean square (RMS) or logarithmic power detector. The detector is configured to have a response time that is greater than the reciprocal of the bandwidth of the OFDM symbol, shorter than the interference mixing interval (or mixing period), and not too long compared to the length of the OFDM symbol. In other words, the detector is not sensitive to the peak of the OFDM signal itself, but can immediately detect the interference and can track a variation of the desired wave. For example, if the interference mixing interval is 5 ms and the desired wave fading period is 25 ms, the response time (and the sampling period of an ADC 301 which will be described later) is preferably about 0.5 ms.
[0041] Next, the processing after the frequency converter 103 ( 108 ) of each reception system will be described.
[0042] In the reception system A 11 , the frequency-converted signal is inputted to the ADC 111 and converted into a digital signal. The converted digital signal is outputted to the FFT unit 112 . The signal of each reception system needs to be a complex signal including in-phase and quadrature components when inputted to the FFT unit 119 , and analog or digital quadrature detection is performed before or after the ADC 111 .
[0043] The FFT unit 112 converts the input signal into a signal of a frequency domain, and outputs the converted signal to the equalizer 113 and the noise calculating unit 114 . The equalizer 113 corrects the amplitude and phase of the input signal and outputs the corrected signal to the combining unit 115 .
[0044] The noise calculating unit 114 calculates a noise amplitude included in the input signal and outputs the noise amplitude to the combining unit 115 . As a noise calculation method, there is, for example, a method of estimating the noise amplitude by using a pilot signal that is a known signal. That is, since the transmission path does not vary greatly temporally in several symbols, the noise amplitude included in the received signal is calculated by subtracting the pilot signal of two consecutive symbols. Besides, there is a method of using the average of the distance between the reception point and an ideal reception point. The noise amplitude is preferably calculated and outputted at the same frequency as the OFDM symbol.
[0045] In the reception system B 12 , the frequency-converted signal is inputted to the ADC 116 . The ADC 116 converts the input signal into a digital signal, and outputs the converted digital signal to the band-stop filter 117 and the interference frequency detector 118 . The band-stop filter 117 uses a filter configured to cut off the frequency of the interference with respect to the signal inputted from the ADC 116 based on a signal indicating the position of the interference frequency inputted from the interference frequency detector 118 which will be described later. By outputting the signal to the FFT unit 119 after removing the frequency at which excessive interference is mixed, it is possible to reduce the deterioration of the C/N due to FFT.
[0046] The interference frequency detector 118 performs frequency spectrum analysis on the input signal, and recognizes the frequency at which the signal level exceeds a threshold value set based on an average value of the signal level as the frequency at which the interference is mixed. Then, the interference frequency detector 118 outputs a signal indicating the interference frequency and the amplitude of the interference to the band-stop filter 117 and the elimination unit 123 . The frequency spectrum analysis differs from the processing of the FFT unit 112 and the like in that an appropriate window function is performed before the FFT processing or a larger number of points are used to expand the scanning range. That is, the output of the interference frequency detector 118 preferably has the same timing as the timing at which the determination result of the OFDM symbol temporally corresponding to the output of the interference frequency detector 118 is processed by the elimination unit 123 , and the operation and output period of the interference frequency detector 118 does not have to match the OFDM symbol period.
[0047] The FFT unit 119 converts the input signal into a signal of a frequency domain and outputs the converted signal to the noise calculating unit 120 and the equalizer 121 . The noise calculating unit 120 , similarly to the noise calculating unit 114 , calculates the noise amplitude from the input signal, and outputs the noise amplitude to the combining unit 115 .
[0048] The equalizer 121 , similarly to the equalizer 113 , corrects the amplitude and phase of the input signal and outputs the corrected signal to the combining unit 115 .
[0049] The combining unit 115 combines the signals of the two reception systems based on the noise amplitude calculated by the noise calculating unit 114 (noise calculating unit 120 ) of each reception system, and outputs the combined signal to the determination unit 122 .
[0050] As a combining method, there are a method of selecting a signal of the reception system with a small noise amplitude, and a method of applying a weight to the signal of each reception system such that it becomes greater as the noise amplitude is smaller and adding the weighted signals. The combining is basically carried out on an OFDM symbol basis.
[0051] The determination unit 122 determines the input signal, associates the determination result with an error correction likelihood, and outputs the resultant signal to the elimination unit 123 . The likelihood is calculated from a magnitude (error vector magnitude (EVM)) of a difference between the determination result and the input signal. Here, the determination unit 122 and the elimination unit 123 constitute an error correction likelihood modifying unit.
[0052] The elimination unit 123 changes the error correction likelihood of the interference frequency according to the amplitude of the interference based on the signal inputted from the interference frequency detector 118 , and outputs the changed error correction likelihood to the FEC unit 124 . For example, if the amplitude of the interference is large, the error correction likelihood of the signal influenced by the interference is lowered by setting the error correction likelihood to have a small value or “0” (negative infinity if it is a log-likelihood).
[0053] The FEC unit 124 performs de-interleaving processing on the input signal to perform error correction based on the error correction likelihood for the determination result.
[0054] By using the circuit described above, it is possible to improve the transmission performance by performing error correction using the signal whose level is adjusted optimally both when the interference is mixed and when the interference is not mixed.
[0055] FIG. 2 is a block diagram of the nonlinear filter A 105 of the receiver of the first embodiment.
[0056] In the nonlinear filter A 105 , an ADC 201 converts the input signal into a digital signal, and outputs the converted digital signal to a multi-stage shift register (holding unit) 202 , a subtracter 203 , an average calculator 204 , and a selector 206 . In the shift register 202 , the input signal is sequentially moved to the next register at an interval of time T 1 , and the value of each register is outputted to the average calculator 204 .
[0057] The average calculator 204 calculates the average value and outputs the calculation result to the subtracter 203 . The subtracter 203 performs subtraction between the current detection signal inputted from the ADC 201 and the average value of the previous detection signals (held by the shift register 202 ) inputted from the average calculator 204 , and outputs the subtraction result to a threshold comparator 205 . The subtraction result represents how rapidly the current detection signal has changed compared to the previous signal.
[0058] The threshold comparator 205 compares the input subtraction result with a preset threshold value. If the subtraction result exceeds the preset threshold value, the threshold comparator 205 determines that the interference is mixed because a sudden level variation occurs, and sets a flag to be outputted to the selector 206 to “Hi.” If the subtraction result does not exceed the preset threshold value, the threshold comparator 205 determines that the interference is not mixed, and sets the flag to “Lo.” According to the flag inputted from the threshold comparator, the selector 206 selects and outputs one signal from among the current detection signal inputted from the ADC 201 and the previous detection signals inputted from the shift register 202 .
[0059] Next, the selection criteria of the selector 206 will be described with reference to FIG. 7E .
[0060] FIGS. 7A to 7E are timing charts for explaining the gain control of the receiver of the first embodiment and the related art.
[0061] When the flag is “Lo,” the selector 206 outputs the current detection signal. When the flag is “Hi,” the selector 206 selects the detection signal before the flag becomes “Hi” and outputs the selected detection signal to a target comparator 207 . Symbols A, B and C shown in FIG. 7E indicate the types of the input signal from the shift register 202 of the selector 206 of FIG. 2 .
[0062] Accordingly, it is possible to provide a protection function such that the gain does not follow the interference level when the detection signal varies greatly because the interference is mixed. Further, it is possible to vary the number of the previous detection signals that can be stored by the number of resisters included in the shift register 202 , and change a period of time that can be protected. The protection period determined by the number of resisters and the time T 1 (sampling rate of the ADC 201 ) is preferably set to be longer than the mixing period of the interference.
[0063] The target comparator 207 compares the input value with a preset target value, generates a gain control signal such that the detection signal becomes close to the target value based on the comparison result, and outputs the gain control signal to a loop filter 208 . The loop filter 208 extracts a low frequency component of the input signal and outputs the low frequency component to a digital-to-analog converter (DAC) 209 .
[0064] Since the loop filter 208 is provided for the purpose of suppressing oscillation, the loop filter 208 has a time constant similar to that of a loop filter 606 . The DAC 209 converts the input digital signal into an analog signal, and outputs the converted analog signal to the AGC unit 102 .
[0065] Thus, the nonlinear filter A 105 uses, as a feedback signal, the latest detection signal if there is no interference, or the detection signal immediately before interference occurs if there is interference.
[0066] FIG. 3 is a block diagram of the nonlinear filter B of the receiver of the first embodiment.
[0067] In the nonlinear filter B 110 , the input value is inputted to the ADC 301 . The ADC 301 converts the input signal into a digital signal, and outputs the converted digital signal to a shift register (holding unit) 302 and a maximum searching unit 303 . In the shift register 302 , the input signal is sequentially moved to the next register at an interval of time T 2 , and the value stored in each register is outputted to the maximum searching unit 303 .
[0068] The maximum searching unit 303 searches for the maximum value of the input value, and outputs the maximum value to a loop filter 304 . Thus, the nonlinear filter B can have a function of holding the maximum value of the input value as many as the number of registers provided in the shift register 302 .
[0069] As described above, the nonlinear filter B 110 always uses the detection signal when the interference is mixed. In other words, the detection signal when the interference is mixed needs to be present in the register of the shift register 302 , the time T 2 is required to be shorter than the interference mixing period, and the number of registers of the shift register 302 is required to set such that the holding period corresponding thereto becomes longer than the interference mixing interval. Further, in order to facilitate following the level variation of the interference, if possible, the holding period is preferably less than twice the interference mixing interval. Since a radar, which is a typical interference source, generally operates periodically and its period is well known, it is easy to set the number of registers as described above. For example, if the interference mixing period is 50 μs, the time T 2 (sampling rate of the ADC 301 ) may be set to be about 25 μs.
[0070] The AGC unit 107 of the reception system B can always control the gain to an optimum gain for the level of the interference so as not to cause nonlinear distortion of the analog element. The loop filter 304 extracts a low frequency component of the input signal and outputs the low frequency component to a DAC 305 . Since the loop filter 304 is also provided for the purpose of suppressing oscillation, the loop filter 304 has a time constant similar to those of the loop filters 208 and 606 . The DAC 305 converts the input digital signal into an analog signal, and outputs the converted analog signal to the AGC unit 107 .
Second Embodiment
[0071] FIG. 4 is a block diagram of a receiver according to a second embodiment of the present invention.
[0072] The signal received by an antenna 401 is inputted to the AGC unit 102 and the AGC unit 107 . Since the subsequent processing is the same as in the first embodiment, a description thereof will be omitted.
[0073] The signal received by one antenna is inputted to two independent gain control units. Similarly to the first embodiment, error correction is carried out by using the gain-adjusted signal different for each system. Thus, it is possible to obtain the same effect as the first embodiment and also reduce the number of antennas.
Third Embodiment
[0074] FIG. 5 is a block diagram for explaining a configuration of a receiver according to a third embodiment of the present invention.
[0075] The signal received by the antenna 101 is inputted to the AGC unit 102 . Since the configurations and operations of the AGC unit 102 to the FFC unit 124 are substantially the same as in the first embodiment except for the following points, a description thereof will be omitted.
[0076] The receiver of the present embodiment includes an interference frequency detector 518 instead of the interference frequency detector 118 . The interference frequency detector 518 detects the presence or absence of a subcarrier subjected to interference and the frequency of the subcarrier at an interval of an OFDM symbol period from the signal converted into a signal of a frequency domain by the FFT unit 112 and outputs the detection result to the elimination unit 123 . The interference frequency detector 518 checks whether, for each subcarrier, the power of the subcarrier exceeds a threshold value set based on the average power of all subcarriers in the OFDM symbol, or a ratio or difference between the power of the subcarrier and the power (average power) of the subcarrier(s) one or more past OFDM symbols exceeds a threshold value, and determines that the subcarrier is subjected to interference if one of the above-described values exceeds the threshold value. When subjected to interference of a strong radar, all subcarriers may disappear completely; however, even in the case that it is not possible to perform the above detection, the present embodiment is effective.
[0077] The elimination unit 123 sets the error correction likelihood of the signal of the frequency and time at which the interference is mixed based on the signal outputted from the interference frequency detector 118 to a fixed small value or “0” and outputs the signal to the FEC unit 124 .
[0078] The FEC unit 124 performs deinterleaving processing on the input signal to perform error correction based on the error correction likelihood for the determination result. The deinterleaving processing is a process performed over a plurality of OFDM symbols (i.e., an interleave length is greater than the number of demodulation bits of one OFDM symbol). The oscillation period of many radars is longer than the OFDM symbol, generally, over several symbols. By performing interleaving over a plurality of OFDM symbols longer than the interference mixing period, it is possible to recover errors.
[0079] By the above-described processing, even in the case of one reception system, even when the received signal level varies greatly because the interference is mixed, the gain of the AGC unit 102 does not follow the interference level. Accordingly, the gain control for a period during which the interference is not mixed can be maintained at an optimum value.
[0080] Also, for a period during which the interference is mixed, by reducing the error correction likelihood, it is possible to achieve efficient error correction processing by not using a signal deteriorated due to the influence of the interference, thereby reducing a code error rate.
Fourth Embodiment
[0081] FIG. 8 is a block diagram of a nonlinear filter 550 according to a fourth embodiment. The nonlinear filter 550 of the present embodiment is used in place of the nonlinear filter A 105 of the first to third embodiments. A description of the same configuration as the nonlinear filter A 105 will be omitted.
[0082] If it is determined that interference occurs in the threshold comparator 205 , a selector 501 selects an output of a first stage of the shift register 202 , i.e., the detection signal outputted from itself at the previous sampling timing, while outputting “Hi,” and selects and outputs the current detection signal from the ADC 201 while outputting “Lo.” Thus, with only the first stage of the shift register, it is possible to continuously hold the detection signal when the interference is not mixed.
[0083] A threshold comparator 502 determines whether the current detection signal from the ADC 201 exceeds a level that does not satisfy the required C/N by saturating the frequency converter 103 or the ADC 111 even though the gain of the AGC unit has been minimized, and outputs a logical value (“Hi” and “Lo”) corresponding thereto.
[0084] An AND device 503 receives the logical value from the threshold comparator 205 and a logical value indicating the presence or absence of noise, and outputs a logic product (AND) thereof. A noise presence/absence indicator may be obtained by the noise calculating unit 114 through threshold processing of the noise amplitude calculated at each OFDM symbol timing, or the C/N value derived therefrom. Since there is a delay of one or more OFDM symbols in the calculated noise amplitude, the threshold value is also preferably delayed and switched depending on a selection state of a selector which will be described later. As the noise presence/absence indicator, “Hi” (true) is preferably held when there is noise that exceeds a threshold value in the interference mixing period.
[0085] A coefficient multiplier 504 multiplies the output of the loop filter 208 by a predetermined coefficient α, and outputs the multiplication result to a selector 505 . The coefficient is to be applied when the threshold comparator 205 determines that there is interference and a logical value indicating the presence of noise is inputted. The coefficient is generally a positive number less than 1.
[0086] The selector 505 selects an input from the coefficient multiplier 504 if the output of the AND device 503 is “Hi” or an input from the loop filter 208 if the output of the AND device 503 is “Lo,” and outputs the input to a selector 508 .
[0087] A D-FF (Flip Flop) 506 , whenever the OFDM symbol timing signal is inputted as a clock, holds the signal from the threshold comparator 502 and outputs the signal to an AND device 507 .
[0088] The AND device 507 receives a signal from the threshold comparator 502 and a signal delayed by the D-FF 506 , and outputs a logic product thereof to the selector 508 .
[0089] The selector 508 selects 0 (or minimum value) if the signal from the AND device 507 is “Hi” or the signal from the selector 505 if the signal from the AND device 507 is “Lo,” and outputs it to the DAC 209 .
[0090] With this configuration, the gain of the AGC unit is switched to a minimum value when reaching the initial OFDM symbol boundary while the output of the threshold comparator 502 is “Hi,” and returns to the signal from the loop filter 208 immediately when the output of the threshold comparator 502 is changed to “Lo.”
[0091] According to the embodiments described above, the receiver of the present invention undergoes the level variation of the received signal as shown in FIG. 7B when the interference is mixed. The desired wave varies with a change in a propagation path, but the variation is a gradual variation compared to the interference mixing interval. Thus, by using a plurality of reception systems, each having an independent gain adjustment function, as shown in FIG. 7D , the gain of the reception system A is allowed to follow only the variation of the desired wave, and the gain of the reception system B is allowed to follow only the level of the interference. In other words, the reception system A 11 maintains the optimum gain even when the interference is mixed by not allowing the gain to follow the level of the interference as well as when the interference is not mixed. On the other hand, the reception system B 12 performs control so as not to cause nonlinear distortion of the analog element even in a period during which the interference is mixed by performing control to follow the level of the interference. Then, by performing a demodulation process on the gain-adjusted signal of each reception system, the reception system is switched between a period during which the interference is mixed and a period during which the interference is not mixed. Further, by applying a weight to the signal of each system and combining the weighted signals, it is possible to perform error correction using the signal adjusted to the optimum gain instantaneously.
[0092] Further, according to the embodiments described above, the receiver of the present invention can perform error correction using the received signal adjusted to the optimum gain both when the interference is mixed and when the interference is not mixed.
INDUSTRIAL APPLICABILITY
[0093] The present invention can be widely applied to a radio receiver, and more particularly to a radio system using an OFDM scheme, a single-carrier modulation with frequency domain equalization (SC-FDE) scheme for performing frequency domain equalization with respect to a desired wave, or a DFT-Spread OFDM scheme, or a radio system using white space frequencies.
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A receiver includes a first and a second amplification unit for amplifying a first and second received signals received by antenna units; a level variation detection unit for performing gain control of the first amplification unit; a maximum received signal level extraction unit for performing gain control of the second amplification unit; and a first and a second frequency conversion unit. The receiver further includes an interference frequency detection unit for detecting a frequency of interference in the second received signal; an interference frequency cut-off unit for cutting off the frequency of the interference; demodulation units for demodulating the respective received signals; noise amplitude calculation unit for calculating noise amplitudes from the respective received signals; equalizing units for correcting amplitudes and phases of the respective received signals; and a combining unit for combining demodulation results from the respective received signals on the basis of noise amplitude detection results.
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DISCUSSION OF PRIOR ART AND BACKGROUND OF THE INVENTION
[0001] The subject invention is a control mechanism for regulating the input flow of gases used in welding processes in a welding machine. In this respect, this intake volume and ultimate burning of such gases causes the burning temperature at the welding torch to increase or decrease as needed in the welding process. In electric arc welding, gases may be used solely for shielding or other supplementary purposes. Irrespective of the role of the gases used in the welding process, the subject invention is conceived as a control mechanism that ultimately makes the welding process more efficient for the operator.
[0002] Such gas flow control devices are known in the art, however, the known devices, as presently used in the art, generally require manual manipulation of control devices that make it difficult and inefficient for use by the welder under such circumstances. More specifically, in welding operations, the welder requires relative freedom of the use of his hands for numerous tasks in the welding process, including handling the welding torch, and elimination of one of those manual tasks will improve efficiency of the process.
[0003] Thus, while there are devices known in the art that are used to help efficiently control the output of welding machines, these devices are not practical in view of the fact that use of hand controls to regulate the gaseous input are cumbersome and interfere with the necessary careful manual handling of the welding torch. If the welder is better able to handle the welding torch without the necessity of additional manipulations for the process of regulating gas flow, with greater efficiency as a result.
[0004] It is also to be noted that the subject invention may be used to regulate amperage and current flow in welding operations.
[0005] In this respect, there are no known devices in the existing art that are structured as an efficient and effective alternative means to control the current output and gas output necessary or otherwise used in welding operations. The few such devices that exist in the art are cumbersome in structural application and use, and thus not effective for the purposes intended. As a result, the subject invention is conceived as a structural means using electronic and wireless transmission means to improve on such art based upon the following objectives.
OBJECTS
[0006] It is an object of the subject invention to provide an improved control mechanism for a welding machine;
[0007] Another object of the subject invention is to provide an improved device for regulating the amperage and current flow used in welding operations;
[0008] Yet another object of the subject invention is to provide an improved welding apparatus;
[0009] Still another object of the subject invention is to provide an improved device for rendering welding operations more-efficient;
[0010] An additional object of the subject invention is to provide an apparatus to help free the hands or feet of a welder to concentrate on his or her manual efforts in the handling of the welding torch;
[0011] A further object of the subject invention is to improve the efficiency of operating a welding machine;
[0012] Another object of the subject invention is to provide an improved device to control the output flow of gases or the current flow in the welding process;
[0013] An additional object of the subject invention is to provide an improved method of regulating the output of any type of gas used in a welding process;
[0014] Other and further objects of the subject invention will become apparent from a reading of the following description in conjunction with the claims and drawings.
IN THE DRAWINGS
[0015] [0015]FIG. 1 is a perspective expanded view of the apparatus embodying the subject invention;
[0016] [0016]FIG. 2 is a perspective view of an alternate embodiment of the subject invention;
[0017] [0017]FIG. 3 is a schematic view of components of the subject invention illustrating their operational relationship;
DESCRIPTION OF GENERAL EMBODIMENT AND SUMMARY OF INVENTION
[0018] The mechanism which is the subject of this invention is centered on a control device adapted to facilitate the control and regulation of the electrical current or the gaseous intake and mixture for a welding machine, thereby regulating the output of the welding machine, such mechanism including a foot-operated pedal member, which, in turn, is mechanically linked to electromechanical means activated by radio transmission means to regulate such electrical current input or the gaseous output.
[0019] In summary, the subject invention is a control mechanism for regulating the intake and flow of gases used in the operation of a welding machine irrespective of the type of gases used in the process and irrespective of what function the gases are used for in the welding process. Such mechanism is focused on a foot-controlled pedal-like member that upon activation by foot pressure, controls the actions of an electromechanical apparatus that, in turn, controls the amperage and current flow in the welding process, or alternately, controls gaseous output of gases used in the welding process.
[0020] The electrical mechanical mechanism is controlled by electric or electronic means through a radio transmitting device or other means to manipulate the gas valve mechanism of a gas container, thereby regulating the gaseous output for the welding machine for welding operations, or alternately, regulateing electric current flow.
[0021] In further summary, the invention centers on a control mechanism for regulating the intake and flow of gases used for any purpose for the operation of a welding machine, such mechanism being focused on a foot-controlled pedal-like member that upon activation by foot pressure controls the actions of an electromechanical apparatus that in turn controls the current used or gaseous flow input to the welding torch in the welding process. The electrical or electronic means operate through a radio transmitting device or other electrical means to impart signals to an electromechanical control mechanism adopted to regulate the volume flow of individual gases used in the welding processs to the welding torch. The amount of current or gaseous flow of the individual gases to the welding gases controls the temperature and other welding aspects at the welding torch.
DESCRIPTION OF PREFERRED EMBODIMENT
[0022] In describing the subject invention, description is provided as to one preferred embodiment. Such a description as limited to one embodiment shall not be considered as limiting the scope of the subject invention as set forth in the claims appended hereto. Additionally, it is to be noted that the invention concepts herein can apply equally to the control of current flow used in the welding process as well as to the control of gases used in the welding process.
[0023] As a background to describing the preferred embodiment of the subject invention, it is to be noted that welding is a process whereby two or more pieces of metal are merged or joined together into one piece. In this welding process the metallic surfaces of pieces to be joined are required to be placed in close contact with each other in order for the atoms of one metal surface to intermingle with the atoms of the other metallic surface. Moreover, during the welding process, a compound referred to as flux is used to dissolve any scale or oxides that have collected on the metal surface during the welding process.
[0024] Most welding processes used today are fusion welding processes. as opposed to pressure welding. Fusion welding includes an electric arc welding, oxyacetylene welding and thermite welding. Electric arc welding is a high temperature welding process at temperatures in the order of 7500 degrees Fahrenheit or above. This process uses an electric current in the process. Another fusion welding process is the termite welding process which involves reaction between aluminum and iron. Oxyacetylene welding is another form of fusion welding primarily using oxygen gas and acetyle gas, each gas emanating from separate containers to be intermixed at the welding torch to provide a relatively high temperature. Another form of fusion, welding is the oxy-hydrogen welding process which uses proportional amounts of oxygen and hydrogen gases drawn from separate containers which use atomic oxygen in conjunction with atomic hydrogen for welding and oxygen separately for cutting. This process is capable of yielding very high welding temperatures. In the latter process, it is important that the proportions of oxygen and hydrogen be closely regulated because excesses of each gas can disrupt the welding process.
[0025] It is again stressed that while the subject invention is generally applicable to electric arc welding processes, as set forth herein, it is also applicable to the other variant welding processes described above.
[0026] Referring now to the drawings in which a preferred embodiment of the subject invention is shown, and specifically referring to FIG. 1 of the drawings, FIG. 1 shows a control unit 10 which incorporates features of the subject invention. This control unit 10 is preferably structured as a self-contained assembly functioning solely as an integrated unit to provide control means to regulate the flow of gases in the particular welding processes used. As seen, the self-contained unit 10 is shown basically having a box-like housing with rectangularly configured externally disposed side walls 20 A, 20 B; 20 C and 20 D and a rectangularly shaped upper surface 30 and lower surface 40 . It is to be noted in this regard that the external housing may have any number of configurations other than the described box-like shape just described.
[0027] As can be seen from the drawings, the housing member 10 is adapted to be rested with its bottom surface on the floor near the welding apparatus to be used as described below. The control box is comprised generally of a foot-activated pedal member 60 which is disposed on the upper, outer portion of the control unit 10 , a potentiometer 100 , which is lever actuated by movement of the foot pedal, a transmitter 200 board controlled by the foot pedal, and a power source in the form of a battery 300 or other appropriate power source. Each of these elements are discussed hereafter.
[0028] Attention is again addressed to FIGS. 1 and 2 of the drawings. As seen in FIG. 1, the foot pedal member is positioned on the upper surface of the housing member. More particularly, foot pedal 60 has a first end 65 and a second end 70 . The first end 65 of the foot pedal is pivotably mounted to a portion of the upper surface 30 of the housing member, as seen. The second end 70 of the foot pedal is raised upwardly above the upper surface 30 of the housing member to be depressed by a downward movement of the operator's foot. Integrally disposed on the undersurface of the foot pedal 60 is a downwardly depending pedal rod member 80 .
[0029] As can be observed in FIG. 1, the upper surface 30 of the housing member has an opening 85 extending from the upper surface to the lower surface thereof. The downwardly depending pedal rod member 80 extends downwardly through such opening 85 . Rod member 80 is interconnected on its lower end to the first end 90 of lever member 92 . The second end 94 of lever member 92 is integrally attached to a perpendicularly extending potentiometer control bar 96 , as shown. As seen in FIG. 1, the potentiometer control bar 96 is interconnected to the potentionmeter 100 to control the output of the potentiometer.
[0030] More specifically, the movable control element 105 on the potentiometer 100 , sometimes referred to as a slider, is structured to rotate back and forth on a guide mechanism 110 and makes electrical contact on a portion thereof with a resistor 115 and the point of contact will vary along the length of the resistor as the control element 105 rotates back and forth along the resistor 115 . As the control element 105 moves along the resistor 115 , the voltage output from such potentiometer will be varied between zero and the desired amount of the voltage input, such output thus being an inverse function of the amount of resistance in this positioning of the control bar 96 for the potentiometer 100 as determined by the exact point of positioning on the control element along the resistor, thereby governing the voltage output of the potentiometer.
[0031] The voltage output generated through the potentiometer circuit is the determining factor of the amount of welding gases to be drawn from individual gas containers, controlled by a gas valve, such as gas valve 400 shown schematically in FIG. 3. This voltage output is to be transmitted through electronic radio means or by direct electric lead lines to a radio receiver 420 , as shown in FIG. 3 to control the electrical current output that controls the operation and output of the gas container valve 400 . This controls the amount of shielding gas or other gas to be transferred to the welding region of the welding torch. For this purpose, the following described method is preferred to minimize the inconvenience of electrical wires.
[0032] The voltage output at potentiometer circuit 260 is fed to transmitter 200 , as discussed above, and this transmitter, in turn, is adapted to receive the input of Vo from the potentiometer 100 and transmit electronic signals of variable strength through transmitter antenna 270 depending on the amount of the voltage output Vo. This signal is thus relayed to radio receiver 420 juxtaposed in the vicinity of gas valve 400 which, in turn, transmits radio signals so received to servo member 490 . The servo member 490 mechanically transfers signals, enhanced by electrical current through the servo circuit 500 to open and close gas valve 400 to the degree needed by the welder.
[0033] The servo electrical circuit comprises a battery or power supply connected in the circuit for each received along with the servo member 490 that is controlled by the electrical current flowing through the circuit, which current flow will be activated by the receiver signal. The servo output action will be proportional to the radio signal received, as stated, and it will cause the gas valve 400 interconnected to such servo 490 to close and open the valve member gradually as signalled.
[0034] Shown in FIG. 2 is an alternate embodiment of the concept herein for electric transmission of the signal to activate valve member on the gas tank. Specifically, the pedal member 60 in the embodiment shown in FIG. 2 is integrally connected to a downwardly extending ratchet arm 600 having gear teeth 670 on the distal end thereof away from the pedal pivot point, which ratchet arm member is adapted to engage the gear teeth 675 on gear 680 . Gear 680 directly turns the potentiometer arm 96 to activate the potentiometer 100 . Additionally, shown in FIG. 2 is a direct electrical lead 700 , which leads to electrical circuit plug 710 for an alternate electrically wired connector through female connector 720 to activate the electrical signal transmission process activation of the gas valve members. This alternate approach can serve as a standby or alternate means to transmit the signal for activation of the gas valves.
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The mechanism which is the subject of this patent application is centered on a control device adapted to facilitate the control and regulation of the electrical current or the gaseous intake and mixture for a welding machine, thereby regulating the output of the welding machine, such mechanism including a foot-operated pedal member, which, in turn, is mechanically linked to electromechanical means activated by radio transmission means to regulate such electrical current input or the gaseous output.
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The present invention relates to a device used to activate a conventional automobile horn.
BACKGROUND OF THE INVENTION
Most horns on automobiles and trucks employ pressure activated switches located either in the center of the steering column or at some other location within the interior region of a steering wheel. In order to activate conventional horn devices, an operator must remove his or her hand from the steering wheel in order to engage the pressure-activated switch. Some drivers are reluctant to remove their hands from the wheel, especially in a dangerous driving situation where it may be desirable to sound the horn. Removing a hand from the steering wheel may diminish the optimal control of the vehicle during a hazardous situation and could actually exacerbate an already dangerous driving condition. For example, in the event a car is drifting into a driver's lane on a high speed expressway, a driver may optimally want to simultaneously sound the horn to communicate the problem to the errant driver and undertake evasive steering maneuvers.
In view of this problem, some automobiles have located horn switches near the annular periphery of the wheel, such as on a rim located circumferentially inside the wheel. Other designs have provided a pressure-activated switch near the circumference of the wheel on the radial arms connecting the wheel to the steering column or central axis upon which the wheel is mounted. At these locations, the horn switch can be manipulated by the thumbs or fingers, depending on the location of the drivers hands on the wheel, without removing the hands from the steering wheel. Although these alternatives allow the simultaneous manipulation of both the wheel and the horn, full control over the wheel is compromised when the horn is activated. Any horn location which diminishes an operator's optimal control over the vehicle by reducing the control over the wheel, and particularly in situations where a severe or sudden turn of the wheel is required, is undesirable. Moving the horn from a central location of the steering wheel has other disadvantages because in the event of an emergency, many drivers impulsively or instinctively hit the center of the wheel to activate the horn. Moving the horn from the center of the steering column may result in the driver experiencing some difficulty in locating the horn, particularly when the driver is unfamiliar with the vehicle. Although many auto manufactures locate the horn activation switch on the steering wheel, the exact location differs depending on the particular model or make of the automobile. The incorporation of air bags has further influenced and limited the location of the horn on an automobile, requiring the horn to be moved from the center position.
SUMMARY OF THE INVENTION
The present invention provides a supplemental controller for a horn which can be activated by movement of the head of a driver into a predetermined area thereby allowing a driver to sound the horn while maintaining his or her hands on the steering wheel. In addition to instinctively reaching for the center of a steering wheel, in the event a driver encounters a dangerous condition, they will also frequently move their head forward in order to improve the visibility of the immediate road conditions and focus on the events unfolding on the roadway. The present invention takes advantage of this instinctive reflex exhibited by many drivers by providing a device to sense this forward movement of the head and body. In this regard, in hazardous driving conditions, drivers will frequently increase the pressure of their grip on the steering wheel and lean forward in order to increase their peripherial vision of the road. Obviously, the horn switch may also be activated by the deliberate forward movement of the head into a predetermined region. In the event the driver's head move forward past a predetermined point, a switch is activated to sound the horn. In an alternative embodiment of the invention, the horn is activated by the forward motion of the head. The present invention is designed to work as an adjunct to conventional horn switches so that the horn can also be activated by the driver in the conventional manner.
One feature of the invention is that it provides an alternative location to activate the horn which can be incorporated in different makes and models of cars. Providing an adjunct location further assists a driver to quickly and effortlessly locate the horn during a time of an emergency. A further feature of the present invention takes advantage of the instinctive or reflexive motion of a driver which occurs when a driver encounters a potential emergency situation or dangerous road condition. The present invention further provides a manner in which to activate a horn which does not require the removal of the hands from the steering wheel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a rear view of a sensor device according to the invention installed in the driver's side of a vehicle.
FIG. 2 is a side view of the device depicted in FIG. 1 showing the relationship between the device and a driver's head within a vehicle.
FIG. 3 is a bottom view of a sensor device shown mounted on a roof of a vehicle.
FIG. 4 sectional view of the light source and light sensor assembly.
FIG. 5 is a schematic representation of the circuit of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Now referring to FIG. 1, the present invention involves providing an electric eye such as an array 10 of light sources 17 and a series of opposite photo detectors 12, which are positioned on opposite sides of a driver's head 13 within the passenger compartment of a vehicle 14. Between the array of light sources 10 and photo detectors 12, a light curtain is created where light is generated by the light sources and is detected by the opposite detectors when the device has been activated. Now referring to FIG. 2, activation of the device is affected by the movement of the driver's head 13 forward toward the windshield 30 and into or though one of the light beam created by the light emitters 17.
As best seen in FIG. 3, the light-emitting elements and light detection elements are connected to each other by stabilizer brackets 21 and 22 which maintain the spacial relationship between each emitter and detector element which make up the electric eye. The location of the emitters and detectors can also be adjusted to conform to the physical dimensions of the particular driver of the vehicle by sliding the assembly along rods 24 and 26 which are attached to the lower surface 28 of the vehicle's roof. The detector assembly can also be adjusted in a vertical direction by adjusting the distance rods 24 and 26 extend from the lower surface 28 of the vehicle's roof. Therefore, the location of the detector assembly can be adjusted to optimally conform to the physical dimensions of any driver. The position of the light curtain is adjusted so it may be interrupted by any driver's forward motion.
As seen in FIG. 4, the light sources 17 within the array 10 consist of a series of light-emitting diodes 17. Opposite each diode is a photo detector 32 which consists of a photo transistor that generates a voltage in response to light impinging on the detector. In a first embodiment, the device employs light-emitting diodes; however, the light sources may be selected from a wide variety of devices, including lasers or conventional light bulbs. Likewise, the wavelength of the light emitted by the light sources may be within the visible spectrum or be within the infra-red or ultraviolet regions. For example, in a further contemplated embodiment, the light source emits an infra red light and the detectors are selected to specifically detect radiation in this wavelength and generate a signal in response thereto. In other contemplated embodiments, light from the light source is focused in a beam by a lens or reflector system towards the opposite photo transistor. In yet a further embodiment, the light source is a low powered laser.
FIG. 5, a schematic drawing of the invention, shows the component of the system, which include the detector assembly 50, a control circuit or controller 52, a horn 54 and the ignition 56. The control circuit 52 or micro processor receives the signal from the photo detectors of the detector assembly 50 and provides an output to control the operation of the horn. Controller 52 can either be a part of a vehicle's existing microprocessor or be provided as an aftermarket device comprising an amplifier and relay. In operation, the controller 52 first receives an input from the ignition 52 to energize the array of lights on the light source. Next, the controller looks for an input signal from the detector assembly 50 and establishes the signal received as a baseline. In the event the path of light going to one of the photo detectors is interrupted, the nature of the signal from the light detectors will change and the controller 52 or microprocessor will detect the interruption and activate the horn. In the first embodiment, controller 52 activates the horn for a predetemined time period using a timer and then deactivates the horn. The controller will then continue to monitor the output from detector 50 and, in the event the signal is again detected, the controller enables the horn to be activated again by the interruption of the light beam. In an alternative embodiment of the invention, the activation of the horn will continue until the controller detects the presence of a signal from the detector reflecting that the beam is no longer interrupted. When the ignition is turned off, the controller no longer recognizes input from the detector. Although in the foregoing embodiment the controller is activated by the vehicle's ignition, in a further contemplated embodiment the activation of the controller and detector assembly may be affected by a separate switch that is provided.
Although in the first embodiment a light curtain is employed to detect the forward motion of the head by its interference with a light beam or a series of beams which form a curtain, it is further contemplated that a wide variety of detection methods would also be effective to detect the forward motion of the head and activate the horn. In this regard, as noted above, it is contemplated that other remote motion detector devices may also be employed to detect the position of the driver's head within a vehicle such as those that detect light in other manners or employ ultrasonic sound waves. Thus, commercially available motion detector technologies such as ultrasonic detectors, infra-red cameras or other optical detection methods can also be adapted for the application disclosed herein. In this regard, commercially available ultrasonic devices sense motion by comparing the doppler shifted wave reflected by a moving object with the original wave created by the device. Any frequency change is accompanied by a continuous phase change between the two waves, which is sensed and ultimately, by employing a relay to switch to higher voltage loads, the signal can be used to activate a horn. The placement of ultrasonic devices with respect to a driver's head may differ from the placement of optical detectors because objects moving toward or away from the device are detected. Moving an object across an ultrasonic detection device may not cause a doppler shift, and therefore may not set off the horn.
A further alternative motion detection device contemplated for use with the invention involves a simple optical method using a camera and dividing an image in the selected area into regions of fixed size and then compare corresponding regions in successive images for changes. Changes in luminance, grayscale or colors may be detected with varying accuracy depending on the processing capabilities of a microprocessor or the output of the camera used to acquire the image.
Although a number of specific embodiments have been described herein, those having skill in the art will appreciate that there are additional arrangements and applications employing the invention which may be substituted for the specific disclosure as described herein. In particular, other remote motion detection methods may be employed for the detection of the forward movement of the head. Having thus described the present invention and its preferred embodiment in detail, it will be readily apparent to those skilled in the art that further modifications to the invention may be made without departing from the spirit and scope of the invention as presently claimed.
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A vehicle horn activation system which is triggered by the forward movement of the vehicle operator's head. An array of light sources and photo detectors create a light curtain which is positioned in a location that allows the driver to move his head into the light curtain, thereby interrupting the emitted light. When the light curtain is broken a signal is generated which activates the horn.
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CROSS REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/316,176 filed on Aug. 30, 2001.
TECHNICAL FIELD
The present invention relates to methods for appliquéing designs and/or names onto fabric items, such as clothing and accessories, and more particularly relates to methods for producing raised appliqués on a substrate and articles therefrom.
BACKGROUND OF THE INVENTION
In the clothing and accessory industry, appliquéing sports team names, brand names, and personalization and the like has become popular. Hats, sweatshirts, jackets, and gym bags are just examples of the types of items that are embroidered with designs or names. Appliqués that are especially desirable are those that are aesthetic, high quality, durable, and unique.
Recently, the standards for desirable appliqué and embroidery on garments and other consumer goods have risen due to the advancement in the machine technology. As the embroidering machines have become more and more computer controlled, such that a consistent product is possible, the ornamental aspects of the embroidery have also advanced.
Sports promotions, corporate clothing, and other promotional goods are increasingly looking for more and more attractive decorations thereon. Even restaurants and theme parks are able to sell T-shirts, polo shirts, hats and the like, so long as their logos and brandings are prominently displayed on the clothing, etc. The current trend in the industry is that anything with a name or logo emblazoned on it will sell in great quantities. Entire stores have been set up just to sell licensed Disney goods, and sport-related paraphernalia, among others. The malls are replete with logo-based merchandise in the stores, and the logo-bearing articles are the big sellers.
Consequently, it has become more and more attractive for the adornment companies to have bigger and better means for decorating clothing and other articles. Embroidery is the method of choice, and is practiced more and more with the new machines. However, there is always room for improvement. As a matter of fact, there is a desire by consumers to have more complicated embroidery, with more colors and more artistic license.
Therefore, it would be an advantage to the industry to have an even more attractive means and method for embroidery even fancier logos and artistic designs onto a substrate, whether that substrate is a garment, a backpack, a hat, or any other desirable article.
SUMMARY OF THE INVENTION
In accordance with achieving the above-described advantage, the present invention includes a method for applying a fancy raised appliqué with a great deal of embroidery onto a substrate in a way that provides uniqueness, quality, aesthetics, and durability to the appliqué. The resulting appliqué is a three dimensional raised appliqué which is lifted up above the height of the fabric, yet has a smooth transition from the fabric to the appliqué. Satin stitching embroidery acts to hold down and secure the raised appliqué to the substrate, while it completely sculpts out the design and defines the perimeter of the design.
Generally, the desired artwork is made and the design is then digitized by any known means, such as computer scanning. Once the design is digitized, that information may be preferably transferred to a modern computer controlled stitching machine. Although, not absolutely necessary to practice the present invention, the present method preferably utilizes the digitized format and first outlines the placement of the appliqué on the desired substrate (such as a hat or jacket), preferably by stitching, but any other known means may be employed, such as printing on the substrate with a paint or other marking.
Then, the same digitized information may be used as a “cut file” on a computerized cutting machine to cut out the desired design. Then, a piece of polyfoam or other wadding material capable of raising the appliqué (hereinafter generically referred to as “polyfoam”), may either be first adhered to the substrate at the outlined location, or the polyfoam may be first adhered to a piece of the appliqué fabric in the approximate shape of the desired appliqué, and then both pieces put down together. It is best for the cutting procedure if the polyfoam is already adhered to the appliqué material prior to the cutting, so that steps are eliminated and they are both exactly the same shape.
Although the terms “appliqué fabric” or “appliqué material” may be used throughout this text, material other than fabric may be used, such as suede, leather, vinyl, and other heavy materials, even including plastic, so long as it can endure the appliqué method and final use of the item which has been appliquéd. After the appliqué fabric and polyfoam have been attached to the substrate, the appliqué fabric and polyfoam are preferably tacked down with stitches to facilitate the embroidery stitching thereafter. Then, the appliqué fabric piece is embroidered around the edges, overlapping the edge of the appliqué fabric piece. Additional embroidery may be added to either the appliqué or in the vicinity of the appliqué to produce the desired end result. The polyfoam raises up the appliqué, and the surrounding embroidery acts to sculpt the design, resulting in a very attractive decoration on the substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the step of sewing an outline stitch on the desired location on the substrate;
FIG. 2 illustrates the step of locating a cut piece of polyfoam over the outline stitch;
FIG. 3 illustrates the step of locating a cut piece of appliqué material over the cut polyfoam;
FIG. 4 illustrates the step of sewing a tack down stitching to hold the polyfoam and the appliqué for later procedures;
FIG. 5 illustrates the step of embroidering around the design, allowing for the appliqué to be raised up and sculpted out; and
FIG. 6 illustrates the final embroidery to finalize the design.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the method and resultant article of the present invention, one of the preferred methods of appliquéing a raised design onto a fabric item is generally illustrated in FIGS. 1-6. The first step of the preferred method is to somehow delineate and outline the desired location for the desired design on the substrate, such as a garment, hat, backpack or other fabric item. One way of outlining the location and shape of the appliqué can be to sew an outline stitch in the likeness of the desired design with the use of a computer-aided sewing machine using CAD (computer aided design) or other computer equipment. Other methods may include stamping a paint thereon, or any other method known.
Preferably, however, a computer attached to an embroidery machine will utilize the digitized format of the desired design to direct the embroidery machine to make an outline stitch in the desired pattern and location. To achieve this outline stitch, the desired design is preferably first digitized in a computer file that can follow the outer perimeter of the design. The computerized sewing machine preferably contains several unique stitches and paths which may be used in the method. Then, from the digitized file, the outline stitch may be generated and sewed onto the substrate or fabric item to designate the location and general shape of the design on the fabric item. To illustrate the step of outlining, FIG. 1 shows a substrate 20 with an outline stitch 22 , representing the outer perimeter of the desired design.
For the next step, there are two possible methods for placing a piece of wadding or other means for raising the appliqué, such as polyfoam, under the appliqué material itself. First, the polyfoam may be in a small sheet the approximate shape of the desired design appliqué, and may be adhered to a similarly sized sheet of the appliqué material prior to cutting. Or, in the alternative, the other method may include individually cutting the polyfoam and the appliqué material to the desired shapes prior to adhering to the desired location on the substrate. In the first method, an approximately sized piece of appliqué fabric is adhered to a similarly sized sheet or piece of the wadding or polyfoam piece. Sheets of polyfoam are most preferred. The most preferred appliqué-raising foam is preferably made of a material composed of about 80% by weight of ethylene, vinyl, acetate and resin, about 3% by weight of blowing agent, about 0.5% to 1.0% by weight of crosslinking agent, about 1.5% by weight stearic acid, about 13% by weight calcium carbonate, and about 3% by weight pigment. The most preferred material is sold under the generic names of “3d Foam” or “Puff Foam”, available commonly in the industry from a number of sources. The preferred polyfoam material is typically from about 0.5 to about 5 mm thick, preferably about 2 mm thick. The appliqué fabric may be essentially any type of fabric but is preferably a dense non-woven material, e.g., suede, leather or other dense materials that can stand up to wear and tear.
This invention may be accomplished in several ways. One preferred way is to perform several substeps, that is, (1) apply an adhesive to a sheet of the appliqué fabric or, in the alternative, an appliqué fabric with adhesive already thereon may be purchased, (2) attach a sheet of polyfoam material to the adhesive-coated appliqué fabric, whether pre-coated from the manufacturer or individually adhesive-coated by spraying at the time, (3) cut both pieces simultaneously to form a puffed up appliqué piece, (4) apply adhesive to the backside (the backside of the polyfoam side) of the combination appliqué/polyfoam piece, and (5) adhere the puffed up appliqué piece to the substrate with the appliqué fabric facing outwardly.
Although any suitable adhesive may be used for any of these steps, the preferred adhesive is sold under the trade name “MSA-1000”, a spray adhesive available from the Madiera Company of the United Kingdom. It is preferred because it can be easily sprayed on, and it will not foul the sewing machine needles during the embroidery operation. The cutting of the polyfoam and appliqué fabric may be accomplished using a computer-aided cutting machine which is controlled by the digitized format which was generated for the outline. The preferred machine is one which can be computer controlled, such as an Ioline 300 blade cutting machine, available from Ioline Corp. of the United States. This machine is capable of cutting multiple pairs of the combined polyfoam/appliqué layers into a desired shape.
Other ways of performing this step may include altering the order of these substeps. Although FIGS. 2 and 3 represent one of the preferred methods, where FIG. 2 shows cut polyfoam piece 24 adhered to fabric item 20 , and FIG. 3 shows cut appliqué piece 26 adhered to the top of polyfoam piece 24 , the present invention contemplates any method of digitizing the cutting and sewing of a puffed up appliqué on a substrate. The most preferred method adheres an approximately shaped small sheet of the appliqué material onto a similarly sized sheet of the polyfoam, followed by cutting both together to the desired size and shape.
In the next general step, the adhered appliquéd piece is preferably stitched in place within the outline stitch via tack stitches, known as tack stitching, to hold it in place, although adhesives, hoops, clips or even gravity itself may also be used to hold the combination polyfoam/appliqué piece in place for later embroidery work. Preferably, the cut-out combined polyfoam/appliqué shape is slightly smaller than the outline stitch, and is somewhat held in place within the outline stitch by the raised threads. After the appliqué piece is in place, tack stitching may hold it in place. The computer controlled embroidery machine can be directed to stitch the tack stitching in a precise pattern within the boundaries of the appliqué piece, yet close enough to the edge to be covered by the satin stitch or embroidery sculpting out stitch, to follow.
As discussed above, this step of tack stitching may be performed by a computer-aided embroidery machine with the result being shown in FIG. 4 illustrating tack down stitching 28 around the perimeter of the appliqué piece 26 . The tack stitching is preferably from about 0.1 mm to about one (1) millimeter within the perimeter, so that the satin stitching procedure described hereinbelow will cover the tack stitching when completed.
Next, the stitched-in-place appliqué is embroidered around the entire design with a wide, closely packed zig-zag stitch, preferably a satin stitch. The satin stitch may be of any width from about 1.0 to about 20 millimeters, but is preferably from about 2 to 5 millimeters wide. The actual thickness of the stitch depends on the choice of the thread itself. If the thread is a light polyester, then the thickness will be slight, while the thickness will be on the order of from about 1 to about 10 millimeters thick if a thick, shiny thread is utilized. FIG. 5 shows embroidery satin stitch 30 which covers the edge of the appliqué item, and extends inwardly into the interior of the raised appliqué design far enough to cover the tack stitching, thereby covering it up. Typically, the embroidery is from 1 to 20 mm wide, but preferably is about 4-5 mm wide. It is also preferred to embroider to the extent that none of the appliqué edge can be seen. The embroidering may be done with any type of thread but 30 weight thread is preferred, which is thicker and more denser than standard 40 weight embroidery thread. Rayon or polyester threads are the preferred types of thread, as they are strong and highlight the embroidery from the remainder of the appliqué. The overall result of the appliqué is a raised appliqué (due to the polyfoam thereunder) which rises smoothly from the surface of the fabric item to the top of the appliqué. This produces an appliqué which is sculpted out.
Optionally, other embroidery may be added, to either another part of the appliqué or in the vicinity of the appliqué. This additional embroidery will act to sculpt out little “pockets” of the raised appliqué, so that various levels of heights may be achieved within the same design. FIG. 6 shows the finished appliqué with additional embroidery 32 . Other direct embroidery can then be done to complete the design. Thread colors and specific types of appliqué material will vary depending upon the design and availability.
Therefore, the present invention provides an attractive raised appliqué, and a method for making same, that can be consistently made with the aid of computer-directed sewing and/or embroidery machines. This process is especially useful in the application of logos and artwork to headwear, outerwear, shirts, luggage, backpacks, handbags, scarves and the like. Of course, this technology is applicable to any fabric or article of manufacture, and shall not be limited by the disclosure herein, but rather only by the limits set by the appended claims.
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A method for securing a raised appliqué to a substrate and the articles resulting therefrom. The preferred method includes various steps of digitizing an ornamental pattern into a computer format, then using that format to stitch, cut, and embroider an appliqué and wadding material onto a substrate, such that the appliqué is three dimensionally raised in portions by the wadding material, and the resulting combination of substrate, wadding material and appliqué material may then be sculpted out to form an attractive raised appliqué design suitable for use on any substrate, but especially garments, headwear and similar articles.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application is a continuation in part of, and seeks priority to, nonprovisional application Ser. No. 11/973,106, entitled “Method for Deriving a High Protein Powder/Omega 3 Oil and Double Distilled Water From Any Kind of Fish or Animal (Protein),” filed Oct. 5, 2007, now U.S. Pat. No. 8,663,725 which is hereby incorporated by reference herein.
COPYRIGHT NOTICE
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 document or patent disclosure as it appears in the Patent and Trademark Office, patent file or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
The present invention relates generally to the derivation of protein powder. More particularly, the invention relates to the derivation of protein powder from aquatic animals.
BACKGROUND OF THE INVENTION
Throughout the centuries, the development of human life has been based upon nutrients and proteins that originate from natural resources. The proteins generated by the food humans consume include animal proteins and vegetable proteins.
Humanity has developed primarily on portions of continents and, secondarily, at the periphery of the oceans. The most widely exploited natural resources are those of the continents. This is a cause of imbalance of the food chain, which, as a result, currently poses great problems and nutritional deficiencies among different populations.
In a 2002 report of the Food and Agriculture Organization of the United Nations (FAO) concerning the insecurity of the food supply throughout the world, the FAO maintained, “progress in the reduction of hunger has virtually stopped.” The FAO advised that “unless this tendency is radically reversed, the world will be very far from reaching the goal of the World Food Summit of 1996 to reduce by half the number of people suffering from hunger by the year 2015.” In order to reach this goal, the reduction in the number of people suffering from hunger would have to number 24 million each year.
Deriving, from a variety of different sources, protein that may be transported to different people in need may solve many problems associated with lack of nutrition. Humans have benefited from proteins in a medical and nutritional form. Markets have been developed that has given rise to industrialization and commercialization in accordance with the identification of a greater protein potential in some species of fish. Unfortunately, industrialization and commercialization has resulted in the specific exploitation of classified groups of fish, which has placed the biologic balance in danger.
There is a large variety of marine animals, continental and oceanic, which have formed part of the food chain. From the nutritional point of view, fish are classified according to oil content and are divided into lean, semi-oily, and oily fish. For example, in white fish or lean fish, the oil content does not typically pass 2.5%. Hake, monkfish, sole, and dory are some examples of whitefish. The lowest index is found in codfish, with an oil content of about 0.25%. Semi-oily fish have a concentration of oils greater than 2.5% without passing 6%. Sea bream, mullet, gold bream, and bass are some examples of semi-oily fish. Oily fish may have a concentration of oil as high as 10%. Fish that have a high concentration of oils are known popularly as blue fish. Examples of oily fish include sardines, boguerón, mackerel, palometa, blue jack mackerel (chicarro), tuna, northern bonita, salmon, eel and swordfish. The oil of blue fish is rich in polyunsaturated fatty acids and is comprised, among other things, of Omega 3 fatty acids. The concentration of lipids also varies greatly from one species to another. For example, some species of fish live in deep zones and, as they do not migrate, they do not have a need to accumulate oils.
The recommended total consumption of protein (meat, fish, or other) is 15% of daily caloric intake, or 0.8 gram per kilo of weight. As in the case of meat, eggs, and milk, fish contribute protein containing all the essential amino acids. It is estimated that 35 grams of consumption a day of pure protein would satisfy an organism's aminoacids requirements like a full meal.
Protein found in fish contains all of the amino acids essential to humans, and for this reason, fish protein is of very high nutritional value. Fish is easily digested and is relatively low in calories. The lipids found in blue fish have been associated with a series of beneficial effects related to the prevention of myocardial heart attacks and arteriosclerosis.
Fish also contain large quantities of vitamins A and D, as well as vitamin E, which afford the protecting effect of an antioxidant. Generally speaking, fish are also a source of vitamins of the B group, specifically B12. Fish are very rich in sodium and potassium, and somewhat less in calcium.
In view of the foregoing, there is a need for a nutritional supplement to fight malnutrition that is high in protein and may be obtained from a wide variety of species of aquatic animals so that certain species of fish are not over-exploited.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an exemplary system for processing of raw material in an embodiment.
FIG. 2 is a flowchart of an exemplary method for processing the raw material in an embodiment.
FIG. 3 is a block diagram of an exemplary system for the derivation of protein powder in an embodiment.
FIG. 4 is a flowchart of an exemplary method for the derivation of protein powder in an embodiment.
FIG. 5 if a block diagram of an exemplary system for the production of oil, production of water, and the recovery of an additive in an exemplary embodiment.
FIG. 6 is a flowchart of an exemplary method for the recovery of oil, water, and additive(s).
FIG. 7 is a flowchart of an exemplary method for processing of omega 3 oil in an embodiment.
SUMMARY OF THE INVENTION
Systems and methods for deriving protein powder are disclosed. In various embodiments, protein powder is prepared by a process comprising sanitizing raw material from aquatic animals mixture with ozone, combining the raw material with a solvent to create a mixture, baking the combined mixture for a first time period, separating, with a filter, liquid from the combined mixture that was baked for the first time period, baking the combined mixture without the separated liquid for a second time period, separating, with a filter, liquid from the combined mixture that was baked for the second time period, curing the combined mixture, and processing the cured mixture to produce protein powder.
In some embodiments, the process further comprises baking the combined mixture without the separated liquid for a third time period and separating liquid from the combined mixture that was baked for the third time period. The process may further comprise filtering amine from the liquid separated by the filter.
The process, in some embodiments, may comprise distilling the liquid and filtering at least a portion of the distilled liquid to produce fish oil. Further, the process may comprise separating the liquid by filtering. One portion of the liquid may be distilled. The other portion may be water which may be purified.
The process may comprise adding solvent to the combined mixture prior to baking for the first time period and adding solvent to the combined mixture prior to baking for the second time period. Further, the process may comprise grinding the raw material prior to combining the raw material and the solvent.
The solvent may comprise isopropyl alcohol. In some embodiments, the combined mixture may be baked for a first time period and the mixture rotated. The process may further comprise distilling the liquid to recover the solvent.
In various embodiments, an exemplary method comprises sanitizing raw material from aquatic animals mixture with ozone, combining the raw material with a solvent to create a mixture, baking the combined mixture for a first time period, separating, with a filter, liquid from the combined mixture that was baked for the first time period, baking the combined mixture without the separated liquid for a second time period, separating, with a filter, liquid from the combined mixture that was baked for the second time period, curing the combined mixture, and processing the cured mixture to produce protein powder.
An exemplary system comprises a preparation tank, a reactor, a filter, a mill, and an oven. The preparation tank may be configured to sanitize raw material from aquatic animals with ozone and to combine the raw material with a solvent to create a mixture. The reactor may be configured to bake the combined mixture for a first time period and bake the combined mixture of a second time period. The filter may be configured to separate solvent, oil, water, and amine from the combined mixture after baking in the reactor for the first time and configured to separate solvent, water, and amine from the combined mixture after baking in the reactor for the second time. The mill may be configured to grind the combined mixture. The oven may be configured to cure the ground combined mixture to produce protein powder.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A large number of different types of aquatic animals may be used to form the basis of raw material. Discussed herein are systems and methods for deriving protein powder from the raw material.
A solvent may be added to the raw material during processing. In some embodiments, the solvent may be extracted for later reuse. Further, fish oil, such as Omega 3 fish oil, may be extracted. Moreover, water may be extracted from the raw material as well. In some embodiments, exemplary systems and methods described herein derive protein powder, fish oil, and water from the raw material.
The protein powder may be a complete aminogram free of fish odor or smell (e.g., amine free). The protein powder may also be hydroscopic and sterile.
Further, the raw material may be derived from a variety of fish. By using a wide variety of different types of aquatic animals to meet current protein, oil, and water needs, overfishing of limited select resources (e.g., certain species of salmon) are avoided while the protein needs of many people may be met.
FIG. 1 is a block diagram of an exemplary system 100 for processing of raw material in an embodiment. In some embodiments, protein powder may comprise 85% or more of the protein that may be separated from the raw material.
Various embodiments discussed herein obtain protein, minerals, omega 3 oils, and/or distilled water from aquatic animals. By way of example, if a large tuna fish of 10 kilos is processed, 2 kilos of pure protein with complete amino gram may be obtained. If a skinny chip fish of 4 kilos is processed, 1 kilo of pure protein worth the complete amino gram may be obtained. The skinny chip fish, however, may produce less oil per volume of protein. The quality of the protein is generally not different between the two fish. Various embodiments may use any and all parts of even waste aquatic animals as long as the aquatic animals are fresh. For example, all part of a fish including the head, viscera, bones, cartilage, tissue etc, may be used. It should be noted that health benefits from the fish's other body parts may also be present in products of some embodiments.
In various embodiments, any kind of aquatic animal may be used as raw material. By using fewer over-exploited aquatic animals, systems and methods described herein may provide a means of avoiding the over exploitation of better-known species, including, for example, sardines, tuna, and salmon shark, robalo, shrimp, octopus, and squid.
A large percentage of the catch from fisherman is not commercial. Often the fisherman throws back fish because there is not a buyer for that kind of fish. Since a wide variety of different kinds of fish and aquatic animals may be used as the basis for the raw material from which the protein powder is obtained, endangered species of fish may be avoided.
An exemplary process uses the whole aquatic animal (e.g., whole fish), using solvents at different stages. The process may be on a closed circuit; for example, solvents may be recovered in order to use the recovered solvents again. The result of the process may be a high-quality protein with the complete amino gram and mineral concentration made at a low cost.
In various embodiments, the system depicted in FIG. 1 may be part of a larger system for producing protein powder, oil, and water, from raw material (e.g., fish and/or other animals). In an example, FIGS. 1 and 3 display an exemplary system for producing protein powder from the raw material. FIGS. 1 and 5 display an exemplary system for retrieving oil (e.g., Omega 3 fish oil) and water from the raw material.
The exemplary system 100 for processing of raw material comprises a warehouse production facility 102 , mills 104 a - b , preparation (e.g., prep.) tanks 106 a - b , an additive tank 108 , reactors 110 a - b , filters 112 a - b , a liquid capture tank 114 , and a mill 116 . Although FIG. 1 depicts two mills 104 a - b , preparation tanks 106 a - b , reactors 110 a - b , filters 112 a - b those skilled in the art will appreciate that there may be any number of mills 104 a - b , preparation tanks 106 a - b , reactors 110 a - b , and filters 112 a - b . Similarly, although only one warehouse production facility 102 , additive tank 108 , liquid capture tank 114 , and mill 116 is depicted, those skilled in the art will appreciate that there may be any number of warehouse production facilities 102 , additive tanks 108 , liquid capture tanks 114 , and mills 116 .
The raw material for the process is stored in a warehouse production facility 102 . In some embodiments, the warehouse production facility 102 includes a refrigeration system to prevent decomposition of the raw material. The warehouse production facility 102 may have any amount of capacity. In one example, the warehouse production facility 102 may store 3,000 tons of bulk fish (e.g., raw material). In some embodiments, the warehouse production facility 102 may include one or more disposal areas to dispose of bulk fish that are sufficiently fresh as well as one or more scales for weighing the raw material prior to processing.
Mills 104 a - b , may be any kind of mill configured to physically break down (e.g., grind or crush) the raw material from the warehouse production facility 102 . In some embodiments, the mills 104 a - b grind the raw material to approximately ¼ inch pieces. Those skilled in the art will appreciate that the raw material may be broken down to any size pieces using any type of device. In some embodiments, the raw material in the warehouse production facility 102 is evaluated for quality and weighed. Predetermined amounts of raw material may then be placed within each mill, respectively. The weighing of the raw material may happen before grinding, after grinding, or both before and after grinding.
Preparation tanks 106 a - b are any tanks that receive the milled raw material from the mills 104 a - b . The preparation tanks 106 a - b may comprise a blending system. In some embodiments, the preparation tanks 106 a - b may rotate in order to agitate raw material and/or be sealable so that air may not escape the tanks.
In various embodiments, if the characteristics of the raw material are different, milled raw material may be placed inside a preparation tank 106 a which may be subsequently sealed. Optionally, ozone may be pumped into the tank in order to sanitize the raw material. In one example, ozone is pumped into the preparation tank 106 a until the pressure within the preparation tank 106 a reaches approximately 20 psi. The preparation tank 106 a is mixed for a period of time (e.g., 40 minutes) to homogenize the raw material and/or increase exposure of the raw material to the ozone. In one example, the preparation tank 106 a is rotated at approximately 50 to 60 rotations per minute (rpm).
Additives may be added either before or after the ozone is pumped into the preparation tanks. Additives may include, but not limited to, a solvent. The additive may also include other materials and/or chemicals. In some embodiments, the preparation tanks have a minimum capacity of 30,000 liters each and are each capable of supporting at least 30 tons of weight.
The additive tank 108 is a tank that holds additives to be mixed with the milled raw material in the preparation tanks 106 a - b and/or the reactors 110 a - b . In one example, the additive tank 108 has a storage capacity of 120,000 liters. In some embodiments, one or more additives, such as a solvent is later recovered (further discussed herein) and added back to the additive tank 108 for later use. Those skilled in the art will appreciate that the additive tank 108 and/or one or more other tanks, may include any kind of additive to add to the raw material.
Reactors 110 a - b receive the prepared material from the preparation tanks 106 a - b . The reactors may be any kind of reaction tank. Each reactor 110 a - b may, in some embodiments, heat and rotate the raw material from the preparation tanks 106 a - b . In various embodiments, the reactor may heat the raw material and solvent to a predetermined temperature (e.g., 90° C.) for a predetermined period of time. In one example of a reactor, the reactor may be heated from 380° to 450° C. in order to quickly heat the raw material to 90° C. (e.g., via one or more boilers). In some embodiments, the raw material is kept at or below 90° C. to prevent the raw material (or components thereof) from burning. The reactors 110 a - b may also have one or more thermometers configured to read the temperature of the mixture. The reactor may rotate at speeds from 4,000 to 5,000 rpm. Those skilled in the art will appreciate that the reactor may rotate at any speed (e.g., 2000 rpm).
In some embodiments, each of these reactors 110 a - b has a capacity of at least 20,000 liters, and each is capable of supporting at least 20 tons. The material inside the reactor 110 a - b may further receive additional additives (e.g., additional solvent). In one example, solvent is added to the raw material in a ratio of 2 parts solvent to 1 part raw material. Once completed, the material in the reactor forms a reactivated mixture. In some embodiments, the heat of the reactors and/or the solvent may further sanitize the milled raw material.
In various embodiments, each of the reactors 110 a - b comprise a blending system to homogenize the mixture prepared with the additives coming from the additive tank 108 . Further, the reactors 110 a - b may comprise one or more pumps to pump the reactivate mixture from the reaction tanks 110 a - b to the filters 112 a - b . The reactor 110 a may comprise automatic valves and sensors to monitor the process.
In some embodiments, a magnetic field is applied to align molecules of the solvent and raw material mixture in the reactor. The alignment of the molecules may, in one example, improve the function of the solvent and/or the process of separating out liquids (e.g., amine, solvent, water, and oil) from the rest of the raw material. Electricity may also be applied to the solvent and raw material mixture for the same or similar purpose.
Once the solvent and milled raw material is placed in the reactor 110 a , the mixture may be heated and rotated for a predetermined period of time. In one example, heat and a magnetic field are applied to the solvent and milled raw material for five minutes at thirty minute intervals for two hours.
In various embodiments, the quality of the protein powder is not degraded as the process is low temperature thus not burning or degrading the protein and keeping the organoleptic structure intact. This may result in a relatively complete if not complete amino gram of high quality concentration of protein on the final product.
Filters 112 a - b filter the reactivated mixture to separate out solids from liquids. In some embodiments, filters 112 a - b are centrifuges. In one example, a centrifuge may rotate at 2,000-3,000 rpm. In other embodiments, the filters 112 a - b may be any kind of filter, strainer, or combination (e.g., combination of filters, strainers, and/or centrifuges). In one example, the filters 112 a - b separate out 70% of the liquids from the raw material. In one example, the filters 112 a - b are a fine mesh for separation of solid materials from solvent-soluble materials.
In some embodiments, the filters 112 a - b comprise centrifuges that operate in a vacuum. In one example, fumes from the solvent may be recovered during filtering. Solvent may be recovered from the fumes and stored for later use (e.g., the solvent may be recovered and stored in the additive tank 108 ).
After filtration, the reactors 110 a - b may receive the solid material from the filters 112 a - b , for further processing. Subsequently, the filters 112 a - b may re-filter the reactivated material and extract more liquid. The filters 112 a - b may, in some embodiments, have the ability to extract at least 21,000 liters of liquids per hour. In various embodiments, each time the reactors receive material (e.g., either from the preparation tanks 106 a - b or the filters 112 a - b ) additive(s) such as solvent(s) may be added to the material from the additive tank 108 .
In some embodiments, the material is reactivated in the reactors 110 a - b and filtered by the filters 112 a three times. In other embodiments, the material is reactivated in the reactors 110 a - b and filtered by the filters 112 a five times. Those skilled in the art will appreciate that the material may be reactivated in the reactors 110 a - b and filtered by the filters 112 a any number of times
The liquid capture tank 114 is any tank that receives liquids (e.g., heavy liquids) from the filters 112 a - b . The liquid in the tank may comprise additive(s) (e.g., solvent(s)), oil, water, and amine. The additives may be recovered from the liquid (as further described herein). Further, oil (e.g., Omega 3 oil) and purified water may be obtained from the liquid. In some embodiments, amines in the liquid are later removed or reduced in order to reduce or eliminate fishy smell or taste from the oil and water. Those skilled in the art will appreciate that the liquid removed from the raw material may comprise any components beyond solvent, oil, water, and amine. In one example, the liquid may comprise salt which may be later removed (e.g., via distillation).
The mill 116 is any mill that may break, grind, and/or crush material from the filter 112 a - b . In one example, the material passed between the reactors 110 a - b and the filters 112 a - b three times before the mill 116 receives the remaining solids from the filter 112 a - b . In one example, the mill 116 may further grind the material to ⅛ th inch pieces. Those skilled in the art will appreciate that the mill 116 may grind the material to any size.
It will be appreciated by those skilled in the art that the system 100 and system 300 depicted in FIGS. 1 and 3 , respectively, may include redundant systems to allow for one or more components to break or maintenance to be performed. For example, if mill 104 a requires maintenance, the raw material may be provided through mill 104 b . Similarly, if preparation tank 106 a is unavailable, mills 104 a - b may provide the milled materials to any number of other preparation tanks other than preparation tank 106 a.
FIG. 2 is a flowchart of an exemplary method 200 for processing the raw material in an embodiment. The discussion regarding FIGS. 2, 4, and 6 refer to single components even if two or more of the same component (e.g., mill 104 a - b in FIG. 1 ) are depicted in FIGS. 1, 3, and 5 . Those skilled in the art will appreciate that although only one component is discussed, any number of components may be used within exemplary systems and methods.
In various embodiments, systems depicted in FIGS. 1 and 3 may have capacity to produce 18 tons of protein powder (e.g., Advanced Protein Powder) and 5,000 liters of fish oil (e.g., omega 3) from 100 tons of fresh fish (e.g., raw material). In various embodiments, the process does not harm the environment with pollutants or toxic fumes.
In step 202 , raw material is verified and milled. In some embodiments, the raw material is sorted and raw material that is not sufficiently fresh is disposed. Those skilled in the art will appreciate that the raw material may be sanitized. Further, the raw material may be de-boned, or less desirable material of the raw material may be disposed. The raw material may also be weighed with a scale and apportioned by weight prior to transport to the preparation tank 106 a.
In various embodiments, the raw material will include any number of aquatic animals of many types. In one example, the raw material includes a limited number of different types of aquatic animals (e.g., salmon, tuna, and sardines only). In another example, the raw material may comprise any number of aquatic animals. Those skilled in the art will appreciate that poison fish may be used without dangerous residues in the finished powder, oil, and water.
In some embodiments, specific type and/or species of fish may be selected based on available protein and/or nutrition content. In other embodiments, the selection of fish is unrelated to protein quality.
In step 204 , the preparation tank 106 a receives solvent and milled raw material to be prepared for the reactor 110 a . In some embodiments, the milled raw material is combined with ozone to sanitize the milled raw material. In one example, raw material is placed within the preparation tank 106 a which is sealed. Ozone may be pumped into the preparation tank 106 a which may then rotate to agitate the milled raw material. After which, solvent may be added to the agitated milled raw material.
In various embodiments, the preparation tank 106 a receives a solvent such as isopropyl alcohol from the additive tank 108 and blends the solvent with the milled raw material. During preparation, the milled raw material may dissolve to form a viscous liquid.
In step 206 , reactor 110 a processes the prepared solvent and milled raw material. The prepared solvent and milled raw material may receive more solvent and/or other additives from the additive tank 108 . In various embodiments, the reactor 110 a heats (e.g., to 90° C.) and rotates (e.g., at speeds from 4,000 to 5,000 rpm) the prepared mixture for 2 hours. In some embodiments, the typical percentage of material in the reactor 110 a is two parts milled raw material to 4 parts solvent. Those skilled in the art will appreciate that the reactor 110 a may heat the prepared solvent and milled raw material at any heat, rotate at any speed, for any length of time.
In step 208 , the filter 112 a filters the processed material from the reactor 110 to separate out liquids. In various embodiments, the filter 112 a is a decanter which decants the processed material for one hour. The filter 112 a (e.g., decanter) may store any liquid in the liquid capture tank 114 . Remaining solids may be returned to the reactor 110 a . In some embodiments, at least some of the solvents may be absorbed.
In step 210 , the reactor 110 a re-processes the filtered solid material a second time. In various embodiments, additional additives such as solvent may be added to the filtered solid material prior to processing. In some embodiments, the filtered solid material and additive(s) may be heated (e.g., to 90° C.) and rotated (e.g., at speeds from 4,000 to 5,000 rpm) for two hours.
In step 212 , the filter 112 a re-filters the re-processed material to separate out liquids a second time. Any separated liquids may be stored in the liquid capture tank 114 . Remaining solids may be returned to the reactor 110 a.
In step 214 , the reactor 110 a re-processes the re-filtered solid material a third time. In various embodiments, additional additives such as solvent may be added to the filtered solid material prior to processing. In some embodiments, the filtered solid material and additive(s) may be heated and rotated for two hours.
In step 216 , the filter 112 a re-filters the re-processed material to separate out liquids a third time. Any separated liquids may be stored in the liquid capture tank 114 . Remaining solids may be provided to a mill (e.g., mill 116 ).
In step 218 , the liquid capture tank 114 receives liquids from the filter 112 a during steps 208 , 212 , and 216 . In step 220 , mill 116 mills the remaining solids received from the filter 506 . In some embodiments, the mill 116 grinds the remaining solids and eliminates or reduces remnants of remaining solvents.
Those skilled in the art will appreciate that at one or more filtration steps, filtration may occur with earth material and/or resin ionic exchange to eliminate amines compounds (e.g., odor of the marine animals).
FIG. 3 is a block diagram of an exemplary system 300 for the derivation of protein powder in an embodiment. The exemplary system 300 for the production of protein powder comprises the mill 116 (e.g., see FIG. 1 ), ovens 302 a - b , protein powder storage 304 , and packaging and shipping 306 . The mill 116 receives the material from the filter 112 a - b as discussed regarding FIG. 1 .
Ovens 302 a - b receive the re-milled material from the mill 116 . The ovens 302 a - b may then cure the re-milled material from the mill 116 . The ovens may be any kind of ovens including vacuum ovens that are configured to heat the milled material from the mill 116 to a temperature of 90° C. which dries the re-milled material. Remaining solvent may be collected from fumes during the curing process. The collected solvent may be stored and reused. In some embodiments, the ovens 302 a - b rotate (e.g., at 40 rpm) to agitate the mixture and speed drying.
The protein powder storage 304 is any facility that may receive the protein powder (e.g., Advanced Protein Powder) from the ovens 302 a - b . The protein powder storage 304 may be a hopper, silo, or any structure that can store the accumulated cooked and milled solids.
The packing and shipping 306 is any facility that may receive the protein powder from the protein powder storage facility 304 and package and/or ship the protein powder.
FIG. 4 is a flowchart of an exemplary method 400 for the derivation of protein powder in an embodiment. In step 402 , the mill 116 receives and grinds the solids from the filter 112 a . In step 404 , the oven 302 a cures the milled remaining solids from the mill 116 to finish protein powder. In some embodiments, the oven 302 a is a vacuum oven and the time of drying is 8 hours per load.
In step 406 the protein powder is stored in the protein powder storage 304 . In some embodiments, final processing or finishing of the protein powder may be performed at the protein powder storage 304 . In one example, the protein powder may be bleached to make the color of the protein powder more attractive and to whiten the protein powder so as to limit the negative impact of adding the protein powder to other foods. In another example, the protein powder may be further ground (e.g., to a flour like consistency).
The protein powder may be pressed into a solid pill form, placed in a capsule to be swallowed, or added to a liquid to be drunk. The protein powder may have a concentration of 85-90%, a transfatty acid content of 0.02%, cholesterol of 0.01%, 120 calories per each 30 gram serving, and is 98.1% digestible. The specific nutritional values in the protein powder created by an exemplary process are shown in the certificate of analysis in TABLE 1, TABLE 2, TABLE 3, and TABLE 4.
In some embodiments, the protein powder may have a lifetime or near-lifetime shelf-life because the protein powder may be non-hydroscopic (e.g., the protein powder does not absorb humidity or grow any bacteriological processes). The protein powder may also be chemically balanced so the protein powder does not change in quality concentration over time.
The protein powder may be both stable and sterile. In various embodiments, the product exceeds FDA requirements for a supplement and is an excellent product for world food needs. As can be seen in the Tables, the 35 gram serving of exemplary protein powder may provide sufficient protein to meet a person's amino acid requirement like a full meal.
For example, some FDA regulations specify that a minimum of 75% of protein and 500 parts per million of solvents, with a maximum of 5% humidity and 1.5 of fat or oil.
In one exemplary protein powder, an analysis indicates:
no more than 2.9% of humidity; no more than 500 parts per million; no more than 0.05% of fat or oil; no noticeable odor; no noticeable smell; no less than 80% of protein; and no measurable bacteria.
The difference between vegetables protein aminogram from animal is that the vegetables aminogram is not complete like the animal. In some embodiments, the protein powder described herein has desirable and unique characteristics including a fine powder cream color, is easy to mix with any type of food or supplement, is non-hydroscopic, and/or is sterile.
In step 408 , the protein powder is packaged and shipped from the packaging and shipping facility 306 .
FIG. 5 if a block diagram of an exemplary system 500 for the production of oil, production of water, and the recovery of an additive in an exemplary embodiment. The system 500 comprises a liquid capture tank 114 coupled with distillation towers 502 a - b . The distillation towers 502 a - b are coupled to filter 504 . The filter 504 separates out and stores at least some additive in additive tank 108 (see also FIG. 1 ). The filter 504 may also be coupled to filter 506 which receives liquids. The filter 506 is coupled to an oil storage 508 and a water storage 510 . The water storage 510 is further coupled to the water purifier 512 which is coupled to the water tank 514 .
In some embodiments, a filter of mineral and/or soils is coupled between the liquid capture tank 114 and the distillation towers 502 a - b . In one example, liquids from the liquid capture tank 114 are filtered before passing through the distillation towers 502 a - b . In various embodiments, the minerals and/or soils absorb amine from the liquid. Those skilled in the art will appreciate that many materials and/or soils may be used to absorb amine.
Although distillation towers 502 a - b depict two distillation towers, those skilled in the art will appreciate that there may be any number of distillation towers. Similarly, although only one liquid capture tank 114 , filter 504 , filter 506 , oil storage 508 , water storage 510 , water purifier 512 , and water tank 514 is depicted, those skilled in the art will appreciate that there may be any number of liquid capture tanks 114 , filters 504 , filters 506 , oil storages 508 , water storages 510 , water purifiers 512 , and water tanks 514 .
In various embodiments, the liquid capture tank 114 has a storage capacity of 40,000 liters and serves the purpose of capturing the heavy liquids that are extracted from the reactivated mixture from filters 112 a - b . In some embodiments, the liquid capture tank 114 transfers to liquid to another liquid capture tank (not depicted). In one example, the other liquid capture tank has a capacity of 120,000 liters and serves the purpose of storing the heavy liquids.
Distillation towers 502 a - b may be any distillation unit that distills liquids received from the liquid capture tank 114 and/or any other liquid capture tank. Although the distillation towers 502 a - b is characterized as a tower, the distillation towers 502 a - b may be any device that can distill liquids. In one example, a distillation tower 502 a - b may comprise different plates that allow different material to pass through. For example, oil may collect on a first plate and water may collect on a second plate.
In various embodiments, solvent, water, and oil are separated by evaporation and reflux compensation in the plate column semi-packed (e.g., a distillation tower or unit). Through this process solvent, oil, and waste water may be retrieved. In some embodiments, a charcoal filter may be used to extract other pollutants from the solvent prior to distillation. Those skilled in the art will appreciate that many components and pollutants may be recovered and/or removed from the solvent, water, and oil.
Filter 504 is any filter that may filter and/or otherwise remove one or more additives from the liquid. In some embodiments, the filter 504 filters solvent from the liquid and/or further removes pollutants from the solvent. In one example, the filter 504 filters 85% of the solvent from the liquid. The removed additive(s) are stored in the additive tank 108 where the additive may be added to the preparation tanks 106 a - b and/or the reactor 110 a - b . The filter 504 may also provide oil and water to the filter 506 . Those skilled in the art will appreciate that the filter 504 or function of the filter 504 may be incorporated within the distillation towers 502 a - b.
The filter 506 may separate out the oil from the water. Oil from the liquid may be stored in the oil storage 508 . The water may be stored in the water storage 510 . In one example, the filter 506 is a centrifuge which has a minimum operating capacity for the separation of 3,500 liters per hour, the purpose being to separate the water from the oil coming from distillation towers 502 a - b . Those skilled in the art will appreciate that the filter 506 or function of the filter 506 may be incorporated within the distillation towers 502 a - b.
The oil storage 508 may be any oil storage tank. In one example, the oil storage 508 has a capacity of 25,000 liters. The water from the filter 506 may be stored in water storage 510 . In one example, the water storage 510 has a capacity of 124,000 liters. In some embodiments, the oil may be further processed and/or purified as discussed further herein.
The water purifier 512 purifies the water from the water storage 510 . In one example, the water purifier 512 is a distillation tower. The purified water is then stored in water tank 514 .
Those skilled in the art will appreciate that one or more components of system 500 discussed herein may be optional. In one example, the water is not purified but rather used in conjunction with boilers to warm the one or more of reactors 110 a - b.
FIG. 6 is a flowchart of an exemplary method 600 for the recovery of oil, water, and additive(s). In step 602 , the liquid capture tank 114 receives liquids from the filters 112 a - b (see FIG. 1 ). There may be any number of liquid capture tanks 114 . In step 604 , the distillation tower 502 a receives the liquid from the liquid capture tank 114 and distills the liquid for four hours.
In step 604 , the captured liquid from the liquid capture tank 114 is distilled by the distillation tower 502 a . The captured liquid may be distilled any number of times to separate out water and oil from additive(s) such as solvents from the captured liquid. In some embodiments, the oil and/or solvent may be rectified. The distillation tower 502 a , may, in some embodiments, remove all or some of the odor causing chemicals from the oil.
In step 606 , the filter 504 filters the distilled liquid to collect additive(s) such as a solvent (e.g., isopropyl alcohol or methylic alcohol) for storage in the additive tank 108 . The filter 504 may also filter the distilled liquid to separate out Omega 3 fish oil from water in step 608 . Further, in some embodiments, the filter 504 serves the purpose of purifying the additive, so that the additive may later be transferred to additive tank 108 .
Those skilled in the art will appreciate that at one or more filtration steps, filtration may occur with earth material and resin ionic exchange to eliminate amines compounds (e.g., to odor of the marine animals). The filtration may occur before the liquids are distilled, after the liquids are distilled, or during distillation.
In step 610 , the oil storage 508 stores the Omega 3 fish oil from the filtered liquid. In step 612 , the Omega 3 fish oil may be processed prior to shipping. In one example, the Omega 3 fish oil may be processed to lighten the color of the Omega 3 fish oil, prepare the oil for encapsulation, or prepare the oil to be taken orally by adding flavors. Those skilled in the art will appreciate that any kind of processing may be performed.
In step 614 , the water purifier 512 purifies water from the filter 506 and in step 616 , the water tank 514 receives the water and prepares the water for bottling. The water may be further purified or additives may be added. In some embodiments, the water is bottled for drinking. In other embodiments, the water may be used for non-potable activities.
In various embodiments, the distillation tower 502 a and the filter 504 may comprise a retort, distillation column, and condenser for retrieving solvent. The retort may have a boiling point of 60-90° C. with a pressure of 540 to 610 mmHG. the distillation column receives the output from the retort and the condenser receives the output from the distillation column. Ultimately, the condenser outputs solvent that may be used again. In one example, the process may retrieve 85% of the solvent.
FIG. 7 is a flowchart of an exemplary method 700 for processing of Omega 3 oil in an embodiment. In various embodiments, the Omega 3 fish oils may be purified and concentrated. In step 702 , fish oil is extracted to the oil storage 508 as discussed herein.
In step 704 , saturated fats may be reduced or eliminated from the fish oil. In one example, saturated fats are reduced or eliminated by winterisation. Winterisation is the process of removing components of the oil with a high melting point. In one example, the oil is cooked gradually and filtered at low temperature. The filter may comprise a centrifuge. In some embodiments, the saturated fats may be reduced or eliminated by cooling the liquid (e.g., by applying nitrogen to the fish oil) and removing the saturated fats that solidify in the oil. Those skilled in the art will appreciate that there are many ways to remove the saturated fats.
In step 706 , heavy metals are reduced from the fish oil. In some embodiments, heavy metals are reduced or eliminated during distillation (e.g., via distillation towers 502 a - b ). In various embodiments, a magnetic field may be applied to the fish oil to remove heavy metals. Further, heavy metals may also be absorbed by a filter within or coupled to one or more distillation towers 502 a - b . Those skilled in the art will appreciate that there are many ways to remove heavy metals from the fish oil.
In step 708 , the fish oil is distilled (e.g., via distillation towers 502 a - b ). In some embodiments, the fish oil is distilled to reduce and/or refine pollutants. In one example, the heavy metal discussed in step 706 is a pollutant.
In step 710 , the oil is converted into ethyl esters. In step 712 , the ethyl esters are heated to further reduce or eliminate saturated fats. In some embodiments, step 710 is optional in view of step 704 .
In step 712 , molecular distillation to make final polish to remove PCBs (i.e., polychlorinated biphenyl). In on example, the output from step 710 is placed within a distillation unit (e.g., a distillation tower 502 a ) for distillation to remove and/or eliminate PCBs.
In some embodiments, the oil is converted into ethyl ester. The ethyl ester fatty acids may then be separated from contaminants in a vacuum system to ensure temperatures are well below the oil's normal boiling point (e.g., via a retort). The ethyl ester fatty acids may be isolated utilizing molecular weights leaving behind contaminants. The distilled fatty acids may then be recovered.
In various embodiments, oil refining may be used. In one example, free fatty acids are removed from the oil through neutralization with a base. An absorbent such as a bleaching earth or active carbon may be used to reduce color pigments and contaminants to within acceptable levels. A combination of steam and vacuum may be employed to remove volatile components responsible for the oil's odor and flavor.
Those skilled in the art will readily recognize, in accordance with the teachings of the present invention, that any of the foregoing steps and/or system modules may be suitably replaced, reordered, removed and additional steps and/or system components may be inserted depending upon the needs of the particular application, and that the systems of the foregoing embodiments may be implemented using any of a wide variety of suitable processes and system components.
Having described at least one embodiment, other equivalent or alternative methods of deriving a high-protein powder/omega 3 oil and water from raw material of aquatic animals will be apparent to those skilled in the art. The present invention(s) are described above with reference to exemplary embodiments. It will be apparent to those skilled in the art that various modifications may be made and other embodiments can be used without departing from the broader scope of the present invention. Therefore, these and other variations upon the exemplary embodiments are intended to be covered by the present invention(s).
TABLE 1
CERTIFICATE OF ANALYSIS AMINOGRAM
Sample Identification:
Sample #: 05-5432 Advance Protein Powder. Serving = 35 g
Method:
AL194: Elemental Scan (65) by ICP MS
Results:
Sample #05-5432
Test
Result
Elemental
(mg/serving)
Result (ppm)
Lithium
<35
<1
Boron
<35
<1
Magnesium
56,000
1,600
Phosphorus
220,000
6,400
Calcium
770,000
22,000
Titanium
77
2.2
Chromium
91
2.6
Iron
4,600
130
Nickel
<35
<1
Zinc
2,070
59
Germanium
<35
<1
Selenium
91
2.6
Strontium
3,900
110
Zirconium
<35
<1
Molybdenum
<35
<1
Rhodium
<35
<1
Silver
<35
<1
Indium
NA
NA
Antimony
<35
<1
Cesium
<35
<1
Lanthanum
<35
<1
Praseodymium
<35
<1
Beryllium
<35
<1
Sodium
70,000
2,000
Aluminum
2,000
56
Potassium
190,000
5,500
Scandium
<35
<1
Vanadium
<35
<1
Manganese
120
3.3
Cobalt
<35
<1
Copper
160
4.7
Advance International
Result
Corporation
Test
(mg/serving)
Result (ppm)
Gallium
<35
<1
Arsenic
<35
<1
Rubidium
49
1.4
Yttrium
<35
<1
Niobium
<35
<1
Ruthenium
<35
<1
Palladium
<35
<1
Cadmium
<35
<1
Tin
<180
<5
Tellurium
<35
<1
Barium
63
1.8
Cerium
<35
<1
Neodymium
<35
<1
Samarium
<35
<1
Gadolinium
<35
<1
Dysprosium
<35
<1
Erbium
<35
<1
Ytterbium
<35
<1
Hafnium
<35
<1
Tungsten
<35
<1
Osmium
<35
<1
Platinum
<35
<1
Mercury
<35
<1
Thorium
<35
<1
Europium
<35
<1
Terbium
<35
<1
Holmium
<35
<1
Thulium
<35
<1
Lutetium
<35
<1
Tantalum
<35
<1
Rhenium
<35
<1
Iridium
<35
<1
Gold
<35
<1
Thallium
<35
<1
Bismuth
<35
<1
Uranium
<35
<1
TABLE 2
CERTIFICATE OF ANALYSIS
Sample Identification
Sample #: 05-5432 Advance Protein Powder, Serving = 35 g
Method:
B0202: Amino Acid Profile (Total) by AOAC 98230
PB100 NLEA Abbreviated Nutrient Package (Proximate)
Results: OF AMINOGRAM Sample #05-5432
Theoretical
Test
/100 g
Serving
Units
Level
Protein - Food
85.4
29.9
grams
85-90%
Protein = Nitrogen × 6.38
Ash
9.20
3.22
grams
Carbohydrates, Calculated
<1.00
<0.35
grams
Calories, Calculated
340
119
calories
Crude Fat By Acid Hydrolysis
1.42
0.497
grams
0.5%
Moisture By Vacuum Oven
7.68
2.69
grams
Total Amino Acid Profile
Tryptophan
1.06
0.371
grams
Cystine
0.83
0.291
grams
Methionine
2.51
0.879
grams
Aspartic Acid
4.58
1.6
grams
Threonine
2.15
0.753
grams
Serine
1.64
0.574
grams
Glutamic Acid
6.64
2.32
grams
Proline
1.89
0.662
grams
Glycine
2.54
0.889
grams
Alanine
2.9
1.015
grams
Valine
2.31
0.809
grams
Isoleucine
2.03
0.711
grams
Leucine
3.51
1.23
grams
Tyrosine
1.54
0.539
grams
Phenylalanine
1.86
0.651
grams
Lysine, Total
3.92
1.37
grams
Histidine
1.22
0.427
grams
Arginine
2.97
1.04
grams
TABLE 3
CERTIFICATE OF ANALYSIS
Sample identification:
Sample #: 05-5432 Advance Protein Powder, Serving = 35 g
Method:
B0003: Customized Analyses (Pepsin (0.2%) Digestible Protein)
B7033: Cholesterol by Gas Chromatography (GC), AOAC 994.10
Q0201: Total Trans Fatty Acid by Gas
Chromatography (GC), AOAC 996.06
Results:
Sample #05-5432
Test
/100 g
/Serving
Units
Pepsin (0.2%) Digestible Protein
98.1
34.3
grams
Total Trans Fatty Acid Isomers
0.02
0.007
grams
Cholesterol
0.0173
0.00605
grams
TABLE 4
SUPPLEMENTAL FACTS
Serving Size 35 grams
Servings Per Container
Amount per
Serving
% of Daily Value*
Calories
120
Protein
30
g
Calcium
770
mg
77
Iron
5
mg
28
Magnesium
56
mg
14
Zinc
2.1
mg
140
Selenium
0.1
mcg
0
Copper
0.2
mg
10
Manganese
0.1
mg
5
Chromium
0.1
mcg
0
Sodium
70
mg
3
Potassium
190
mg
5
Isoleucine
710
mg
**
Leucine
1.2
g
**
Lysine
1.4
g
**
Methionine
880
mg
**
Cystine
290
mg
**
Phenylalanine
650
mg
**
Tryosine
540
mg
**
Threonine
750
mg
**
Valine
810
mg
**
Serine
570
mg
**
Glutamic Acid
2.3
g
**
Proline
66o
mg
**
Glycine
890
mg
**
Alanine
100
mg
**
Histidine
430
mg
**
Arginine
1.0
g
**
*Percent of Daily Values based on a 2000 calorie diet.
**Daily Value not established.
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Systems and methods for producing protein powder are disclosed. In various embodiments, protein powder is prepared by a process comprising sanitizing raw material from aquatic animals mixture with ozone, combining the raw material with a solvent to create a mixture, baking the combined mixture for a first time period, separating, with a filter, liquid from the combined mixture that was baked for the first time period, baking the combined mixture without the separated liquid for a second time period, separating, with a filter, liquid from the combined mixture that was baked for the second time period, curing the combined mixture, and processing the cured mixture to produce protein powder.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates generally to securities information technology systems, and more particularly, to a computerized system and method for rating an underlying asset of a securitized instrument, such as, without limitation, a commercial mortgage-backed security.
[0003] 2. Background of Related Art
[0004] A security is a financial instrument having a value based on the value of one or more underlying assets. Securities may be characterized by the underlying asset type, e.g., debt securities (e.g., bonds, mortgages, commercial paper, and loans), equity securities (e.g., shares of common stocks), and derivative contracts (e.g., forwards, futures, options and swaps). However, in practice, any type of asset can be pooled into a security. The assets which comprise a security may be selected in part upon the investment goals of the security, e.g., risk level, income production, capital appreciation, tax minimization, short- or long-term financial investment, whether an indefinite term (an open-ended security) or a fixed maturity date (a closed-ended security) is desired, and so forth. Pooling assets into a security instrument may also reduce the risks associated with any one underlying asset by spreading risk among the plurality of assets held in the security. In this manner, an unfavorable return on one asset may be offset by favorable returns on other assets held within the security. Securities also enable smaller or individual investors to participate in the market which would otherwise require capital outlays beyond the means of such investors.
[0005] A commercial mortgage-backed security (CMBS) is a type of security typically having as its assets a pool of mortgages held on commercial real estate properties, such as without limitation, office and apartment buildings, hotels, warehouses, industrial parks, and retail centers and malls. A single CMBS may include many individual mortgage loans of varying size, property type and location. The selected commercial mortgages are pooled and transferred to a trust. In turn, the trust issues a series of bonds that may vary in investment grade, yield, duration, and payment priority. The bonds are then offered to investors, who may purchase such bonds based on the desired level of risk, yield, and duration sought. A CMBS can be attractive to investors, since commercial real estate mortgages are typically more rigidly structured than residential mortgages and consequently carry less risk of uncompensated prepayment, or foreclosure.
[0006] Financial analysts are commonly employed to evaluate the merits of an asset being considered for inclusion within a security instrument, using manual analysis and, more recently, computer-aided analysis. Analysts may use standardized and/or proprietary techniques to study myriad properties of applicants, such as asset class, asset value, financial ratios (e.g., debt yield, debt service coverage, and loan-to-value), rate of return, beta (e.g., a correlation between an individual asset and a universe of related assets), risk factors, and creditworthiness. In the case of a CMBS, an analyst may consider such factors as location, identities of the mortgagor and/or mortgagee, credit history of the mortgagor, demographics, comparable property values (e.g., “comps”), tenancy data, and so forth. While ideally these factors are applied in an objective manner, the biases and preconceptions of an analyst may color the asset evaluation process, which may result in less than optimal accuracy of the rating of the securitized instrument. Asset rating may be conducted on behalf of an “applicant” or “issuer”, which may be an underwriting bank or other entity engaged in the securitization of the loans and assets being rated.
SUMMARY
[0007] Disclosed is a system and method for rating a security, and in particular, for performing a three stage, double-blind credit rating of a security and/or an asset thereof. In an embodiment, the disclosed system includes a processor and a secure database operably coupled to the processor. The secure database further includes therein a stage one database, a stage two database, and a stage three database. The system includes a rating module operably coupled to the processor that includes a set of instructions executable on the processor for performing a method of rating one or more assets. In an embodiment, the disclosed system and method performs a three stage, double-blind credit rating of a commercial mortgage backed security and/or an asset thereof.
[0008] In one aspect, the disclosed system and method may perform an initial rating of a commercial mortgage backed security and/or an asset thereof. In another aspect, the disclosed system and method may perform one or more ratings of a commercial mortgage backed security and/or an asset thereof, which may include, without limitation, an upgrade or a downgrade of a rating of a commercial mortgage backed security and/or an asset thereof. Such upgrade and/or downgrade ratings may be performed subsequent to an initial rating, and/or prior to the issuance of the security and/or asset thereof.
[0009] In an embodiment, the method for rating an includes the steps of receiving asset raw data from an applicant, wherein the applicant raw data includes stage one data, stage two data, and stage three data. The stage one data is stored in the stage one database, the stage two data is stored in the stage two database, and the stage three data is stored in the stage three database. A stage one access token is generated, whereupon presentation of the stage one access token grants access to the stage one database. A stage two access token is generated, whereupon presentation of the stage two access token grants access to the stage two database. A stage three access token is generated, whereupon presentation of the stage three access token grants access to the stage three database.
[0010] The stage one database is accessed using the stage one access token, and the stage one data is evaluated. The evaluation may be performed by a stage one analyst using appropriate criteria, e.g., objective criteria. The stage one data is evaluated to generate a stage one score, and the stage one score is then stored in the stage two database. The stage two database is accessed using the stage two access token, and the stage two data is evaluated. The evaluation may be performed by a stage two analyst, using appropriate criteria, e.g., objective criteria. The stage two data is evaluated to generate a stage two score, and the stage two score is then stored in the stage three database. The stage three database is accessed using the stage three access token, and the stage three data is evaluated. The evaluation may be performed by a stage three analyst, using appropriate criteria, e.g., objective criteria. The stage three data is evaluated to generate a final rating, and final rating is transmitted to the applicant.
[0011] In an embodiment the secure database includes a results database, and a final rating access token is generated. The final rating is stored in the results database and the final rating access token is transmitted to the applicant. The applicant accesses the results database using the final rating access token.
[0012] Also disclosed is one or more computer-readable media storing instructions that are executable by a computer and cause the computer to perform a method of rating an applicant in accordance with the present disclosure as described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Various embodiments of the disclosed system and method are described herein with reference to the drawings wherein:
[0014] FIG. 1 is a block diagram of an embodiment of a system for double-blind, three stage credit rating process for securities in accordance with the present disclosure;
[0015] FIG. 2 is a process diagram of an embodiment of a double-blind, three stage credit rating process for securities in accordance with the present disclosure;
[0016] FIG. 3 is a flowchart of an embodiment of a first stage of a three stage credit rating process for securities in accordance with the present disclosure;
[0017] FIG. 4 is a flowchart of an embodiment of a second stage of a three stage credit rating process for securities in accordance with the present disclosure; and
[0018] FIG. 5 is a flowchart of an embodiment of a third stage of a three stage credit rating process for securities in accordance with the present disclosure.
DETAILED DESCRIPTION
[0019] Particular embodiments of the present disclosure are described hereinbelow with reference to the accompanying drawings; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure, which may be embodied in various forms. Well-known functions or constructions are not described in detail to avoid obscuring the present disclosure in unnecessary detail. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure in virtually any appropriately detailed structure.
[0020] Additionally, the present invention may be described herein in terms of functional block components and various processing steps. It should be appreciated that such functional blocks may be realized by any number of hardware and/or software components configured to perform the specified functions. For example, the present invention may employ various integrated circuit components, e.g., memory elements, processing elements, logic elements, look-up tables, and the like, which may carry out a variety of functions under the control of one or more processors or other control devices. Similarly, the software elements of the present invention may be implemented with any programming or scripting language such as C, C++, C#, Java, Javascript, Visual Basic™, COBOL, assembler, PERL, PHP, or the like, with the various algorithms being implemented with any combination of data structures, objects, processes, routines or other programming elements. The object code created can be executed on a variety of operating systems, including without limitation Windows, Macintosh, and/or Linux. Further, it should be noted that the present invention may employ any number of conventional techniques for data transmission, signaling, data processing, network control, and the like.
[0021] It should be appreciated that the particular implementations shown and described herein are illustrative of the invention and its best mode, and are not intended to otherwise limit the scope of the present invention in any way. Examples are presented herein which may include sample data items which are intended as examples and are not to be construed as limiting. Indeed, for the sake of brevity, conventional data networking, application development and other functional aspects of the systems (and components of the individual operating components of the systems) may not be described in detail herein. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent example functional relationships, physical, and/or virtual couplings between the various elements. It should be understood that many alternative or additional functional relationships or physical or virtual connections may be present in a practical electronic data communications system.
[0022] As will be appreciated by one of ordinary skill in the art, the present invention may be embodied as a method, a data processing system, a device for data processing, and/or a computer program product. Accordingly, the present invention may take the form of an entirely software embodiment, an entirely hardware embodiment, or an embodiment combining aspects of both software and hardware. Furthermore, the present invention may take the form of a computer program product on a computer-readable storage medium having computer-readable program code means embodied in the storage medium. Any suitable computer-readable storage medium may be utilized, including hard disks, CD-ROM, DVD-ROM, optical storage devices, magnetic storage devices, semiconductor storage devices, organic storage devices, and/or the like.
[0023] The present invention is described below with reference to block diagrams and flowchart illustrations of methods, apparatus (e.g., systems), and computer program products according to various aspects of the invention. It will be understood that each functional block of the block diagrams and the flowchart illustrations, and combinations of functional blocks in the block diagrams and flowchart illustrations, respectively, can be implemented by computer program instructions. These computer program instructions may be loaded onto a general purpose computer, a special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions that execute on the computer or other programmable data processing apparatus create means for implementing the functions specified in the flowchart block or blocks.
[0024] 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 that implement the function specified in the flowchart 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 that execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart block or blocks.
[0025] Accordingly, functional blocks of the block diagrams and flowchart illustrations support combinations of means for performing the specified functions, combinations of steps for performing the specified functions, and program instruction means for performing the specified functions. It will also be understood that each functional block of the block diagrams and flowchart illustrations, and combinations of functional blocks in the block diagrams and flowchart illustrations, can be implemented by either special purpose hardware-based computer systems that perform the specified functions or steps, or suitable combinations of special purpose hardware and computer instructions.
[0026] The scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given herein. For example, the steps recited in any method claims may be executed in any order and are not limited to the order presented in the claims. Moreover, no element is essential to the practice of the invention unless specifically described herein as “critical” or “essential.”
[0027] FIG. 1 illustrates an embodiment of a system 100 for performing a double blind credit rating analysis of a security, e.g., a CMBS. The disclosed embodiment of the system 100 includes a data processing unit 110 that is coupled to one or more user data terminals 140 by a data network 130 . Data processing unit includes a processor 112 that is operably associated with a storage unit 114 and a rating module 120 . Data network 130 may encompass any suitable data communication link now or in the future known, including without limitation, the public Internet, a local area network (LAN), a wide area network (WAN), and may utilize any suitable signaling protocol and/or transmission media, including without limitation, TCP/IP, Ethernet, fiber optic media, wireless transmission via 802.11 “WiFi”, Bluetooth, cellular (e.g., CDMA, GSM) and the like. Processor 112 is operatively coupled to a communication interface 118 . Communication interface 118 may support any suitable communication protocol or standard, including without limitation, wired and/or wireless protocols, e.g., wired Ethernet 10BASE-T, 100BASE-T, and/or 1000BASE-T protocols, wireless IEEE 802.11 “WiFi” protocols, and the like. Communications interface 118 operably couples processor 112 , storage device 114 , and/or rating module 120 to data network 130 . Data network 130 may be a private network, a public network, or a combination of a public and private network. Data processing unit 110 may optionally be embodied as a single computer, in a cluster of two or more computers, and/or may be embodied in one or more virtual machines using, e.g., VMware™ or Xenserver™ virtualization.
[0028] One or more user data terminals 140 are in communication with data processing unit 110 . User data terminal 140 may include any suitable device capable of enabling user interaction with data processing unit 110 , and/or with rating module 120 as described in detail herein. For example, and without limitation, user data terminal 140 may include a computing device running the Windows™ operating system sold by Microsoft Corp. of Redmond, Wash., United States (e.g., Windows XP, Windows Vista, Windows 7, Windows CE, and other Windows version), the MacOS and/or IOS operating systems sold by Apple Inc., of Cupertino, Calif., United States, linux, and/or unix. In an embodiment, user data terminal 140 includes a web browser, such as without limitation, Firefox (Mozilla), Internet Explorer, Safari, Opera, Pine, and so forth. User interaction between a user and system 100 may be conducted via any suitable user interface, such as, without limitation, an interface presented in a web browser (e.g., coded in HTML, Javascript, Flash, Ajax, Cold Fusion, and the like), via dedicated application software, by a voice interface, a touchpad interface (e.g., telephone keypad interface), a touchscreen interface, and/or by any suitable user interface capable of facilitating man-machine interaction now or in the future known. The user data terminal 140 may include a biometric authentication device, such as a fingerprint scanner, a retina scanner, voice recognition, and the like. Additionally, optionally, or alternatively, user data terminal 140 may include an automatic identification device, such as without limitation, a barcode scanner, magstripe reader, and/or an RFID tag interrogator.
[0029] The system 100 includes rating module 120 that is executable on processor 112 that is configured to perform a method of double-blind rating of a security, e.g., a credit rating of a prospective asset of a CMBS as described herein. The rating module 120 is further configured to accept the input of raw data corresponding to an asset. Such asset may prospectively be considered for inclusion in a CMBS. The raw data is input into rating module 120 by any suitable manner of data input, including without limitation, manual data entry, data download, and/or via data mining (e.g., screen scraping and other common methods of acquiring data from disparate sources). The raw data is segregated into a plurality of subsets, or “stages”, each stage being designated for review by an independent analyst. In an embodiment, three such stages are established.
[0030] For example, and without limitation, a stage one dataset may include data relating to the identity of the issuer of the securities, the identity of the borrower (mortgagor), the identity of the sponsor(s), the identity of any principals who, directly or indirectly, own or control the sponsor(s), and the identity of any guarantor(s). A stage two dataset may include, without limitation, data relating to the property location. A stage three dataset may include any other relevant data relating to the asset, such as, without limitation, incomes and expenses of the property, rent roll, age of property, physical condition, tenancy, loan-to-value, debt yield and/or debt service coverage ratios, and the like.
[0031] After establishing the stage datasets, an access token associated with each stage is generated, which may be a unique string of alphanumeric and/or symbolic characters. Each access token, in turn, is provided to the corresponding stage analyst to faciliate exclusive access to the corresponding stage dataset. Utilizing a user data terminal 140 , a stage one analyst provides the required access token to the rating module 120 to obtain access to the stage one dataset only (e.g., the stage one access token provides access to the stage one dataset, but not the stage two or three datasets). The stage one analyst studies the stage one dataset and issues a stage one score thereof based upon objective criteria. In an embodiment, rating module 120 may automatically provide a preliminary rating of each individual data item of the first stage dataset. Additionally or alternatively, rating module 120 may provide a preliminary aggregate rating of all, or at least a portion of, the first stage dataset. The first stage analyst then may adjust the preliminary ratings to arrive at a final stage one score. The final stage one score is communicated to and/or included within the stage two dataset.
[0032] A stage two analyst provides the stage two access token to the rating module 120 to access only to the stage two dataset and the final stage one score. The stage two analyst studies the stage two dataset and issues a stage two score thereof based upon objective criteria. Rating module 120 may provide a preliminary rating of each individual data item of the stage two dataset. Additionally or alternatively, rating module 120 may provide a preliminary aggregate rating of all, or at least a portion of, the second stage dataset. The second stage analyst then may adjust the preliminary ratings to arrive at a final stage two score. The final stage one and final stage two scores are communicated to and/or included within the stage three dataset.
[0033] A stage three analyst provides the stage three access token to the rating module 120 to obtain access to the stage three dataset, the final stage one score, and the final stage two score. The stage three analyst studies the stage three dataset and provides a score thereof based upon objective criteria. Rating module 120 may provide a preliminary rating of each individual data item within the stage three dataset. Additionally or alternatively, rating module 120 may provide a preliminary aggregate rating of all, or at least a portion of, the third stage dataset. The stage three analyst may adjust the preliminary ratings to arrive at a final stage three score.
[0034] Optionally, the stage two and/or the three analyst may respectively present questions to the applicant, e.g., for clarification or to obtain additional information. Such questions are transmitted to the applicant via a sequence of messages that pass through, in the case of the stage three analyst presenting questions, the stage two analyst, the stage one analyst, and finally to the applicant, or, in the case of the stage two analyst presenting questions, through the stage one analyst, and then to the applicant. The applicant's response is recorded and added to the appropriate dataset, e.g., the stage one, stage two, or stage three dataset, whereupon the appropriate analyst will review the updated dataset and, if warranted, updating or revising a corresponding stage score reflecting the additional information received from the applicant. The question and answer cycle may be repeated.
[0035] Upon completion of the stage three analysis, the stage three analyst issues a final rating score. The final rating score may be based at least in part on the stage one score and the stage two score. A final rating access token is generated, and is transmitted to the applicant. The applicant may then utilize the final rating access token to obtain access to the final rating score, and, optionally or alternatively, additional analytical material provided by one or more of the analysts.
[0036] An access token may be generated in any suitable manner, including without limitation, generation of a random or pseudo-random string, a hash of data elements derived from the applicant data, and may include a checksum character and/or a timestamp. The access token may be human-readable, e.g., enterable by a user via a user interface (keyboard, touch screen, and so forth). Optionally or alternatively, the access token may be operably associated with or encoded onto an authentication device, such as an access card bearing a magnetic strip or barcode, which, in turn, may be read by the user access device 140 to grant the bearer of the authentication device, e.g., an analyst, appropriate access to the corresponding database. In an embodiment, the access token may be associated with a biometric parameter of the analyst assigned to the corresponding database, such that access to the database may only be achieved when the correct biometric credentials (e.g., the analysts' fingerprint, retina scan, or voice scan) is presented to a user access terminal 140 .
[0037] Turning to FIG. 2 , data and process flows of an embodiment of a double-blind, three stage credit rating system for securities 200 in accordance with the present disclosure are presented. The system 200 includes a secure database 216 having the capability to control or restrict access to data stored therein in response to one or more credentials presented thereto. In an embodiment, secure database 216 includes the capability to restrict access to at least one of read-write, read-only, or write-only (e.g., “drop-box” access) in response to one or more credentials presented thereto. Secure database 216 may include a relational database (e.g., SQLServer, MySQL, Oracle™), a flat file, an indexed file (e.g., Btrieve, ISAM, RMS), or any other suitable data storage architecture having record-oriented random access read and write capability. Secure database 216 includes stage one database 210 , stage two database 212 , and stage three database 214 . The applicant 205 provides raw data 206 representative of the asset, which may be a commercial mortgage loan, being submitted for analysis. The raw data 206 , which includes a plurality of data items, is communicated to secure database 216 . Each data item communicated to the secure database 216 is then segregated by a classification module 211 into the corresponding stage one, stage two, or stage three database depending upon whether the data items corresponds to a stage one dataset, a stage two dataset, or a stage three dataset, as described hereinabove. In an alternative embodiment, the segregation is performed by the stage one analyst 230 . In yet another embodiment, at least a part of the segregation is performed by at least one of classification module 211 and/or the stage one analyst 230 .
[0038] A database credential, or unique access token, is generated for each stage database 210 , 212 , 214 of the applicant 205 . An analyst must present the correct access token to the system 200 , which, in turn, causes the system 200 to grant the appropriate analyst access to the corresponding stage dataset. A stage one token 220 grants stage one analyst 230 access to stage one database 210 ; a stage two token 222 grants stage two analyst 232 access to stage two database 212 ; and a stage three token 224 grants stage three analyst 230 access to stage three database 214 . The stage three token optionally or additionally enables access by the stage three analyst 234 to a final results database 218 which is configured to store the results of the credit rating process. A unique final results access token 226 is generated which, when presented to the system 200 by the applicant 205 , enables access to the final results database 218 by the applicant 205 .
[0039] Turning now to FIGS. 3 , 4 , and 5 , a method of performing a three stage, double-blind credit rating analysis of a CMBS is presented. In FIG. 3 the stage one process 300 is shown wherein in step 305 , applicant raw data received, provided, and/or collected. In step 310 , the raw input data is segregated into a stage one database (including e.g., applicant, borrower, sponsor, and guarantor information), a stage two database (including, e.g., geographic, demographic, appraisal, zoning, crime rates, and occupancy information) and a stage three database (including, e.g., property cash flows, rent roll, age of property, physical condition, tenancy, loan-to-value, debt yield, debt service coverage ratios, and ad hoc information as may be required or requested by the third stage analyst).
[0040] In step 315 , a stage one access token unique to the applicant data is generated. In step 320 , a stage one analyst presents the stage one access token to access the stage one database. The stage one analysis is conducted by the stage one analyst in step 325 , wherein the stage one data is scrutinized, reviewed, studied, and/or evaluated in accordance with objective criteria to arrive at a stage one rating. The stage one rating may be a single score, or may include a discrete rating for one or more subgroups of the stage one dataset, including without limitation, an applicant score, a sponsorship score, and a guarantor score. The stage one rating is communicated to the stage two database, and to the stage two analyst, in step 330 . In step 335 , a stage two access token is generated and forwarded to the stage two analyst. Stage one concludes in step 340 whereupon the stage two process 400 commences with step 405 .
[0041] In step 405 , a stage two analyst presents the stage two access token to access the stage two database. The stage two analysis is conducted by the stage two analyst in step 410 , wherein the stage two data is scrutinized, reviewed, studied, and/or evaluated in accordance with objective criteria to arrive at a stage two rating. The stage two rating may be a single score, or may include a discrete rating for one or more subgroups of the stage two dataset, including without limitation, a geographic score, a demographic score, a local occupancy rate score, and a crime rate score.
[0042] The stage two analyst may optionally inquire of the applicant to obtain additional information therefrom. In step 415 the stage two analyst determines whether further inquiry of the applicant is necessary. If further inquiry is indicated, in the step 440 , the inquiry is communicated indirectly to the applicant through the first stage analyst, in order to maintain three stage, double blind anonymity. In an embodiment, the stage two analyst communicates the query to the stage one database using a write-only access mechanism, which enables one way communication from the stage two analyst to the stage one database without exposing the first stage dataset to the stage two analyst. The stage one analyst, having full (read/write) access to the stage one database, then propounds the query to the applicant.
[0043] In step 445 , the applicant provides a response to the request, which, in turn, is communicated to the stage one analyst. The stage one analyst segregates the information provided in the applicant's answer into the stage two database for analysis by the stage two analyst in step 460 . In an embodiment, the applicant's response is communicated as additional raw data that is then segregated into the stage two database accessible to the stage two analyst. Additionally or alternatively, the applicant's response may include data germane to the stage one or stage three dataset. Such additional data may be segregated into the first and/or third stage database as appropriate, whereupon the first and/or this stage analyst may evaluate or re-evaluate the corresponding stage score, which, in turn, is fed forward to the next stage dataset as described herein for consideration by the corresponding subsequent analyst.
[0044] In the step 460 , the second stage screener evaluates the response received from the applicant, and the process iterates to step 415 wherein the third stage analyst determines whether the applicant's response was sufficient, whether additional inquiries are required, or whether no further questions are necessary. If additional questions are warranted the process iterates to step 440 as described hereinabove. If no additional questions are required, the process continues with step 420 wherein the stage two rating is communicated to the stage three database, and to the stage three analyst. In step 425 , the stage three dataset is transmitted to the stage three database. In step 430 , a stage three access token is generated and forwarded to the stage three analyst. Stage two concludes in step 435 whereupon the stage three process 500 commences with step 505 .
[0045] In step 505 , a stage three analyst presents the stage three access token to access the stage three database. The stage three analysis is conducted by the stage one analyst in step 510 , wherein the stage three data is scrutinized, reviewed, studied, and/or evaluated in accordance with objective criteria to arrive at a preliminary stage three rating. The stage three rating may be a single score, or may include a discrete rating for one or more subgroups of the stage three dataset, including without limitation, a property cash flow score, a rent roll score, a property age and/or physical condition score, a tenancy score, a loan-to-value score, a debt yield score, and a debt service coverage ratio score.
[0046] Once a preliminary stage three rating has been established, the stage three analyst may optionally inquire of the applicant to obtain additional information therefrom. In step 515 the stage three analyst determines whether further inquiry of the applicant is necessary. If further inquiry is indicated, in the step 530 , the inquiry is communicated indirectly to the applicant through the first stage analyst, in order to maintain three stage, double blind anonymity. In an embodiment, the stage three analyst communicates the query to the stage one database using a write-only access mechanism, which enables one way communication from the third stage analyst to the first stage database without exposing the first stage dataset to the third stage analyst. The first stage analyst, having full (read/write) access to the first stage database, then propounds the query to the applicant.
[0047] In step 535 , the applicant provides a response to the request, which, in turn, is communicated to the stage one analyst. The stage one analyst segregates the information provided in the applicant's answer into the stage three database for analysis by the stage three analyst in step 540 . In an embodiment, the applicant's response is communicated as additional raw data that is then segregated into the third stage database accessible to the third stage screener. Additionally or alternatively, the applicant's response may include data germane to the stage one or stage two dataset. Such additional data may be segregated into the first and/or second stage database as appropriate, whereupon the first and/or second stage analyst may re-evaluate the corresponding stage score, which, in turn, is fed forward to the next stage dataset as described herein for consideration by the corresponding subsequent analyst.
[0048] It will be appreciated that during follow-on questioning, the first stage analyst receives the question from the second or third stage analyst. In turn, the first stage analyst forwards the question verbatim to the applicant to be answered. Since the first stage analyst may already know the identity of the applicant, double blindness is not compromised. In embodiments, upon receipt of applicant's response, the first stage analyst may then segregate the data received from the applicant so that, prior to transmitting such information to the second or third stage dataset. In this manner, the data is stripped of any information that might reveal, e.g., the identity of the applicant. The second stage analyst would then segregate the data received from the second stage dataset and strip any information that would reveal, e.g., the location of the property before forwarding to the third stage dataset. The third stage analyst would thereby after receiving the answer to his question still be deprived of any potentially biasing information as to the identity of the applicant or the property location.
[0049] In the step 545 , the third stage screener evaluates the response received from the applicant, and the process iterates to step 515 wherein the third stage analyst determines whether the applicant's response was sufficient, whether additional inquiries are required, or whether no further questions are necessary. If additional questions are warranted the process iterates to step 530 as described hereinabove. If no additional questions are required, the process continues with step 520 wherein the stage three analyst issues the final credit rating and a final rating access token is generated. In the step 525 , the final credit rating, and optionally, additional rating information and assessment data, notes, etc., are transmitted to a results database and the final rating access token is provided to the applicant, which, in turn, enables the applicant to access the results database. Additionally or alternatively, the final rating access token is provided to a third party, e.g., a securities manager, an underwriter, or to a regulatory body, to enable such third parties to access the results database.
[0050] It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. It is contemplated that the steps of a method in accordance with the present disclosure can be performed in a different order than the order provided herein. Therefore, the herein description should not be construed as limiting, but merely as examples of particular embodiments. The claims can encompass embodiments in hardware, software, or a combination thereof.
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Disclosed is a computer-implemented system and method for rating an asset, and, in embodiments, a system and method for performing a double-blind, three stage credit rating of a securitized instrument, such as without limitation, a commercial mortgage backed security or an asset thereof. The disclosed method utilizes a secure database structure which trifurcates information relating to the asset being rated into first, second, and third analytical stages. Asset information is distributed such that analysts at each stage have access to only that information which is relevant to the scope of the particular analytical stage being performed, while irrelevant and prejudicial information is withheld from the analyst. Unique access tokens are employed to control access to stage data and to maintain the integrity of the analytical process.
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This application claims benefit of Provisional Application No. 60/055,298 filed Aug. 8, 1997.
BACKGROUND OF THE INVENTION
This invention relates generally to a portable spraying and drinking apparatus.
Generally, fans used for personal cooling are designed for static use, i.e., the fan is placed in a desired location and plugged in an electrical outlet. However, a stationary fan, which must be plugged into an electrical outlet, cannot be readily used when outside and moving from place to place such as occurs when visiting an amusement park.
It is known to have battery powered, hand held or otherwise portable, self-contained fans. An example of such a fan is shown in my U.S. Pat. No. 5,304,035, which is incorporated herein by reference. It is also known to provide a hand held fan capable of spraying a cooling mist to enhance the cooling action of the fan through evaporation of moisture sprayed onto the skin. Fans incorporating misting apparatus are shown in U.S. Pat. Nos. 3,997,115 and 4,839,106.
In addition, personal cooling and comfort is enhanced by the consumption of liquids. However, in order to both hold a fan and consume liquid, both hands must be used. One hand must hold the fan while the other holds the drink container. It would be desirable to have a personal cooling device which would also provide a drinking liquid source. Such a design would further promote cooling of the user by helping to replace liquids lost through perspiration.
SUMMARY OF THE INVENTION
Among the several objects and features of the present invention may be noted the provision of a portable spraying and drinking apparatus which efficiently and economically cools and hydrates the user; the provision of such apparatus which is compact and can be carried in one hand; the provision of such apparatus which inhibits injury associated with accidental contact with rotating blades of a fan of the device; the provision of such apparatus which permits easy removal of a hydration unit for use independently of a personal cooling unit; and the provision of such apparatus which permits easy removal of the cooling unit for use independently of the hydration unit.
Portable spraying and drinking apparatus for personal cooling and hydration constructed according to the principles of the present invention generally comprises a liquid container, a liquid spraying device for pumping liquid from the container and spraying the liquid, and a liquid drinking device, for removing liquid from the container for consumption by the user. The liquid spraying and drinking devices are incorporated into a single unit capable of being held in one hand.
In another aspect of the invention, a rotating fan blade assembly generally comprises a hub and a plurality of blades extending radially outward from the hub. The blades each have an airfoil shape for moving air as the blade assembly is rotated. Each blade has a radially inner portion of a rigidity selected to hold the shape of the blade as it is rotated and a peripheral edge portion made of softer and more flexible material than the radially inner portion to inhibit injury upon contact with a human body.
Other objects and features will be in part apparent and in part pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a portable spraying and drinking apparatus of a first embodiment;
FIG. 2 is an enlarged, fragmentary elevational view of the apparatus with parts of a fan housing of the apparatus broken away;
FIG. 3 is an elevational view of the apparatus with a portion of a liquid container of the apparatus broken away;
FIG. 4 is an enlarged, fragmentary view of an upper portion of the liquid container separated from a lower portion, with the fan housing and fan removed, and with parts broken away to show internal construction;
FIG. 5 is a bottom plan view of the upper portion of FIG. 4 with parts broken away to show details of construction;
FIG. 6 is an elevational view of a portable spraying and drinking apparatus of a second embodiment;
FIG. 7 is an elevational view of apparatus of a third embodiment having separate internal compartments for drinking and spraying liquids;
FIG. 8 is an elevational view of a fourth embodiment of the portable spraying and drinking apparatus with a "thread-on" drinking liquid compartment;
FIG. 9 is an elevational view of a fifth embodiment of the portable spraying and drinking apparatus with a "snap-on" drinking liquid compartment;
FIG. 10 is a fragmentary, elevational view of a spraying device of the portable spraying and drinking apparatus forming a sixth embodiment of the present invention;
FIG. 11 is an elevational view of a spraying device of the portable spraying and drinking apparatus forming a seventh embodiment of the present invention;
FIG. 12 is an elevational view of a combination spraying and drinking device of the portable spraying and drinking apparatus forming an eighth embodiment of the present invention;
FIG. 13 is the elevational view of the spraying and drinking device of FIG. 12 showing a pull top in a raised position;
FIG. 13A is a sectional view of the spraying and drinking device of FIG. 12;
FIG. 14 is a front elevational view of a fan blade assembly;
FIG. 15 is a rear elevational view of the fan blade assembly; and
FIG. 16 is a side elevational and partial sectional view of another embodiment of the fan blade assembly.
Corresponding reference characters indicate corresponding parts throughout the several views.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, a portable spraying and drinking apparatus for use as a personal cooling and drinking device is indicated generally at 10. (FIG. 1). The portable spraying and drinking apparatus comprises a fan 12, a spray assembly 50 and a liquid container 70 (all reference numerals designating their subjects generally). The fan 12 provides a cooling flow of air and facilitates the evaporation of liquid on the user's skin. As illustrated in FIG. 2, the fan 12 includes a housing 18 containing a motor 20, a switch 22, batteries 24, a battery access door 26, and wiring 28. When the switch 22 is moved to the "on" position, the switch completes an electrical circuit between the batteries 24 and the motor 20, thereby energizing the motor. A shaft 30, rotatably connected to the motor 20 and extending from an opening in the fan housing 18 is rotated by the motor. A shroud 32 mounted on the housing 18 encloses a fan blade assembly, generally indicated at 40. The fan blade assembly 40 is mounted on the shaft 30 for conjoint rotation with the shaft. The fan blade assembly 40 comprises a hub 42 and blades 44.
The spray assembly 50 is comprised of a spray head 52, a spray nozzle 54, a nozzle cage 56, a spray siphon tube 58, and a nozzle tube 60. (FIGS. 1 and 2). A spray nozzle 54 in the shape of a frustum of a cone is rotatably mounted on the exterior of the shroud 32 along the axis of the shaft 30, so that the spraying assembly 50 is capable of delivering atomized liquid into the center of an air stream 62 created by the fan blade assembly 40. The spray nozzle 54 is attached to the fan shroud 32 by the nozzle cage 56. The nozzle cage 56 allows the spray nozzle 54 to rotate about its axis, such that the user can rotate the nozzle and adjust the water flow and spray shape. The spray head 52 is fully integrated into the fan housing 18 and pumps liquid. The construction and operation of the spray head 52 is well known in the art. The spray head 52 draws water into the spray siphon tube 58, and delivers it through nozzle tube 60, and out the spray nozzle 54 in response to the pumping of a trigger 64. The nozzle tube 60 directs water from the spray head 52, around the bottom and up the front of the fan shroud 32 to the nozzle 54 so that the nozzle is located generally in the center of the shroud and the center of the air stream 62 generated by the fan 12.
The fan 12 and spray assembly 50 would be threadably attached to a container 70 of the apparatus 10 by a threaded neck ring 46. However, it is to be understood that the fan housing 18 may be integrally attached to the container 70 or formed as one piece with the container without departing from the scope of the resent invention. In the first embodiment, the container 70 includes two pieces, an upper dome 72 and a lower jacket 74. (FIGS. 1 and 3). When the dome 72 and the jacket 74 are threadably interconnected via their threaded portions at the top edge of the jacket and the bottom edge of the dome, the container 70 has two chambers. An upper chamber 76, completely within the dome 72, holds liquid for spraying through the spraying assembly 50. A lower chamber 78 encloses a pre-packaged beverage container 79 which is accessed for drinking through a straw 80. The upper chamber 76 is separated from the lower chamber 78 by an internal wall 82, arranged horizontally across the lower portion of the dome 72. The spray siphon tube 58 extends from the spray head 52, through the neck 84 of the container 70, and into the liquid held in the upper chamber 76. (FIGS. 3-5).
A removable filling cap 86 is releasably attached to the dome 72 and can be removed to expose a filling orifice 94 in the dome for filling the upper chamber 76 with liquid. The removable filling cap 86 is tethered to the dome by a ring 88 and a strap 90 so that the when the cap is removed, it is retained with the container 70. The ring 88 is slightly smaller than a lip (not shown) around the filling orifice 94, so that the ring 88, strap 90, and filling cap 86 will not separate from the container 70.
The dome 72 also includes an angled guide tube 96 which guides a drinking straw 80 through a drinking orifice 98 in the dome 72 and into the lower chamber 78. (FIGS. 4 and 5). The guide tube 96 is cylindrical in shape and is slightly larger than the drinking straw 80 so that the user can slide the straw into the container 70, through the dome 72 and internal wall 82, and into the pre-packaged beverage container 79. The guide tube 96 forms a seal with both the dome 72 and the internal wall 82 so that the liquid in the upper chamber 76 does not leak outside the container 70 or into the lower chamber 78. The guide tube 96 ends in the center of a threaded connector 100 defined in the internal wall 82. (FIG. 4). The threaded connector 100 is sized to receive the pre-packaged beverage container 79 (shown in the form of a conventional 20 ounce plastic soft drink bottle) which has an approximately one inch mouth 104. The threaded connector 100 is constructed to mate with the threads formed to receive the cap (not shown) of the beverage container 79 when it is packaged. The cap is removed prior to connection to the threaded connector. The jacket 74 can then be screwed into the dome 72 to surround and insulate the beverage container 79. The pre-package beverage container 79 forms a drinking liquid compartment in the first embodiment. The jacket 74 may also form a drinking liquid compartment if no pre-package beverage container 79 is used.
In a second embodiment (FIG. 6), the liquid container 70 has only a single chamber 104 which holds liquid for both spraying and drinking. A pull up drinking cap 106 allows the user to drink from the container 70. The cap 106 is releasably attached by threaded connection to the container so that the cap can be removed to expose a larger opening (not shown) for filling the container 70. The bottom of the container 70 is a screw on cover 108 which can be removed from the container to expose a much larger opening for putting ice into the container. The cover 108 is constructed for sealing connection with the remainder of the container 70 when it is screwed onto the bottom of the container. The container 70 including the cover 108 preferably incorporate a thermally insulating material to keep the liquid inside the container cold. A pull off plug 110 on the container 70 is also provided so that a straw can be inserted into the container for drinking the liquid.
A third embodiment is closely similar to the second embodiment except that the liquid container 70 is divided internally into two compartments, the spraying liquid compartment 120 and the drinking liquid compartment 122. (FIG. 7). The drinking liquid compartment 122 is partitioned from the spraying liquid compartment 120 by means of a generally vertical internal wall 182, a bottom end wall 124, and the upper end of the container 70, entirely separating the drinking liquid compartment from the spraying liquid compartment, thereby preventing mixing of the two liquids. The vertical internal wall 182 is generally parallel to the sides of the container 70. The drinking liquid compartment 122 is closed at the top by the top of the container 70 and at the bottom by the bottom end wall 124. The spraying liquid compartment 120 includes the remaining internal space occupied by the liquid container 70.
In a fourth embodiment (FIG. 8), the liquid container 70 is again divided into upper and lower compartments 130, 132. The upper compartment 130 functions as both a spraying liquid compartment and a drinking liquid compartment. In this regard, it will be noted that the spray siphon tube 58 terminates within the upper compartment 130. In addition, the pull up cap 106 is in fluid communication with the upper compartment 130 for drinking and for refilling that compartment only. The lower compartment 132 holds liquid for drinking only.
The upper compartment 130 is constructed with internal threads in a bottom recess and the lower compartment 132 has external threads on an upper flange for threaded interconnection. The lower compartment 132 may be unscrewed and removed from the upper compartment 130 so that it can be used as a drink container apart from the rest of the apparatus. It is to be understood that other types of connections between the compartments 130, 132 are envisioned, such as a snap on connection.
The lower compartment 132 further contains a bottom recess 134 in the bottom where a pull top drinking cap 136 is threadably received on a threaded liquid container opening (not shown). The bottom recess 134 is of an adequate depth to ensure the pull top drinking cap 136 does not protrude beyond the bottom plane of the container 70. The recess 134 allows the container 70 to rest in a stable manner on a flat surface. A cover 138, which defines the recess 134 is attached by threads to the remainder of the lower compartment 132. Removal of the cover 138 permits access to the interior of the lower compartment 132 for re-filling and to add ice.
In a fifth embodiment (FIG. 9), the liquid container 70 is again separated into two compartments, the spraying liquid compartment 220 and the drinking liquid compartment 222. The releasable and replaceable drinking liquid compartment 222 fits into a complementary recess 151 formed on the spraying liquid compartment 220. Both compartments 220, 222 fit closely together to form a continuous, visually appealing surface. The drinking liquid compartment 222 is snapped and held in place by an interference fit created between a plurality of resilient tabs 152 formed on the drinking liquid compartment and a plurality of corresponding seats 154 formed in the spraying liquid compartment 220. The pull top drinking cap 106 is removably, threadably connected to a threaded liquid container opening of the drinking liquid compartment 222 and is engaged by lifting up the cap. The spraying siphon tube 58 is located in the spraying liquid compartment 220 for receiving liquid to be sprayed onto the user.
In a sixth embodiment (FIG. 10), the fan 12 and liquid spraying device 50 are replaced by a spraying assembly generally indicated at 150. The spraying assembly is constructed to spray water when a spray button 160 on the top of the spraying assembly is repeatedly depressed. (FIG. 10). The vertical motion of the button 160 draws liquid from the liquid container 70 into a spray siphon tube 58, and ejects it from the nozzle 54 which is incorporated into the button 160. This alternate construction of the liquid spraying assembly 150 is also well known in the art. It is to be understood that the spray button 160 may be used with all the previously described embodiments in place of the fan 12 and the spray assembly 50, as well as in other combinations.
A seventh embodiment (FIG. 11) is closely similar to the sixth embodiment shown in FIG. 10. However, a different form of liquid spraying assembly (indicated generally at 250) having a lever actuator 64 is used in place of the push button 160. The construction and operation of the spray assembly 250 is well known to those of ordinary skill in the art.
In an eighth embodiment (FIGS. 12, 13 and 13A), the liquid spray assembly 350 is a modification of the push button 160 of the sixth embodiment incorporating a pull top for drinking into a single combination cap 180. The combination cap 180 is threadably received on the threaded neck 182 of the container 70. As in the sixth embodiment, depressing the spray button 360 causes liquid to be pumped from the liquid container 70, through a spray siphon tube 58, and out the spray button nozzle 54. In addition, by lifting the pull top 256 up from the combination cap 180, the liquid drinking device is engaged and liquid will now pass from the liquid container 70 and through a passage 184 placed in the combination cap 180. (FIG. 13A). Once the pull top 256 is pulled upward, the drinking device of this embodiment functions similarly to the pull top drinking cap discussed previously. The pull top 256 is slidably received in an annular cavity in the spray button 360 for movement up and down relative to the spray button. Raising the pull top 256 lifts it off of a seat 258 formed in the button 360 at the end of the passage 184. Lowering the pull top 256 causes a friction fit between the top and the seat 258 which seals the passage.
Referring now to FIGS. 14-16, a fan blade assembly for use as a personal cooling device is indicated generally at 110. The fan blade assembly 110 comprises a hub 190 and a plurality of airfoil shaped blades 192 extending radially outward from the hub. The hub 190 is cylindrically formed from a rigid material having a cylindrical bore 194 located along its cylindrical axis for fixedly receiving a rotatable shaft 30 of a motor 20 (not shown). The rotatable shaft 30 may be rotated by any means and is fixedly held in the hub 190 such that the rotating shaft 30, hub 190, and fan blades 192 rotate together, creating an air stream 62.
The fan blades 192 comprise a rigid inner blade 196 attached to a more flexible and resilient outer blade 198. The face of the outer blade 198, larger than the inner blade 196, is fixedly attached to the face of the inner blade. The rigid inner blade 196 is fixedly attached to the hub 190. When the hub 190 rotates about its cylindrical axis, the rigid inner blade 196 simultaneously rotates and subsequently causes rotation of the outer blade 198. The inner blade 196 must be sufficiently rigid to withstand the rotational forces exerted by the hub 190 as well as the force due to air resistance exerted against it as it pushes the outer blade 198 through the air so as to substantially maintain the shape of the blade 192. The outer blade 198 must be sufficiently flexible and resilient such that an object, such as human skin, coming in contact with the blade 192 will not be damaged. In combination, the rigid backing blade 196 and soft outer blade 198 allow the size of the overall fan blade 192 to increase, while retaining the blade shape. Before the current invention, it is believed that soft blades were limited in size because they would deform unacceptably during rotation. The outer blade 198 edge may also be beveled or rounded to increase airflow.
Each fan blade 192 may, in another embodiment, be unitary construction and formed from a resilient closed cell foam of variable density. (FIG. 16). (e.g., Softlite Ionomer Foam, available from the Gilman Corporation of Gilman, Conn.). The blade 192 is constructed to have a higher density near the hub 190 and a proportionally lower density as the blade extends radially outward from the hub 190 toward the blade edge. The higher density portion 200 of the blade 192 near the hub 190 results in a correspondingly more rigid blade near the center, and the lower density portion 202 nearer the peripheral edge portions of the blade define a more flexible and resilient outer portion. The higher density portion 200 near the hub 190 allows the blade 192 to withstand the rotational force exerted by the rotating hub 190 while the lower density portion 202 allows the fan blade 192 to be soft, flexible, and non-dangerous during contact with human skin or other objects. The variable density foam permits the size of the overall fan blade 192 to increase to much larger sizes than previous soft bladed fans, while maintaining blade shape during rotation. The edge of the blade 192 may also be beveled or rounded.
In employing any embodiment, it is understood that a fan motor 20 (not shown), a shaft 30 (not shown), a fan housing 18 (not shown), a fan shroud 32 enclosing the blade assembly (not shown), a fan stand (not shown) or any other known fan component or apparatus may be added to the disclosed embodiments without departing from the scope of the invention.
In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.
As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
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A portable spraying and drinking apparatus with soft fan blades having a spraying apparatus, a drinking apparatus, and at least one container for holding drinking and/or spraying liquids. The spraying apparatus directs a cooling liquid through a nozzle placed in the air stream created by a portable fan. The airflow over wet surfaces increases cooling by speeding evaporation. The apparatus also has a separate drinking container which can be filled with a beverage in order to further hydrate and cool the user. The entire drinking and spraying containers can additionally have an insulating jacket surrounding them to keep the liquids cold.
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RELATED PATENT APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 09/662,981, filed Sep. 15, 2000, now U.S. Pat. No. 6,371,972, which is a continuation of U.S. patent application Ser. No. 09/330,462, filed Jun. 11, 1999 now abandoned, which is a continuation of U.S. patent application Ser. No. 09/025,707, filed Feb. 18, 1998, now U.S. Pat. No. 5,941,888; the entirety of each is hereby incorporated by reference.
FIELD OF THE INVENTION
This invention generally relates to the delivery of an occlusion device to a desired site in a mammal to facilitate the formation of mechanical blockage or thrombi in arteries, veins, aneurysms, vascular malformations and arteriovenous fistulas. More specifically, the invention involves one or more vaso-occlusive members that can be sequentially and selectively delivered by electrolytic detachment of a sacrificial link to a desired thrombus formation site. This invention permits a physician effectively to select the length of a vaso-occlusive device for delivery to a selected site without removing the delivery wire from the delivery catheter.
BACKGROUND OF THE INVENTION
Approximately 25,000 intracranial aneurysms rupture each year in North America. The primary purpose of treatment for a ruptured intracranial aneurysm is to prevent rebleeding. There are a variety of ways to treat ruptured and non-ruptured aneurysms.
Possibly the most widely known of these procedures is an extravascular approach using surgery or microsurgery. This treatment is common with intracranial berry aneurysms. The method comprises a step of clipping the neck of the aneurysm, performing a suture ligation of the neck, or wrapping the entire aneurysm. Each of these procedures is formed by intrusive invasion into the body and performed from the outside of the aneurysm or target site. General anesthesia, craniotomy, brain retraction, and placement of a clip around the neck of the aneurysm are typically required in these surgical procedures. The surgical procedure is often delayed while waiting for the patient to stabilize medically. For this reason, many patients die from the underlying disease or defect prior to the initiation of the procedure.
Another procedure—the extra-intravascular approach—involves surgically exposing or stereotactically reaching an aneurysm with a probe. The wall of the aneurysm is then perforated from the outside and various techniques are used to occlude the interior in order to prevent it from rebleeding. The techniques used to occlude the aneurysm include electrothrombosis, adhesive embolization, hog hair embolization, and ferromagnetic thrombosis. These procedures are discussed in U.S. Pat. No. 5,122,136 to Guglielmi et al., the entirety of which is incorporated by reference.
A still further approach is the least invasive and is additionally described in Guglielmi et al. It is the endovascular approach. In this approach, the interior of the aneurysm is entered by use of a catheter such as those shown in U.S. Pat. No. 4,884,575 and U.S. Pat. No. 4,739,768, both to Engelson. These patents describe devices utilizing core wires and catheters, respectively, which allow access to the aneurysm from remote portions of the body. By the use of catheters having very flexible distal regions and core wires which are steerable to the region of the aneurysm, embolic devices which may be delivered through the catheter are an alternative to the extravascular and extra-intravascular approaches.
The endovascular approach typically includes two major steps. The first step involves the introduction of the catheter to the aneurysm site using catheters such as shown in the Engelson patents. The second step often involves filling the aneurysm in some fashion or another. For instance, a balloon may be introduced into the aneurysm from the distal portion of the catheter where it is inflated, detached, and left to occlude the aneurysm. In this way, the parent artery is preserved. Balloons are becoming less favorable because of the difficulty in introducing the balloon into the aneurysm sac, the possibility of an aneurysm rupture due to overinflation of the balloon within the aneurysm, and the risk associated with the traction produced when detaching the balloon.
A highly desirable embolism-forming device which may be introduced into an aneurysm using endovascular placement procedures is found in U.S. Pat. No. 4,994,069 to Ritchart et al. The device, typically a platinum/tungsten alloy coil having a very small diameter, may be introduced into an aneurysm through a catheter such as those described in Engelson above. These coils are often made of wire having a diameter of 2-6 mils. The coil diameter may be 10-30 mils. These soft, flexible coils may be of any length desirable and appropriate for the site to be occluded. For instance, the coils may be used to fill a berry aneurysm. Within a short period of time after the filling of the aneurysm with the embolic device, a thrombus forms in the aneurysm and is shortly thereafter complemented with a collagenous material which significantly lessens the potential for aneurysm rupture. Coils such as those seen in Ritchart et al. may be delivered to the vasculature site in a variety of ways including, e.g., mechanically detaching them from the delivery device as is shown in U.S. Pat. No. 5,250,071 to Palermo, or by electrolytic detachment as is shown in Guglielmi et al. (U.S. Pat. No. 5,122,136) as discussed above.
Guglielmi et al. teaches an embolism-forming device and procedure for using that device. Specifically, Guglielmi et al. fills a vascular cavity such as an aneurysm with an embolic device such as a platinum coil which has been endovascularly delivered. The coil is then severed from its insertion tool by the application of a small electric current. Desirably, the insertion device involves a core wire which is attached at its distal end to an embolic device by an electrolytic, sacrificial joint. Guglielmi et al. suggests that when the embolic device is a platinum coil, the coil may have a length ranging from 1 cm to 50 cm or longer as is necessary. Proximal of the embolic coil is an insulated core wire or pusher wire, often stainless steel in construction. The core wire is used to push the platinum embolic coil, obviously with great gentleness, into the vascular site to be occluded. The Guglielmi et al. patent shows a variety of ways to link the embolic coil to the core wire. For instance, the core wire is tapered at its distal end and the distal tip of the core wire is welded into the proximal end of the embolic coil. Additionally, a stainless steel coil is wrapped coaxially about the distal tapered portion of the core wire to provide column strength to the core wire. This coaxial stainless steel wire is joined both to the core wire and to the embolic coil. Insulation may be used to cover a portion of the strength-providing stainless steel coil. This arrangement provides for two regions which must be electrolytically severed before the embolic coil is severed from the core wire.
A still further variation found in Guglielmi et al. includes a thin, threadlike extension between the core wire core and the proximal end of the embolic coil. In this way, the core wire does not extend to the embolic coil, but instead relies upon a separately introduced extension.
A continuation-in-part of the Guglielmi et al. patent discussed above, U.S. Pat. No. 5,354,295, describes the use of mechanically detachable embolic devices as well as those which are electrolytically detachable. The embolic devices may be augmented with attached filaments. U.S. Pat. No. 5,540,680, a continuation of U.S. Pat. No. 5,354,295, further describes such mechanically and electrolytically detachable embolic devices. U.S. Pat. No. 5,569,245, a continuation-in-part of the U.S. Pat. No. 5,540,680 patent, adds several new aspects including a new method for electrocoagulation.
A further variation of the Guglielmi et al. device is one in which the distal tip of the stainless steel core wire is crimped onto the proximal end of the embolic device. A simple tapered stainless steel wire extends from the stainless steel pusher wire to the embolic coil.
Taki et al. have devised a variation of the Guglielmi detachable coil using a copper link between the core wire and the coil, described in Treatment of a Spontaneous Carotid Cavernous Fistula Using an Electrodetachable Microcoil, American Journal of Neuroradiology , Vol. 14 (1993).
U.S. Pat. Nos. 5,423,829 and 5,624,449, both to Pham et al., describe an electrolytically detachable vaso-occlusive device containing a discrete sacrificial link between the core wire and the vaso-occlusive device to allow clean and quick detachment from the core wire, reducing the possibility of multiple electrolysis sites. The use of extensive electrical insulation about the core wire and sacrificial link as well as the use of scoring on the insulation to focus electrolysis on a targeted, specific site on the link is also taught by Pham et al.
In order to tailor the length of the vaso-occlusive member during implantation so to effectively treat the aneurysm, U.S. Pat. No. 5,522,836 to Palermo discloses a vaso-occlusive device such as a coil in which the length of the coil can be tailored during the procedure. This is accomplished by the use of an electrode which is movable relative to the vaso-occlusive coil.
U.S. Pat. No. 5,312,415 to Palermo teaches another device that enables more accurate placement of a vaso-occlusive coil. In this device, a catheter having a constricted or feathered distal end to retain vaso-occlusive coils on a core wire, allowing the delivery of a number of coils loaded on one pusher, thereby eliminating the need to remove the core wire from the catheter and re-insert it between coil deliveries.
None of the disclosed devices suggests the use of a vascular occlusion member assembly in which multiple vaso-occlusive devices can be selectively detached via multiple electrolytically disintegratible links.
SUMMARY OF THE INVENTION
This invention is a device for forming a vascular occlusion at a selected site. Generally, the device comprises a vaso-occlusive member having an electrically insulative joint located proximally on the vaso-occlusive member, an electrolytically disintegratible link located proximally of the insulative joint, and an electrically conductive region, which may be a section of conductive vaso-occlusive material, proximal of the link which connects to an additional vaso-occlusive member. In conjunction with this assembly is a delivery catheter having an integral distal electrode configured for electrical contact with the electrically conductive region of the vaso-occlusive members. These vaso-occlusive members may be placed nose-to-tail. Upon application of electric current to the electrically conductive region, a nearby electrolytically disintegratible link disintegrates, releasing a portion of the assembly. The presence of multiple disintegratible links, typically separated from each other by insulative joints, allows the placement of a selected number of vaso-occlusive members into the therapeutic site as the physician chooses. An alternative variation utilizes two catheters, one for delivering one or more vaso-occlusive members, the other for deploying an electrode for electrolytically detaching the desired number of vaso-occlusive members by disintegrating one of the links.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of one variation of the vaso-occlusive member assembly of the present invention.
FIG. 2 is the vaso-occlusive member assembly in conjunction with a delivery catheter containing an electrode.
FIG. 3 is a cross-sectional view of the distal end of a catheter containing an alternative electrode arrangement.
FIGS. 4A and 4B are cross-sectional and perspective views, respectively, of the distal end of a catheter containing another alternative electrode arrangement.
FIG. 5 schematically depicts the method of deploying the vaso-occlusive member assembly of the present invention into a vascular aneurysm.
FIG. 6 is an alternative variation of the present invention in which a second catheter containing an electrode is used for detaching the vaso-occlusive member.
DETAILED DESCRIPTION OF THE INVENTION
An artery, vein, aneurysm, vascular malformation or arterial fistula is occluded through endovascular occlusion by the endovascular insertion of a vaso-occlusive member into the vascular cavity. Because of the unique design of the present invention, the appropriate length vaso-occlusive member or members can effectively be selected by the physician without removal of the delivery wire from the delivery catheter.
FIG. 1 shows the basic vaso-occlusive assembly 100 of the present invention. The term “proximal” generally refers to the right side and the term “distal” generally refers to the left side of the figures in this document. Distal vaso-occlusive member 102 and proximal vaso-occlusive member 104 are shown as helical coils, although they may be any other suitable device or form, such as a ribbon, a braided member, or the like. Vaso-occlusive members 102 and 104 should be of a size sufficiently small that they may be advanced through a catheter (not shown) that is appropriately sized for accessing the targeted vascular site. For instance, when accessing a brain aneurysm in a small vessel, an appropriately sized catheter is quite small and very flexible. The vaso-occlusive member in such a situation must be small enough to fit through the catheter and out its distal end at the treatment site. Optionally, vaso-occlusive members 102 and 104 may be elongated, depending upon the form the vaso-occlusive member takes. For instance, if vaso-occlusive members 102 and 104 are in the form of coils as shown in FIG. 1, they may be elongated by containing an increased number of total windings from their proximal to distal ends. As shown in FIG. 1, vaso-occlusive assembly 100 can consist of multiple vaso-occlusive members 102 and 104 . Additionally, assembly 100 may consist of any number of vaso-occlusive members, depending on the specific treatment desired by the physician.
Vaso-occlusive members 102 and 104 are desirably made up of a radiopaque, physiologically compatible material. Suitable metals and alloys for the wire making up those regions include the Platinum Group metals, especially platinum, rhodium, palladium, rhenium, as well as tungsten, gold, silver, tantalum, and alloys of these metals. These metals have significant radiopacity and in their alloys may be tailored to accomplish an appropriate blend of flexibility and stiffness. They are also largely biocompatible. Highly preferred is a platinum/tungsten alloy, e.g., 8% tungsten and the remainder platinum.
Certain polymers are also suitable as vaso-occlusive member material either alone or in conjunction with metallic markers to provide radiopacity. These materials are chosen so that the procedure of locating the vaso-occlusive member within the vessel may be viewed using radiography. However, it is also contemplated that the vaso-occlusive members may be made of various other biocompatible polymers or of carbon fibers. The vaso-occlusive device may be covered or connected with fibrous materials tied to the outside of the coil or braided onto the outer cover of the coil as desired. Such fibrous adjuvants may be found in U.S. Pat. Nos. 5,354,295 to Guglielmi et al., 5,382,259 to Phelps et al., or 5,226,911 to Chee et al.; the entirety of each are incorporated herein by reference. The particular form and choice of material used for the vaso-occlusive members will of course depend on the desired application. It is preferred that at least one of the vaso-occlusive members be electrically conductive so to make possible electrolytic separation of the assembly as will be described below.
When one or more of the vaso-occlusive members is a coil, its shape and constituent winding will depend upon the use to which the coil will be placed. For occluding peripheral or neural sites, the coils will typically be made of 1 mil to 5 mil diameter wire (platinum or platinum/tungsten alloy) that may be wound to have an inner diameter of 5 mils to 60 mils with a minimum pitch—that is to say that the pitch is equal to the diameter of the wire used in the coil. The outer diameter is then typically between 0.007 and 0.700 inch.
The length of the coil will normally be in the range of 0.5 to 60 cm, preferably 0.5 to 40 cm. As discussed in conjunction with FIG. 2 below, any number of vaso-occlusive devices may be used in the present invention, subject to considerations of safety, the length of the coils chosen, the therapy being administered by the attending physician, and the desire to maintaining the overall optimal stiffness of the vaso-occlusive member assembly. When, for instance, the vaso-occlusive members are coils, anywhere from two to twenty coils may be used, with a preferable number being two to ten, and an even more preferable number being two to five. Balancing the tendency for the overall stiffness of the joined coil assembly to increase with additional coils versus safety and other considerations is critical in determining the optimal number of coils or other vaso-occlusive members to be used in the present invention.
If desired, the coils may be formed in such a way that they are essentially linear as they pass through the catheter and yet assume a randomly oriented relaxed condition after they are released from the distal end of the catheter. A discussion of this variation may be found in U.S. Pat. No. 4,994,069 to Ritchart et al.
Electrolytically disintegratible link 106 is shown between vaso-occlusive members 102 and 104 in FIG. 1 . Link 106 is preferable bare and is relatively more susceptible to electrolysis in an ionic solution such as blood or most other bodily fluids than is vaso-occlusive members 102 and 104 . Alternatively, link 106 may be tapered or otherwise modified, or coated with a layer 107 of an insulative polymer and scored to form a groove 109 , such as described in U.S. Pat. No. 5,624,449 to Pham et al., the entirety of which is incorporated herein by reference, to limit the area of electrolytic disintegration of link 106 to a more discrete region or point. For all figures herein, the electrolytically disintegratible link may take the form of a straight member (as shown in FIG. 1 for link 106 ), or it may take the form of other shapes; for example, a coil. One advantage of having link 106 take the form of a coil is that this configuration would help preserve the uniform diameter of vaso-occlusive members 102 and 104 .
Central to this invention is electrical isolation of vaso-occlusive members 102 and 104 by electrically insulative joint 108 , which joins the proximal end of vaso-occlusive member 102 to link 106 . Without wishing to be bound by theory, it is believed that electrical isolation of vaso-occlusive members 102 and 104 prevents or lessens current flow through the vaso-occlusive members and concentrates the current flow through link 106 . Preferably, as shown in FIG. 1, insulative joint 108 surrounds link 106 and is contained within the lumen defined by vaso-occlusive member 102 .
Insulative joint 108 serves two primary functions. The first is to electrically insulate link 106 from vaso-occlusive member 102 so that electrical energy is not transmitted from the link to vaso-occlusive member or any part of the assembly of the present invention distal to the particular link 106 selected for electrolytic disintegration. The second is to reliably and fixedly join link 106 to vaso-occlusive member 102 .
Preferably, electrically insulative joint 108 is comprised of a biocompatible, electrically insulative material such as polyfluorocarbons (e.g. TEFLON), polyethylene terepthalate, polypropylene, polyurethane, polyimides, polyvinylchloride, and silicone polymers.
In addition to the polymers listed above, another desirable material is generically known as parylene. There are a variety of polymers (e.g., polyxylylene) based on para-xylylene. These polymers are typically placed onto a substrate by vapor phase polymerization of the monomer. Parylene N coatings are produced by vaporization of a di(P-xylylene) dimer, pyrolization, and condensation of the vapor to produce a polymer that is maintained at a comparatively lower temperature. In addition to parylene-N, parylene-C is derived from di(monochloro-P-xylylene) and Parylene-D is derived from di(dichloro-P-xylylene). There are a variety of known ways to apply parylene to substrates. Their use in surgical devices has been shown, for instance, in U.S. Pat. Nos. 5,380,320 (Morris), 5,174,295 (Christian et al.), 5,067,491 (Taylor et al.), and the like.
Alternatively, thermoplastic materials such as those disclosed in U.S. Pat. No. 5,944,733 to Engelson, the entirety of which is hereby incorporated herein by reference, are contemplated for use as adhesives in comprising insulative joint 108 in the present invention, alone or in combination with the other polymers herein described.
The thermoplastic, polymer or combination of such used to comprise insulative joint 108 may be formed in any number of ways. One technique, for example, is dipping or coating link 106 in a molten or substantially softened polymer material, but other techniques as known in the art, such as shrink-wrapping, line-of-sight deposition in the form of a suspension or latex, or others may be used as well.
Another material that may be used for electrically resistive insulative joint 108 , alone or in combination with one or more thermoplastic or polymer layer, is a biocompatible and electrically resistive metallic oxide. Oxides with a high dielectric constant, such as those of tantalum or titanium or their alloys, are preferred, with the various oxides of tantalum as most preferred. Such oxides can be formed in any number of ways. For example, they may be in the form of a deposited film, such as that made by plasma deposition of the base metal (e.g., in elemental or alloy form), or they may exist in the form of a sleeve or hypotube of the base metal that is welded, brazed, soldered, mechanically joined, or otherwise fixed to link 106 . This base metal layer can then be subsequently oxidized (by imposition of the appropriate electrical current or other such excitation, such as by welding during assembly of the device) to form the desired electrically insulative oxide layer. Alternatively, the oxide may be deposited directly in oxide form by any number of techniques that does not require subsequent oxidation of the base metal in elemental or alloy form.
Whether electrically insulative joint 108 is comprised of a monolithic layer of a single polymer or thermoplastic, multiple layers of various polymers or thermoplastics, or an electrically insulative metallic oxide (alone or in combination with any number of polymers or thermoplastics), its thickness (as measured radially outward from the surface of link 106 towards vaso-occlusive member 102 ) can range from 0.002 inch to 0.040 inch, with 0.001 inch to 0.018 inch being preferred and 0.003 inch to 0.0010 inch as most preferred. It is preferred that the total thickness of insulative joint 108 be no greater than 0.060 inch (or, alternatively, no greater than the inner diameter of vaso-occlusive member 102 and no less than the minimum to allow insulative joint 108 to perform its intended functions of joining and electrically insulating vaso-occlusive member 102 and link 106 .
The optimal thickness of each layer will depend on the desired thermal, electrical and mechanical properties of the insulative joint 108 , the types and combinations of materials used, dimensional constraints relative to link 106 and vaso-occlusive member 102 , and manufacturing, engineering, cost and other factors as well. For instance, the thickness of insulative joint 108 can range from one or a few hundred angstroms (for example if an oxide layer was used) to as thick as the remaining inner diameter of the vaso-occlusive member 102 (for example if a polymer or thermoplastic was used), taking into consideration the diameter of link 106 , in which it is positioned. This latter thickness is especially desirable from a manufacturing standpoint as the insulative joint 108 most readily serves its two aforementioned functions of electrical insulation and joining.
Insulative joint 108 may join vaso-occlusive member 102 to link 106 by any number of various techniques. For example, joint 108 may be formed by an interference, or friction, fit. Alternatively, insulative joint 108 can be formed by line-of-sight deposition methods while link 106 and vaso-occlusive member 102 are aligned in the desired position so that as link material is deposited, it “fixes” the link 106 and vaso-occlusive member 102 into a locked position relative to one another.
Proximal of link 106 , electrically conductive joint 110 joins the distal end of vaso-occlusive member 104 to link 106 . Preferably, as shown in FIG. 1, conductive joint 110 surrounds link 106 and is contained within the lumen defined by vaso-occlusive member 104 .
Conductive joint 110 serves two primary functions. The first is to provide an electrical pathway between link 106 from vaso-occlusive member 104 so that electrical current is readily transmitted between these two members. The second is to reliably and fixedly join link 106 to vaso-occlusive member 104 .
Conductive joint 110 can be made from any biocompatible, electrically conductive material, preferably a suitable metal such as platinum or stainless steel hypotubing. In addition, a superelastic material such as nitinol may be used if desired; however, care must be taken in this case to keep it free from surface oxidation prior to fixing the joint 110 to the coil (such as by fabrication in a substantially oxygen-free environment or by plating the joint 110 with a conductive metal such as, for example, gold, silver, etc.). If conductive joint 110 comprises a stainless steel hypotube, the joint may be assembled by welding, brazing, soldering, mechanically joining (as by crimping, for example) or otherwise connecting a hypotube having a wall thickness appropriate to join link 106 and vaso-occlusive member 104 to proximal end of link 106 . This hypotube is then welded, brazed, soldered, or otherwise fixed to vaso-occlusive member 104 .
FIG. 2 shows, in partial cross-section, a series of vaso-occlusive members as described according to FIG. 1 in cooperation with the distal end of a catheter 202 having distal electrode 204 similar to that described in U.S. Pat. No. 6,059,779 to Mills, the entirety of which is incorporated by reference.
Preferably, and as described in U.S. Pat. No. 6,059,779, catheter 202 comprises an elongated tubular member or tube having a laminate structure comprising a pair of concentrically arranged tubular members or tubes 206 and 208 . The inner surface or wall of first tube 206 defines lumen 210 through which the vaso-occlusive members, numbered generally as 212 , are passed. Other catheter constructions may be used without departing from the scope of the invention.
Catheter 202 is preferably equipped with an annular distal electrode 204 , partially embedded between first tube 206 and second tube 208 , as shown in FIG. 2 . Electrode 204 may comprise any conductive biocompatible material. For example, electrode 204 may comprise conductive metals and their alloys (for example, steel, titanium, copper, platinum, nitinol, gold, silver or alloys thereof), carbon (fibers or brushes), electrically conductive doped polymers or epoxies, or any combination thereof. In this variation, electrode 204 and tubes 206 and 208 are preferably designed so that the electrode 204 and catheter lumen 210 present a continuous, nonobstructed, smooth surface to allow vaso-occlusive member 212 to pass smoothly out of the distal end of catheter 202 . Such an annular construction maximizes the electrode's exposed surface area so to increase current flow efficiencies by avoiding too large a current density passing therethrough. Finally, it is preferred in this variation that distal surface 214 of electrode 204 is substantially flush with the distal surface 216 of catheter 202 . However, other configurations wherein the electrode 204 is spaced inwardly from the distal surface 216 of catheter 202 to eliminate or minimize interference with other vaso-occlusive members, as disclosed in U.S. Pat. No. 6,059,779, is also within the scope of this invention. In the case where electrode 204 is spaced inwardly, it is preferred that the maximum offset from the distal surface 216 of catheter 202 be the distance between electrolytically disintegratible links 224 . Likewise, configurations in which electrode 204 is spaced outwardly from the distal surface 216 of catheter 202 to ensure conductive contact with vaso-occlusive member 212 may also be used.
Catheter 202 is further provided with a conductor 218 . As shown in FIG. 2, conductor 218 is in the form of an annular extension of electrode 204 . Alternatively, conductor 218 can be in the form of a wire or ribbon whose distal end is coupled, for example by welding, to electrode 204 . Conductor 218 extends from electrode 204 between tubular members 206 and 208 to proximal end portion of catheter 202 where it can be electrically connected to a power supply either directly or with a lead as would be apparent to one of ordinary skill in the art.
Vaso-occlusive members 212 are as described above in conjunction with FIG. 1 . Accordingly, each is provided on its proximal end with an electrically insulative joint 222 joining vaso-occlusive member 212 to electrolytically disintegratible link 224 . Likewise, link 224 is affixed to the distal end of vaso-occlusive member 212 via electrically conductive joint 226 as described above. The most proximal of vaso-occlusive members 212 , which in FIG. 2 is depicted as located within the lumen 210 of catheter 202 , is connected to a core wire 228 via electrically insulative joint 222 . This core wire 228 is used by the physician to advance the series of vaso-occlusive members 212 through the catheter lumen and to the desired therapeutic site as is well-known in the art.
Although the configuration of insulative joint 222 being distal to conductive joint 226 , as shown in FIG. 2, is preferable, it is also within the scope of this invention to switch the respective locations of these elements so that insulative joint 222 lies proximal to conductive joint 226 . In this latter alternative configuration, detachment will occur by electrolytic dissolution of a link 224 that is positioned proximal of electrode 204 .
An alternative electrode-catheter configuration is shown in cross section in FIG. 3 . In this variation, conductor 300 is connected to, or can be an integral part of, electrode 302 . Electrode 302 is partially covered and conductor 300 is completely covered on the inner diameter of catheter 304 with an electrically insulative covering 306 . This covering serves to electrically isolate conductor 300 and all but a distal section of electrode 302 from the lumen of catheter 304 , as well as to provide a continuous, nonobstructed, smooth surface to allow vaso-occlusive members (not shown) to pass smoothly out of the distal end 308 of catheter 304 . Electrically insulative covering 306 may be comprised of an electrically insulative polymer or polymers as described above, and may additionally or singly comprise an electrically insulative metallic oxide such as tantalum oxide or the like. In this configuration, conductor 300 may, for example, be a metallic braid, while electrode 302 may, for example, be a platinum or platinum alloy hypotube. Of course, conductor 300 and electrode 302 can take other forms or configurations. Electrode 302 may also extend beyond the distal end 308 of catheter 304 to ensure electrical contact with vaso-occlusive members.
It is within the scope of this invention for the electrode to take on other forms, for example, a tubular braided structure such as described in U.S. Pat. No. 6,059,779. A braided configuration has the advantage of allowing the designer to vary the stiffness of the catheter by varying the mesh size of the braid along the length of the catheter.
Although FIG. 3 shows electrode 302 to be substantially flush with the distal surface 308 of catheter 304 , electrode 302 can be spaced inwardly from the distal surface 308 of catheter 304 to eliminate or minimize interference with other vaso-occlusive members. Likewise, electrode 302 can be spaced outwardly from the distal surface 308 of catheter 304 to ensure conductive contact with a vaso-occlusive member.
Turning now to FIGS. 4A and 4B, yet another variation of the electrode design which additionally accommodates vaso-occlusive members of different sizes is presented. In this configuration, the electrode consists of one or more radial extensions 402 located near the distal end of catheter 404 . Radial extensions 402 extend radially towards the center of the catheter lumen from an electrically connected embedded conductor 406 . Extensions 402 can be arranged symmetrically along the circumference of catheter 404 as shown in FIGS. 4A and 4B, or they may be arranged asymmetrically depending on the design of the invention. Although four extensions 402 are shown in FIGS. 4A and 4B, it is anticipated that from 1 to 10 extensions can exist in the distal end of catheter 404 .
Extensions 402 can comprise any electrically conductive material, as discussed before, such as stainless steel, platinum, or nitinol, for example. It is important that extensions 402 be comprised of a material that has a relatively high degree of flexibility to allow passage of vaso-occlusive members (not shown) through the distal end of catheter 404 while being stiff enough to maintain electrical contact with the vaso-occlusive members so that electrical energy can be transmitted to the electrolytically disintegratible link (not shown).
Additionally, FIGS. 4A and 4B shows a preferred configuration for extensions 402 . In this variation, extensions 402 are disposed at an acute angle α as measured from the catheter inner surface on the distal side of extension 402 . This design facilitates passage of vaso-occlusive members out through the distal end of catheter 404 and into the therapeutic site, while simultaneously hindering motion in the opposite direction back into the lumen of catheter 404 . It is contemplated that extensions 402 can be disposed at an angle α which is acute or even, in some cases, ninety degrees or slightly obtuse.
Extensions 402 can be in the form of ribbons, for example, that are welded, brazed, soldered, glued, or otherwise electrically and fixedly attached to conductor 406 . Extensions 402 may also be an integral part of conductor 406 . For example, extensions 402 can be cut from a nitinol hypotube on three sides and bent to the desired angle α along the still-intact fourth side which joins the hypotube. This hypotube can then be assembled with catheter 202 . Alternatively, extensions 402 can be formed from one or more coils.
FIG. 5 shows placement of a vaso-occlusive member 502 of the present invention within a vessel 504 with the distal end of catheter 506 placed near neck 508 of aneurysm 510 . Conventional catheter insertion and navigational techniques involving core wires or flow-directed devices may be used to access the aneurysm 510 . Once the distal end of catheter 506 is positioned at the site, often by locating its distal end through the use of radiopaque marker material and fluoroscopy, the catheter is cleared. For instance, if a core wire has been used to position the catheter, it is withdrawn from the catheter and then the core wire 512 having any number of vaso-occlusive members 502 at the distal end is advanced through the catheter. The core wire 512 is advanced so that the link 522 to be electrolytically severed is just outside the distal end of catheter 506 and is in electrical contact with the electrode 514 through conductive joint 516 . To assist the physician in positioning the desired link 522 to be electrolytically detached, radiopaque marker 524 can be used. Because different occlusions, such as aneurysm 510 , will require varying amounts of vaso-occlusive material for proper treatment, it may be necessary to deploy multiple vaso-occlusive members 522 into aneurysm 510 . With the assistance of radiopaque marker 524 , the physician can selectively deploy one or more vaso-occlusive member 502 into the aneurysm 510 as required until the aneurysm 510 has been sufficiently filled.
This marker 524 , which is preferably comprised of a platinum hypotube, is embedded in catheter 506 and spaced proximally from the distal end of catheter 506 a distance that corresponds to the spacing between link 522 and link 526 . Vaso-occlusive members 502 preferably are radiopaque while links 522 and 526 preferably are not.
When used in combination with electrode 514 (which can serve as or can additionally contain a radiopaque marker to indicate the distal end of catheter 504 ), a physician positions wire 512 so that link 526 is centered under radiopaque marker 524 as shown in FIG. 5 . By doing so, the physician will know that the next most distal link 522 is positioned just distal of electrode 514 (through conductive joint 516 ) and that electrolytic detachment will occur at distal link 522 .
Depending on constraints such as the condition and size of the occlusion, the physician may desire to use vaso-occlusive members 502 of varying length. Therefore, it is contemplated that catheter 504 can contain multiple radiopaque markers 524 , each positioned in from the distal end of catheter 504 a distance corresponding to the spacing between links that separate vaso-occlusive members of varying length. This will give the physician maximum flexibility in accurately, reliably, and safely deploying any number of vaso-occlusive members of identical or varying lengths, singly or in combination, into the site to be occluded.
A positive electric current of approximately 0.01 to 2 milliamps at 0.1 to 6 volts is next applied to core wire 512 by power supply 518 to form a thrombus within aneurysm 510 . Typically, the negative pole 520 of power supply is placed in electrical contact with the skin.
After the thrombus has been formed and the aneurysm occluded, link 522 just distal of electrode 514 is electrolytically disintegrated, detaching the desired number of vaso-occlusive devices from core wire 512 .
After link 522 is completely dissolved or eroded by electrolytic action, typically within 0.5 to 10 minutes, the core wire 512 and catheter 506 are removed from vessel 504 , leaving aneurysm 510 occluded.
Finally, FIG. 6 illustrates an alternative variation of the inventive device as used in a mammal vasculature (not shown). In this configuration, catheter 602 containing core wire (not shown) and vaso-occlusive member 606 does not contain an electrode. A second microcatheter 608 containing an electrode 610 is used to access an exposed electrolytically disintegratible link 612 or vaso-occlusive member 606 to electrolytically disintegrate link 612 and detachment of the desired number of vaso-occlusive members 606 into the therapeutic site.
Although shown in FIG. 6 as an elongated wire, electrode 610 may take any number of forms as long as it effectively transmits electric current to a vaso-occlusive member 606 or link 612 . Additionally, although first catheter 602 is shown in FIG. 6 as not having an electrode, this is not required. For example, a dual-catheter system in which the first catheter 602 contains an electrode that has become inoperative is within the scope of the invention.
Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. The illustrated variations have been used only for illustration and clarity and should not be taken as limiting the invention as defined by the following claims.
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This device is an apparatus for endovascular occlusion through the formation of thrombi in arteries, veins, aneurysms, vascular malformations, and arteriovenous fistulas. In particular, the device includes multiple vaso-occlusive members connected by electrolytically disintegratible links. Each link connects to the vaso-occlusive member by electrically insulative and conductive joints on opposite ends of the link. The vaso-occlusive members are delivered through a delivery catheter having on its distal end an electrode for electrical contact with the vaso-occlusive member. Upon application of an electrical current through the electrode to the vaso-occlusive member and its conductive joint to the electrolytically disintegratible link, the link disintegrates, selectively detaching the desired number of vaso-occlusive members into the target thrombus formation site.
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This application claims benefit of U.S. Provisional patent application No. 60/529,932, filed Dec. 16, 2003.
BACKGROUND OF THE INVENTION
The present invention is directed to peptide analogues of glucagon-like peptide-1, the pharmaceutically-acceptable salts thereof, to methods of using such analogues to treat mammals and to pharmaceutical compositions useful therefor comprising said analogues.
Glucagon-like peptide-1 (7-36) amide (GLP-1) is synthesized in the intestinal L-cells by tissue-specific post-translational processing of the glucagon precursor preproglucagon (Varndell, J. M., et al., J. Histochem Cytochem, 1985:33:1080-6) and is released into the circulation in response to a meal. The plasma concentration of GLP-1 rises from a fasting level of approximately 15 pmol/L to a peak postprandial level of 40 pmol/L. It has been demonstrated that, for a given rise in plasma glucose concentration, the increase in plasma insulin is approximately threefold greater when glucose is administered orally compared with intravenously (Kreymann, B., et al., Lancet 1987:2, 1300-4). This alimentary enhancement of insulin release, known as the incretin effect, is primarily humoral and GLP-1 is now thought to be the most potent physiological incretin in humans. In addition to the insulinotropic effect, GLP-1 suppresses glucagon secretion, delays gastric emptying (Wettergren A., et al., Dig Dis Sci 1993:38:665-73) and may enhance peripheral glucose disposal (D'Alessio, D. A. et al., J. Clin Invest 1994:93:2293-6).
In 1994, the therapeutic potential of GLP-1 was suggested following the observation that a single subcutaneous (s/c) dose of GLP-1 could completely normalize postprandial glucose levels in patients with non-insulin-dependent diabetes mellitus (NIDDM) (Gutniak, M. K., et al., Diabetes Care 1994:17:1039-44). This effect was thought to be mediated both by increased insulin release and by a reduction in glucagon secretion. Furthermore, an intravenous infusion of GLP-1 has been shown to delay postprandial gastric emptying in patients with NIDDM (Williams, B., et al., J. Clin Endo Metab 1996:81:327-32). Unlike sulphonylureas, the insulinotropic action of GLP-1 is dependent on plasma glucose concentration (Holz, G. G. 4 th , et al., Nature 1993:361:362-5). Thus, the loss of GLP-1-mediated insulin release at low plasma glucose concentration protects against severe hypoglycemia. This combination of actions gives GLP-1 unique potential therapeutic advantages over other agents currently used to treat NIDDM.
Numerous studies have shown that when given to healthy subjects, GLP-1 potently influences glycemic levels as well as insulin and glucagon concentrations (Orskov, C, Diabetologia 35:701-711, 1992; Holst, J. J., et al., Potential of GLP -1 in diabetes management in Glucagon III, Handbook of Experimental Pharmacology, Lefevbre P J, Ed. Berlin, Springer Verlag, 1996, p. 311-326), effects which are glucose dependent (Kreymann, B., et al., Lancet ii: 1300-1304, 1987; Weir, G. C., et al., Diabetes 38:338-342, 1989). Moreover, it is also effective in patients with diabetes (Gutniak, M., N. Engl J Med 226:1316-1322, 1992; Nathan, D. M., et al., Diabetes Care 15:270-276, 1992), normalizing blood glucose levels in type 2 diabetic subjects (Nauck, M. A., et al., Diagbetologia 36:741-744, 1993), and improving glycemic control in type 1 patients (Creutzfeldt, W. O., et al., Diabetes Care 19:580-586, 1996), raising the possibility of its use as a therapeutic agent.
GLP-1 is, however, metabolically unstable, having a plasma half-life (t 1/2 ) of only 1-2 min in vivo. Exogenously administered GLP-1 is also rapidly degraded (Deacon, C. F., et al., Diabetes 44:1126-1131, 1995). This metabolic instability limits the therapeutic potential of native GLP-1.
A number of attempts have been taken to improve the therapeutic potential of GLP-1 and its analogs through improvements in formulation. For example, International patent publication no. WO 01/57084 describes a process for producing crystals of GLP-1 analogues which are said to be useful in the preparation of pharmaceutical compositions, such as injectable drugs, comprising the crystals and a pharmaceutical acceptable carrier. Heterogeneous micro crystalline clusters of GLP-1(7-37)OH have been grown from saline solutions and examined after crystal soaking treatment with zinc and/or m-cresol (Kim and Haren, Pharma. Res. Vol. 12 No. 11 (1995)). Crude crystalline suspensions of GLP(7-36)NH 2 containing needle-like crystals and amorphous precipitation have been prepared from phosphate solutions containing zinc or protamine (Pridal, et. al., International Journal of Pharmaceutics Vol. 136, pp. 53-59 (1996)). European patent publication no. EP 0619322A2 describes the preparation of micro-crystalline forms of GLP-1 (7-37)OH by mixing solutions of the protein in pH 7-8.5 buffer with certain combinations of salts and low molecular weight polyethylene glycols (PEG). U.S. Pat. No. 6,566,490 describes seeding microcrystals of, inter alia, GLP-1 which are said to aid in the production of purified peptide products. U.S. Pat. No. 6,555,521 (US '521) discloses GLP-1 crystals having a tetragonal flat rod or a plate-like shape which are said to have improved purity and to exhibit extended in vivo activity. US '521 teaches that such crystals are relatively uniform and remain in suspension for a longer period of time than prior crystalline clusters and amorphous crystalline suspensions which were said to settle rapidly, aggregate or clump together, clog syringe needles and generally exacerbate unpredictable dosing.
A biodegradable triblock copolymer of poly [(dl-lactide-co-glycolide)-b-ethylene glycol-b-(-lactide-co-glycolide)] has been suggested for use in a controlled release formulation of GLP-1. However like other polymeric systems, the manufacture of triblock copolymer involves complex protocols and inconsistent particulate formation.
Similarly, biodegradable polymers, e.g., poly(lactic-co-glycolic acid) (PLGA), have also been suggested for use in sustained delivery formulations of peptides. However the use of such biodegradable polymers has been disfavored in the art since these polymers generally have poor solubility in water and require water-immiscible organic solvents, e.g., methylene chloride, and/or harsh preparation conditions during manufacture. Such organic solvents and/or harsh preparation conditions are considered to increase the risk of inducing conformational change of the peptide or protein of interest, resulting in decreased structural integrity and compromised biological activity. (Choi et al., Pharm. Research, Vol. 21, No. 5, (2004).) Poloxamers have been likewise faulted. (Id.)
The GLP-1 compositions described in the foregoing references are less than ideal for preparing pharmaceutical formulations of GLP's since they tend to trap impurities and/or are otherwise difficult to reproducibly manufacture and administer. Also, GLP analogs are known to induce nausea at elevated concentrations, thus there is a need to provide a sustained drug effect with reduced initial plasma concentrations. Hence, there is a need for GLP-1 formulations which are more easily and reliably manufactured, that are more easily and reproducibly administered to a patient, and that provide for reduced initial plasma concentrations in order to reduce or eliminate unwanted side-effects.
SUMMARY OF THE INVENTION
The invention may be summarized in the following paragraphs (1) through (67), below, as well as the claims. Accordingly:
(1) In one aspect the present invention is directed to a pharmaceutical composition comprising at least one insulinotropic molecule from glucagon-like peptide-1, exendin4, and analogs and derivatives thereof, whose aqueous solubility is lower than 1 mg/mL, preferably lower than 0.5 mg/mL, at pH between 6 and 8 and at about 4-40° C. (2) Preferably said insulinotropic molecule has an isoelectric point about 5-9, more preferably about 6-8, provided that the molecule is not human GLP-1 (7-36)NH 2 or human GLP-1 (7-37)-OH. (3) In one embodiment the invention features a composition according to paragraph (1), further comprising water. (4) A composition according to any one of paragraphs (1) to (3), further comprising non-aqueous medium. (5) A composition according to any one of paragraphs (1) to (4) wherein the molecule is present in an aqueous solution with pH lower than 7, preferably lower than 5. (6) A composition according to any one of paragraphs (1) to (5), wherein the molecule is present in a clear solution with pH equal or lower than 4.5. (7) A composition according to any one of paragraphs (1) to (4), wherein the molecule is present in an aqueous solution with pH higher than 7, preferably higher than 8. (8) A composition according to paragraph (7), wherein the molecule is present in a clear solution with pH equal or higher than 10. (9) A composition according to any one of paragraphs (1) to (4), wherein the particles of the molecule are present in an aqueous suspension or gel. (10) A composition according to paragraphs (9), wherein the particles of the molecule are present in an aqueous suspension or gel with pH about 4-10. (11) A composition according to any one of paragraphs (1) to (3), wherein the particles of the molecule are present in a non-aqueous medium. (12) A composition according to any one of paragraphs (1) to (11), wherein the molecule is present in a concentration of about 0.001-500 mg/mL, preferable about 0.1-10 mg/mL. (13) A composition according to any one of paragraphs (1) to (12), further comprising a preservative. (14) A composition according to paragraph (13), wherein said preservative is selected from the group consisting of m-cresol, phenol, benzyl alcohol and methyl paraben. (15) A composition according to paragraph (14), wherein said preservative is present in a concentration from 0.01 mg/mL to 50 mg/mL. (16) A composition according to any one of paragraphs (1) to (15), further comprising an isotonic agent. (17) A composition according to paragraphs (1) to (16), wherein said isotonic agent is present in a concentration from 0.01 mg/mL to 50 mg/mL. (18) A composition according to any one of paragraphs (1) to (17), further comprising Aa divalent ion, preferably zinc. (19) A composition according to paragraph (18), wherein said zinc is present in a concentration from 0.0005 mg/mL to 50 mg/mL. (20) A composition according to any one of paragraphs (1) to (19), further comprising a stabilizer. (21) A composition according to paragraph (20), wherein said stabilizer is selected from the group consisting of imidazole, arginine and histidine. (22). A composition according to any one of paragraphs (1) to (21), further comprising a surfactant. (23) A composition according to any one of paragraphs (1) to (22), further comprising a chelating agent. (24) A composition according to any one of paragraphs (1) to (23), further comprising a buffer. (25) A composition according to paragraph (24), wherein said buffer is selected from the group consisting of Tris, ammonium acetate, sodium acetate, glycine, aspartic acid, and Bis-Tris. (26) A composition according to any one of paragraphs (1) to (25), further comprising a basic polypeptide. (27) A composition according to paragraphs (26), wherein said basic polypeptide is selected from the group consisting of polylysine, polyarginine, polyornithine, protamine, putrescine, spermine, spermidine, and histone. (28) A composition according to any one of paragraphs (1) to (27), further comprising alcohol or mono or disaccharide. (29) A composition according to paragraph (28), wherein said alcohol or mono or disaccharide is selected from the group consisting of methanol, ethanol, propanol, glycerol, trehalose, mannitol, glucose, erythrose, ribose, galactose, fructose, maltose, sucrose, and lactose. (30) A composition according to any one of paragraphs (1) to (29), further comprising ammonium sulfate. (31) The composition of any one of paragraphs (1) to (30), wherein the molecule is selected from the group consisting of GLP-1 analogs and derivatives that have at least two residues selected from the group consisting of L- or D-Arg and L- or D-hArg. (32) The composition of paragraph (31), wherein the molecule is selected from the group consisting of GLP-1 analogs and derivatives, wherein at least one of residues 26 and 34 is L- or D-Arg or L- or D-hArg. (33) The composition of paragraph (32), wherein the said GLP-1 analog is a compound according to formula (I)
H-A 7 -A 8 -A 9 -A 10 -A 11 -A 12 -A 13 -A 14 -A 15 -A 16 -A 17 -A 18 -A 19 -A 20 -A 21 -A- 22 -A 23 -A 24 -A 25 -A 26 -A 27 -A 28 -A 29 -A 30 -A 31 -A 32 -A 33 -A 34 -A 35 -A 36 -A 37 -R 1 , (I)
wherein:
A 7 is L-His or deleted; A 8 is Ala, D-Ala, Aib, Gly, Ser, Gly, β-Ala, Val, Acc, N-Me-Ala, N-Me-D-Ala or N-Me-Gly; A 9 is Glu, N-Me-Glu, N-Me-Asp or Asp; A 10 is Gly, Acc, β-Ala or Aib; A 11 is Thr or Ser; A 12 is Phe, Acc, Aic, Aib, 3Pal, 4Pal, 1Nal, 2Nal, Cha, Trp or (X 1 ) n -Phe; A 13 is Thr or Ser; A 14 is Ser or Aib; A 15 is Asp or Glu; A 16 is Val, Acc, Aib, Leu, Ile, Tle, Nle, Abu, Ala, 1Nal, 2Nal or Cha; A 17 is Ser or Thr; A 18 is Ser or Thr; A 19 is Tyr, Cha, Phe, 3Pal, 4Pal, Acc, 1Nal, 2Nal or (X 1 ) n -Phe; A 20 is Leu, Acc, Aib, Nle, lie, Cha, Tle, Val, Phe, 1Nal, 2Nal or (X 1 ) n -Phe; A 21 is Glu or Asp; A 22 is Gly, Acc, β-Ala or Aib; A 23 is Gln or Asn; A 24 is Ala, Aib, Val, Abu, Tle or Acc; A 25 is Ala, Aib, Val, Abu, Tle or Acc; A 26 is Lys, Arg, hArg, Orn, Dab, or Dap; A 27 is Glu or Asp; A 28 is Phe, 3Pal, 4Pal, 1Nal, 2Nal, Aic, Acc, Aib, Cha, Trp or (X 1 ) n -Phe; A 29 is lie, Acc, Aib, Leu, Nle, Cha, Tle, Val, Abu, Ala, Phe, 1Nal, 2Nal or (X 1 ) n -Phe; A 30 is Ala, Aib or Acc; A 31 is Trp, 2Nal, 3Pal, 4Pal, Phe, Acc, Aib, Cha or (X 1 ) n -Phe; A 32 is Leu, Acc, Aib, Nle, Ile, Cha, Tle, 1Nal, 2Nal, Phe, (X 1 ) n -Phe or Ala; A 33 is Val, Acc, Aib, Leu, Ile, Tle, Nle, Cha, Ala, 1Nal, 2Nal, Phe, Abu, Lys or (X 1 ) n -Phe; A 34 is Lys, Arg, hArg, Orn, Dab or Dap; A 35 is Gly, β-Ala, Gaba, Ava, HN—(CH 2 ) m —C(O), Aib, Acc, a D-amino acid, or deleted; A 36 is L- or D-Arg, D- or L-Lys, D- or L-hArg, D- or L-Orn, L- or D-Dab, L- or D-Dap, or deleted; and A 37 is Gly, β-Ala, Gaba, Ava, Aib, Acc, Ado, Aun, Aec, a D-amino acid, or deleted; X 1 for each occurrence is independently for each occurrence (C 1 -C 6 )alkyl, OH or halogen; n is 1, 2, 3, 4, or 5; R 1 is OH, NH 2 , (C 1 -C 30 )alkoxy, or NH—X 2 —CH 2 -Z 0 , wherein X 2 is a (C 1 -C 12 )hydrocarbon moiety, and Z 0 is H, OH, CO 2 H or CONH 2 ; (34) A composition according to paragraph (33), wherein said GLP-1 analog is a compound according to formula:
(Aib 8 , Arg 26 )hGLP-1(7-36)NH 2 ; (Aib 8 , Arg 26 , Phe 31 -Ala35)hGLP-1(7-36)NH 2 ; (Aib 8 , Arg 26 , β-Ala 35 )hGLP-1(7-36)NH 2 ; (Aib 8 , Arg 26,34 )hGLP-1(7-36)NH 2 ; (Aib 8 , Arg 26,34 , β-Ala 35 )hGLP-1(7-36)NH 2 ; (Aib 8 , Arg 34 )hGLP-1(7-36)NH 2 ; (Aib 8 , Arg 34 , Phe 31 , β-Ala 35 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 34 , β-Ala 35 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , 1Nal 12 , Arg 26,34 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , 1Nal 12 , Arg 26,34 , Phe 31 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , 1Nal 12,31 , Arg 26,34 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , 1Nal 19 , Arg 26,34 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , 1Nal 19 , Arg 25,34 , Phe 31 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , 1Nal 19,31 , Arg 26,34 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , 2Nal 12 , Arg 26,31 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , 2Nal 12 , Arg 26,31 , Phe 34 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , 2Nal 12,31 , Arg 26,34 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , 2Nal 19 , Arg 26,34 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , 2Nal 19 , Arg 26,34 , Phe 31 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , 2Nal 19,31 , Arg 26,34 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 26 )hGhLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 26 , Phe 31 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 26,34 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 26,34 , 1Nal 28 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 26,34 , 1Nal 28 , Phe 31 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 26,34 , 1Nal 26,31 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 26,34 , 1Nal 31 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 26,34 , 2Nal 28 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 26,34 , 2Nal 28 , Phe 31 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 26,34 , 2Nal 28,31 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 26,34 , 2Nal 31 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 26,34 , Phe 34 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 34 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Phe 31 , Arg 34 )hGLP-1(7-36)NH 2 ; (Arg 26 )hGLP-1(7-36)NH 2 ; (Arg 26 , Aib 35 )hGLP-1(7-36)NH 2 ; (Arg 26 , β-Ala 35 )hGLP-1(7-36)NH 2 ; (Arg 26,34 )hGLP-1(7-36)NH 2 ; (Arg 26 , 34 , Aib 35 )hGLP-1(7-36)NH 2 ; (Arg 26,34 , β-Ala 35 )hGLP-1(7-36)NH 2 ; (Arg 34 )hGLP-1(7-36)NH 2 ; (Arg 34 , Aib 35 )hGLP-1(7-36)NH 2 ; (Arg 34 , β-Ala 35 )hGLP-1(7-36)NH 2 ; (D-Ala 8 , Arg 26 )hGLP-1(7-36)NH 2 ; (D-Ala 8 , Arg 26 , Aib 35 )hGLP-1(7-36)NH 2 ; (D-Ala 8 , Arg 26 , β-Ala 35 )hGLP-1(7-36)NH 2 ; (D-Ala 8 , Arg 26,34 )hGLP-1(7-36)NH 2 ; (D-Ala 8 , Arg 26,34 , Aib 35 )hGLP-1(7-36)NH 2 ; (D-Ala 8 , Arg 26,34 , β-Ala 35 )hGLP-1(7-36)NH 2 ; (D-Ala 8 , Arg 34 )hGLP-1(7-36)NH 2 ; (D-Ala 8 , Arg 34 , Aib 35 )hGLP-1(7-36)NH 2 ; (D-Ala 8 , Arg 34 , β-Ala 35 )hGLP-1(7-36)NH 2 ; (Gly 8 , Arg 26 )hGLP-1(7-36)NH 2 ; (Gly 8 , Arg 26 , Aib 35 )hGLP-1(7-36)NH 2 ; (Gly 8 , Arg 26 , β-Ala 35 )hGLP-1(7-36)NH 2 ; (Gly 8 , Arg 26,34 )hGLP-1(7-36)NH 2 ; (Gly 8 , Arg 26,34 , Aib 35 )hGLP-1(7-36)NH 2 ; (Gly 8 , Arg 26,34 , β-Ala 35 )hGLP-1(7-36)NH 2 ; (Gly 8 , Arg 34 )hGLP-1(7-36)NH 2 ; (Gly 8 , Arg 34 , Aib 35 )hGLP-1(7-36)NH 2 ; (Gly 8 , Arg 34 , β-Ala 35 )hGLP-1(7-36)NH 2 ; (N-Me-D-Ala 8 , Arg 26,34 )hGLP-1(7-36)NH 2 ; (N-Me-D-Ala 8 , Arg 26,34 , Aib 35 )hGLP-1(7-36)NH 2 ; (N-Me-D-Ala 8 , Arg 26,34 , β-Ala35)hGLP-1(7-36)NH 2 , (Ser 8 , Arg 26 )hGLP-1(7-36)NH 2 ; (Ser 8 , Arg 26 , Aib 35 )hGLP-1(7-36)NH 2 ; (Ser 8 , Arg 26 , β-Ala 35 )hGLP-1(7-36)NH 2 ; (Ser 8 , Arg 26,34 )hGLP-1(7-36)NH 2 ; (Ser 8 , Arg 26,34 , Aib 35 )hGLP-1(7-36)NH 2 ; (Ser 8 , Arg 26,34 , β-Ala 35 )hGLP-1(7-36)NH 2 ; (Ser 8 , Arg 34 )hGLP-1(7-36)NH 2 ; (Ser 8 , Arg 34 , Aib 35 )hGLP-1(7-36)NH 2 ; (Ser 8 , Arg 34 , β-Ala 35 )hGLP-1(7-36)NH 2 ; (Val 8 , Arg 26 )hGLP-1(7-36)NH 2 , (Val 8 , Arg 26 , Aib 35 )hGLP-1(7-36)NH 2 , (Val 8 , Arg 26 , β-Ala 35 )hGLP-1(7-36)NH 2 , (Val 8 , Arg 26,34 )hGLP-1(7-36)NH 2 ; (Val 8 , Arg 26,34 , Aib 35 )hGLP-1(7-36)NH 2 ; (Val 8 , Arg 26,34 , β-Ala 35 )hGLP-1(7-36)NH 2 ; (Val 8 , Arg 34 )hGLP-1(7-36)NH 2 ; (Val 8 , Arg 34 , Aib 35 )hGLP-1(7-36)NH 2 ; or (Val 8 , Arg 34 , β-Ala 35 )hGLP-1(7-36)NH 2 .
(35) In a more preferred embodiment the invention features a composition according to paragraph (34), wherein said GLP-1 analog is a compound according to the formula:
(Aib 8 , Arg 26,34 , β-Ala 35 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 26 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 26 , Phe 31 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 26,34 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 26,24 , 2Nal 31 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 26,34 , Phe 31 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Arg 34 )hGLP-1(7-36)NH 2 ; (Aib 8,35 , Phe 31 , Arg 34 )hGLP-1(7-36)NH 2 ;
(36) In a still more preferred embodiment the invention features a composition according to paragraph (34), wherein said GLP-1 analog is a compound according to the formula:
(Aib 8,35 , Arg 26,34 , Phe 31 ) h GLP-1(7-36)NH 2 .
(37) A method of eliciting an agonist effect from a GLP-1 receptor in a subject in need thereof which comprises administering to said subject an effective amount of a compound according to paragraph (1) or paragraph (33), or a pharmaceutically acceptable salt thereof. (38) A method of treating a disease selected from the group consisting of Type I diabetes, Type II diabetes, obesity, glucagonomas, secretory disorders of the airway, metabolic disorder, arthritis, osteoporosis, central nervous system disease, restenosis and neurodegenerative disease, in a subject in need thereof which comprises administering to said subject an effective amount of a composition according to paragraph (1) or a pharmaceutically acceptable salt thereof. Preferably said disease is Type I diabetes or Type II diabetes. (39) Another more preferred compound of formula (I) for use in a formulation of the present invention is each of the compounds that are specifically exemplified hereinbelow in the Examples section of the present disclosure, or a pharmaceutically acceptable salt thereof. (40). In yet another aspect, the present invention provides a method of eliciting an agonist effect from a GLP-1 receptor in a subject in need thereof which comprises administering to said subject a formulation of the instant present invention comprising an effective amount of a compound of formula (I) as defined hereinabove or a pharmaceutically acceptable salt thereof. (41) In a further aspect, the present invention provides a method of treating a disease selected from the group consisting of Type I diabetes, Type II diabetes, obesity, glucagonomas, secretory disorders of the airway, metabolic disorder, arthritis, osteoporosis, central nervous system disease, restenosis, neurodegenerative disease, renal failure, congestive heart failure, nephrotic syndrome, cirrhosis, pulmonary edema, hypertension, and disorders wherein the reduction of food intake is desired, in a subject in need thereof which comprises administering to said subject for use in a formulation of the present invention comprising an effective amount of a compound of formula (I) as defined hereinabove or a pharmaceutically acceptable salt thereof. A preferred method of the immediately foregoing method is where the disease being treated is Type I diabetes or Type II diabetes. (42) In a still more preferred aspect, the invention features a method according to paragraphs (40) or (41) wherein said composition comprises and aqueous solution consisting essentially of a salt of [Aib 8,35 , Arg 26,34 , Phe 31 ]hGLP-1(7-36)NH 2 and a salt of zinc, more preferably wherein the pH of said composition is lower than 7.0, more preferably still, lower than 5.0, more preferably still, lower than 4.0. (43) In a more preferred embodiment the invention features a composition of paragraph wherein the concentration of [Aib 8,35 , Arg 26,34 , Phe 31 ]hGLP-1(7-36)NH 2 is 0.5 to 8.0 mg/ml, more preferably about 2.0 to about 6.0 mg/ml, more preferably still about 3.5 to 5.5 mg/ml., even more preferably still about 4.0 mg/ml. (44) Further preferred embodiments of the invention are described in following paragraphs (45) to (77): (45) A pharmaceutical composition of a clear solution or a gel comprising zinc and an analog of GLP-1 or exendin-4. (46) A pharmaceutical composition according to paragraph (45), wherein said composition forms a precipitate after subcutaneous administration to a subject. (47) A composition according to paragraph (46), further comprising water. (48) A composition according to any one of paragraphs (46) and (47), further comprising non-aqueous medium. (49) A composition according to any one of paragraphs (47)-(48), wherein the molecule is present in an aqueous solution with pH between 2.5 and 10.5, preferably between 3.5 and 8. (50) A composition according to any one of paragraphs (46-49), wherein the molecule is present in a concentration of about 0.001-500 mg/mL, preferable about 0.1-10 mg/mL. (51) A composition according to any one of paragraphs (46-50), further comprising a preservative. (52) A composition according to paragraph (51), wherein said preservative is selected from the group consisting of m-cresol, phenol, benzyl alcohol and methyl paraben. (53) A composition according to paragraph (52), wherein said preservative is present in a concentration from 0.01 mg/mL to 50 mg/mL. (54) A composition according to any one of paragraphs (45-53), further comprising an isotonic agent. (55) A composition according to paragraph (54), wherein said isotonic agent is present in a concentration from 0.01 mg/mL to 50 mg/mL. (56) A composition according to any one of paragraphs (46-55), wherein said zinc is present in a concentration from 0.0005 mg/mL to 50 mg/mL. (57) A composition according to any one of paragraphs (46-56), further comprising a stabilizer. (58) A composition according to paragraph (57), wherein said stabilizer is selected from the group consisting of imidazole, arginine and histidine. (59) A composition according to any one of paragraphs (46-58), further comprising a surfactant. (60) A composition according to any one of paragraphs (46-59), further comprising a chelating agent. (61) A composition according to any one of paragraphs (46-60), further comprising a buffer. (62) A composition according to paragraph (61), wherein said buffer is selected from the group consisting of Tris, ammonium acetate, sodium acetate, glycine, aspartic acid, and Bis-Tris. (63) A composition according to any one of paragraphs (46-62), further comprising a basic polypeptide. (64) A composition according to paragraph (63), wherein said basic polypeptide is selected from the group consisting of polylysine, polyarginine, polyornithine, protamine, putrescine, spermine, spermidine, and histone. (65) A composition according to any one of paragraphs (46-64), further comprising alcohol or mono or disaccharide. (66) A composition according to paragraph (65), wherein said alcohol or mono or disaccharide is selected from the group consisting of methanol, ethanol, propanol, glycerol, trehalose, mannitol, glucose, erythrose, ribose, galactose, fructose, maltose, sucrose, and lactose. (67) A composition according to any one of paragraphs (46-66), comprising (Aib 8,35 , Arg 26,34 , Phe 3 )hGLP-1(7-36)NH 2 ; or a pharmaceutically acceptable salt thereof. (68) A pharmaceutical composition consisting essentially of an analog according to the formula [Aib 8 35, Arg 26 34, Phe 31 ]hGLP-1(7-36)NH 2 , or a pharmaceutically acceptable salt thereof. (69) A pharmaceutical composition according to paragraph 68 in the form of a solid microtablet. (70) A pharmaceutical composition according to paragraph 68, further comprising water, wherein said composition forms a semi-solid. (71) A pharmaceutical semi-solid composition according to paragraph 70, wherein said composition contains approximately 25% (wt/wt) of (Aib 8,35 , Arg 26,34 , Phe 31 )hGLP-1(7-36)NH 2 . (72) A pharmaceutical composition comprising an analog according to the formula:
[Aib 8,35 , Arg 26,34 , Phe 31 ]hGLP-1(7-36)NH 2 ;
or
[Aib 8,35 )hGLP-1(7-36)NH 2 ,
together with zinc and a pharmaceutically acceptable carrier or diluent.
(73) A composition according to paragraph 72, wherein said zinc is present in a concentration from 0.0005 mg/mL to 50 mg/mL. (74) A composition according to paragraph 73, wherein said zinc is present in a concentration from 0.01 mg/mL to 0.50 mg/mL. (75) A composition according to paragraph 72, wherein said diluent comprises a pharmaceutically acceptable aqueous solution. (76) A composition according to paragraph 75, wherein said diluent comprises sterile water. (77) A method of treating a disease selected from the group consisting of Type I diabetes, Type II diabetes, obesity, glucagonomas, secretory disorders of the airway, metabolic disorder, arthritis, osteoporosis, central nervous system disease, restenosis, neurodegenerative disease, renal failure, congestive heart failure, nephrotic syndrome, cirrhosis, pulmonary edema, hypertension, and disorders wherein the reduction of food intake is desired, in a subject in need thereof which comprises administering to said subject a formulation selected, independently for each occurrence, from the list of formulations comprising those described in each of paragraphs (43) and (45) - (76). A preferred method of the immediately foregoing method is where the disease being treated is Type I diabetes or Type II diabetes.
With the exception of the N-terminal amino acid, all abbreviations (e.g. Ala) of amino acids in this disclosure stand for the structure of —NH—CH(R)—CO—, wherein R is the side chain of an amino acid (e.g., CH 3 for Ala). For the N-terminal amino acid, the abbreviation stands for the structure of (R 2 R 3 )—N—CH(R)—CO—, wherein R is a side chain of an amino acid and R 2 and R 3 are as defined above, except when A 7 is Ura, Paa or Pta, in which case R 2 and R 3 are not present since Ura, Paa and Pta are considered here as des-amino amino acids. Amp, 1Nal, 2Nal, Nle, Cha, 3-Pal, 4-Pal and Aib are the abbreviations of the following (α-amino acids: 4-amino-phenylalanine, β-(1-naphthyl)alanine, β-(2-naphthyl)alanine, norleucine, cyclohexylalanine, β-(3-pyridinyl)alanine, β-(4-pyridinyl)alanine and (α-aminoisobutyric acid, respectively. Other amino acid definitions are: Ura is urocanic acid; Pta is (4-pyridylthio) acetic acid; Paa is trans-3-(3-pyridyl) acrylic acid; Tma-His is N,N-tetramethylamidino-histidine; N-Me-Ala is N-methyl-alanine; N-Me-Gly is N-methyl-glycine; N-Me-Glu is N-methyl-glutamic acid; Tle is tert-butylglycine; Abu is a-aminobutyric acid; Tba is tert-butylalanine; Orn is ornithine; Aib is α-aminoisobutyric acid; β-Ala is β-alanine; Gaba is γ-aminobutyric acid; Ava is 5-aminovaleric acid; Ado is 12-aminododecanoic acid, Aic is 2-aminoindane-2-carboxylic acid; Aun is 11-aminoundecanoic acid; and Aec is 4-(2-aminoethyl)-1-carboxymethyl-piperazine, represented by the structure:
What is meant by Acc is an amino acid selected from the group of 1-amino-1-cyclopropanecarboxylic acid (A3c); 1-amino-1-cyclobutanecarboxylic acid (A4c); 1-amino-1-cyclopentanecarboxylic acid (A5c); 1-amino-1-cyclohexanecarboxylic acid (A6c); 1-amino-1-cycloheptanecarboxylic acid (A7c); 1-amino-1-cyclooctanecarboxylic acid (A8c); and 1-amino-1-cyclononanecarboxylic acid (A9c). In the above formula, hydroxyalkyl, hydroxyphenylalkyl, and hydroxynaphthylalkyl may contain 14 hydroxy substituents. COX 5 stands for —C═O.X 5 . Examples of —C═O.X 5 include, but are not limited to, acetyl and phenylpropionyl.
The full names for other abbreviations used herein are as follows: Boc for t-butyloxycarbonyl, HF for hydrogen fluoride, Fm for formyl, Xan for xanthyl, Bzl for benzyl, Tos for tosyl, DNP for 2,4-dinitrophenyl, DMF for dimethylformamide, DCM for dichloromethane, HBTU for 2-(1H-Benzotriazol-1-yl)-1,1,3,3-tetramethyl uronium hexafluorophosphate, DIEA for diisopropylethylamine, HOAc for acetic acid, TFA for trifluoroacetic acid, 2ClZ for 2-chlorobenzyloxycarbonyl, 2BrZ for 2-bromobenzyloxycarbonyl, OcHex for O-cyclohexyl, Fmoc for 9-fluorenylmethoxycarbonyl, HOBt for N-hydroxybenzotriazole; PAM resin for 4-hydroxymethylphenylacetamidomethyl resin; Tris for Tris(hydroxymethyl)aminomethane; and Bis-Tris for Bis(2-hydroxyethyl)amino-tris(hydroxymethyl)methane (i.e., 2-Bis(2-hydroxyethyl)amino-2-(hydroxymethyl)-1,3-propanediol).
The term “halo” or “halogen” encompasses fluoro, chloro, bromo and iodo.
The terms “(C 1 -C 12 )hydrocarbon moiety”, “(C 1 -C 30 )hydrocarbon moiety” and the like encompass branched and straight chain alkyl, alkenyl and alkynyl groups having the indicated number of carbons, provided that in the case of alkenyl and alkynyl there is a minimum of two carbons.
A peptide of this invention is also denoted herein by another format, e.g., (A5c 8 )hGLP-1(7-36)NH 2 , with the substituted amino acids from the natural sequence placed between the first set of parentheses (e.g., A5c 8 for Ala 8 in hGLP-1). The abbreviation GLP-1 means glucagon-like peptide-1; hGLP-1 means human glucagon-like peptide-1. The numbers between the parentheses refer to the number of amino acids present in the peptide (e.g., hGLP-1(7-36) is amino acids 7 through 36 of the peptide sequence for human GLP-1). The sequence for hGLP-1 (7-37) is listed in Mojsov, S., Int. J. Peptide Protein Res,. 40,1992, pp. 333-342. The designation “NH 2 ” in hGLP-1 (7-36)NH 2 indicates that the C-terminus of the peptide is amidated. hGLP-1(7-36) means that the C-terminus is the free acid. In hGLP-1(7-38), residues in positions 37 and 38 are Gly and Arg, respectively, unless otherwise indicated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts the time course plasma concentration of a peptide administered to rats using compositions according to the invention, according to Example H.1.
FIG. 2 depicts the time course plasma concentration of a peptide administered to rats using compositions according to the invention, according to Example H.2.
FIG. 3 depicts the time course plasma concentration of a peptide administered to rats using compositions according to the invention, according to Example H.3.
FIG. 4 depicts the time course plasma concentration of a peptide administered to beagle dogs using compositions according to the invention, according to Example H.4.
FIG. 5 depicts the time course plasma concentration of a peptide administered to rats using compositions according to the invention, according to Example 1.1.
FIG. 6 depicts the time course plasma concentration of a peptide administered to rats using compositions according to the invention, according to Example 1.2.
FIG. 7 depicts the time course plasma concentration of a peptide administered to rats using compositions according to the invention, according to Example 1.3.
DETAILED DESCRIPTION
Synthesis of Peptides
Peptides useful for practicing the present invention can be and were prepared by standard solid phase peptide synthesis. See, e.g., Stewart, J. M., et al., Solid Phase Synthesis (Pierce Chemical Co., 2d ed. 1984). The substituents R 2 and R 3 of the above generic formula may be attached to the free amine of the N-terminal amino acid by standard methods known in the art. For example, alkyl groups, e.g., (C 1 -C 30 )alkyl, may be attached using reductive alkylation. Hydroxyalkyl groups, e.g., (C 1 -C 30 )hydroxyalkyl, may also be attached using reductive alkylation wherein the free hydroxy group is protected with a t-butyl ester. Acyl groups, e.g., COE 1 , may be attached by coupling the free acid, e.g., E 1 COOH, to the free amine of the N-terminal amino acid by mixing the completed resin with 3 molar equivalents of both the free acid and diisopropylcarbodiimide in methylene chloride for one hour. If the free acid contains a free hydroxy group, e.g., p-hydroxyphenylpropionic acid, then the coupling should be performed with an additional 3 molar equivalents of HOBT.
When R 1 is NH—X 2 —CH 2 —CONH 2 , (i.e., Z 0 =CONH 2 ), the synthesis of the peptide starts with BocHN-X 2 —CH 2 —COOH which is coupled to the MBHA resin. If R 1 is NH—X 2 —CH 2 —COOH, (i.e., Z 0 =COOH) the synthesis of the peptide starts with Boc-HN—X 2 —CH 2 —COOH which is coupled to PAM resin. For this particular step, 4 molar equivalents of Boc-HN—X 2 —COOH, HBTU and HOBt and 10 molar equivalents of DIEA are used. The coupling time is about 8 hours.
The protected amino acid 1-(N-tert-butoxycarbonyl-amino)-1-cyclohexane-carboxylic acid (Boc-A6c-OH) was synthesized as follows. 19.1 g (0.133 mol) of 1-amino-1-cyclohexanecarboxylic acid (Acros Organics, Fisher Scientific, Pittsburgh, Pa.) was dissolved in 200 ml of dioxane and 100 ml of water. To it was added 67 ml of 2N NaOH. The solution was cooled in an ice-water bath. 32.0 g (0.147 mol) of di-tert-butyl-dicarbonate was added to this solution. The reaction mixture was stirred overnight at room temperature. Dioxane was then removed under reduced pressure. 200 ml of ethyl acetate was added to the remaining aqueous solution. The mixture was cooled in an ice-water bath. The pH of the aqueous layer was adjusted to about 3 by adding 4N HCl. The organic layer was separated. The aqueous layer was extracted with ethyl acetate (1×100 ml). The two organic layers were combined and washed with water (2×150 ml), dried over anhydrous MgSO 4 , filtered, and concentrated to dryness under reduced pressure. The residue was recrystallized in ethyl acetate/hexanes. 9.2 g of the pure product was obtained. 29% yield.
Boc-A5c-OH was synthesized in an analogous manner to that of Boc-A6c-OH. Other protected Acc amino acids can be prepared in an analogous manner by a person of ordinary skill in the art as enabled by the teachings herein.
In the synthesis of a peptide containing A5c, A6c and/or Aib, the coupling time is 2 hrs. for these residues and the residue immediately following them. For the synthesis of (Tma-His 7 )hGLP-1(7-36)NH 2 , HBTU (2 mmol) and DIEA (1.0 ml) in 4 ml DMF are used to react with the N-terminal free amine of the peptide-resin in the last coupling reaction; the coupling time is about 2 hours.
The substituents R 2 and R 3 of the above generic formula can be attached to the free amine of the N-terminal amino acid by standard methods known in the art. For example, alkyl groups, e.g., (C 1 -C 30 )alkyl, can be attached using reductive alkylation. Hydroxyalkyl groups, e.g., (C 1 -C 30 )hydroxyalkyl, can also be attached using reductive alkylation wherein the free hydroxy group is protected with a t-butyl ester. Acyl groups, e.g., COX 1 , can be attached by coupling the free acid, e.g., X 1 COOH, to the free amine of the N-terminal amino acid by mixing the completed resin with 3 molar equivalents of both the free acid and diisopropylcarbodiimide in methylene chloride for about one hour. If the free acid contains a free hydroxy group, e.g., p-hydroxyphenylpropionic acid, then the coupling should be performed with an additional 3 molar equivalents of HOBT.
The following examples describe synthetic methods that can be and were used for making peptides with which the instant invention may advantageously be practiced, which synthetic methods are well-known to those skilled in the art. Other methods are also known to those skilled in the art. The examples are provided for the purpose of illustration and is not meant to limit the scope of the present invention in any manner.
Boc-βAla-OH, Boc-D-Arg(Tos)-OH and Boc-D-Asp(OcHex) were purchased from Nova Biochem, San Diego, Calif. Boc-Aun-OH was purchased from Bachem, King of Prussia, Pa. Boc-Ava-OH and Boc-Ado-OH were purchased from Chem-Impex International, Wood Dale, Ill. Boc-2Nal-OH was purchased from Synthetech, Inc. Albany, Oreg.
EXAMPLE 1
(Aib 8 , 35 , Arg 26 , 34 , Phe 31 )hGLP-1(7-36)NH 2
The title peptide was synthesized on an Applied Biosystems (Foster City, Calif.) model 430A peptide synthesizer which was modified to do accelerated Boc-chemistry solid phase peptide synthesis. See Schnolzer, et al., Int. J. Peptide Protein Res., 90:180 (1992). 4-methylbenzhydrylamine (MBHA) resin (Peninsula, Belmont, Calif.) with the substitution of 0.91 mmol/g was used. The Boc amino acids (Bachem, Calif., Torrance, Calif.; Nova Biochem., LaJolla, Calif.) were used with the following side chain protection: Boc-Ala-OH, Boc-Arg(Tos)-OH, Boc-Asp(OcHex)-OH, Boc-Tyr(2BrZ)-OH, Boc-His(DNP)-OH, Boc-Val-OH, Boc-Leu-OH, Boc-Gly-OH, Boc-Gln-OH, Boc-Ile-OH, Boc-Lys(2CIZ)-OH, Boc-Thr(Bzl)-OH, Boc-Ser(Bzl)-OH, Boc-Phe-OH, Boc-Aib-OH, Boc-Glu(OcHex)-OH and Boc-Trp(Fm)-OH. The synthesis was carried out on a 0.20 mmol scale. The Boc groups were removed by treatment with 100% TFA for 2×1 min. Boc amino acids (2.5 mmol) were pre-activated with HBTU (2.0 mmol) and DIEA (1.0 mL) in 4 mL of DMF and were coupled without prior neutralization of the peptide-resin TFA salt. Coupling times were 5 min. except for the Boc-Aib-OH residues and the following residues, Boc-Lys(2ClZ)-OH and Boc-His(DNP)-OH wherein the coupling times were 2 hours.
At the end of the assembly of the peptide chain, the resin was treated with a solution of 20% mercaptoethanol/10% DIEA in DMF for 2×30 min. to remove the DNP group on the His side chain. The N-terminal Boc group was then removed by treatment with 100% TFA for 2×2 min. After neutralization of the peptide-resin with 10% DIEA in DMF (1×1 min), the formyl group on the side chain of Trp was removed by treatment with a solution of 15% ethanolamine/15% water/70% DMF for 2×30 min. The peptide-resin was washed with DMF and DCM and dried under reduced pressure. The final cleavage was done by stirring the peptide-resin in 10 mL of HF containing 1 mL of anisole and dithiothreitol (24 mg) at 0° C. for 75 min. HF was removed by a flow of nitrogen. The residue was washed with ether (6×10 mL) and extracted with 4N HOAc (6×10 mL).
The peptide mixture in the aqueous extract was purified on reverse-phase preparative high pressure liquid chromatography (HPLC) using a reverse phase VYDAC® C 18 column (Nest Group, Southborough, Mass.). The column was eluted with a linear gradient (20% to 50% of solution B over 105 min.) at a flow rate of 10 mUmin (Solution A=water containing 0.1% TFA; Solution B=acetonitrile containing 0.1% of TFA). Fractions were collected and checked on analytical HPLC. Those containing pure product were combined and lyophilized to dryness. Approximately 18 mg of a white solid were obtained. Purity was 99% based on analytical HPLC analysis. Electro-spray mass spectrometer (MS(ES)) analysis gave the molecular weight at 3356.6 (in agreement with the calculated molecular weight of 3356.77).
The synthesis of Examples 2-82, as well as other peptidyl compounds useful to practice the present invention, can be accomplished in substantially the same manner as the procedure described for the synthesis of (Aib 8,35 , Arg 26,34 , Phe 31 )hGLP-1(7-36)NH 2 in Example 1 above, but using the appropriate protected amino acids depending on the desired peptide.
EXAMPLES 2-82
Ex. No. Compound
2. (Aib 8 , Arg 26 )hGLP-1(7-36)NH 2 ;
3. (Aib 8 , Arg 26 , Phe 31 , β-Ala 35 )hGLP-1(7-36)NH 2 ;
4. (Aib 8 , Arg 26 , β-Ala 35 )hGLP-1(7-36)NH 2 ;
5. (Aib 8 , Arg 26,34 )hGLP-1(7-36)NH 2 ;
6. (Aib 8 , Arg 26,34 , β-Ala 35 )hGLP-1(7-36)NH 2 ;
7. (Aib 8 , Arg 34 )hGLP-1(7-36)NH 2 ;
8. (Aib 8 , Arg 34 , Phe 31 , β-Ala 35 )hGLP-1(7-36)NH 2 ;
9. (Aib 8 , Arg 34 , β-Ala 35 )hGLP-1(7-36)NH 2 ;
10. (Aib 8,35 , 1Nal 12 , Arg 26,34 )hGLP-1(7-36)NH 2 ;
11. (Aib 8,35 , 1Nal 12 , Arg 26,34 , Phe 31 )hGLP-1(7-36)NH 2 ;
12. (Aib 8,35 , 1Nal 12,31 , Arg 26,34 )hGLP-1(7-36)NH 2 ;
13. (Aib 8,35 , 1Nal 91 , Arg 26,34 )hGLP-1(7-36)NH 2 ;
14. (Aib 8,35 , 1Nal 19 , Arg 26,34 Phe 31 )hGLP-1(7-36)NH 2 ;
15. (Aib 8,35 , 1Nal 19,31 , Arg 26,34 )hGLP-1(7-36)NH 2 ;
16. (Aib 8,35 , 2Nal 12 , Arg 26,34 )hGLP-1(7-36)NH 2 ;
17. (Aib 8,35 , 2Nal 12 , Arg 26,35 , Phe 31 )hGLP-1(7-36)NH 2 ;
18. (Aib 8,35 , 2Nal 12 , Arg 26,34 )hGLP-1(7-36)NH 2 ;
19. (Aib 8,35 , 2Nal 19 , Arg 26,34 )hGLP-1(7-36)NH 2 ;
20. (Aib 8,35 , 2Nal 19 , Arg 26,34 , Phe 31 )hGLP-1(7-36)NH 2 ;
21. (Aib 8,35 , 2Na 19,31 , Arg 26,34 )hGLP-1(7-36)NH 2 ;
22. (Aib 8,35 , Arg 26 )hGLP-1(7-36)NH 2 ;
23. (Aib 8,35 , Arg 26,34 , Phe 31 )hGLP-1(7-36)NH 2 ;
24. (Aib 8,35 , Arg 26,34 )hGLP-1(7-36)NH 2 ;
25. (Aib 8,35 , Arg 26,34 , 1Nal 28 )hGLP-1(7-36)NH 2 ;
26. (Aib 8,35 , Arg 26,34 , 1Nal 28 , Phe 31 )hGLP-1(7-36)NH 2 ;
27. (Aib 8,35 , Arg 26,34 , 1Nal 28,31 )hGLP-1(7-36)NH 2 ;
28. (Aib 8,35 , Arg 26,34 , 1Nal 28 )hGLP-1(7-36)NH 2 ;
29. (Aib 8,35 , Arg 26,34 , 2Nal 28 )hGLP-1(7-36)NH 2 ;
30. (Aib 8,35 , Arg 26,34 , 2Nal 28 , Phe 31 )hGLP-1(7-36)NH 2 ;
31. (Aib 8,35 , Arg 26,34 , 2Nal 28,31 )hGLP-1(7-36)NH 2 ;
32. (Aib 8,35 , Arg 26,34 , 2Nal 31 )hGLP-1(7-36)NH 2 ;
33. (Aib 8,35 , Arg 34 )hGLP-1(7-36)NH 2 ;
34. (Aib 8,35 , Phe 31 , Arg 34 )hGLP-1(7-36)NH 2 ;
35. (Arg 26 )hGLP-1(7-36)NH 2 ;
36. (Arg 26 , Aib 35 )hGLP-1(7-36)NH 2 ;
37. (Arg 26 , β-Ala 35 )hGLP-1(7-36)NH 2 ;
38. (Arg 26,34 )hGLP-1(7-36)NH 2 ;
39. (Arg 26,34 , Aib 35 )hGLP-1(7L36)NHg;
40. (Arg 26,34 , β-Ala 35 )hGLP-1(7-36)NH 2 ;
41. (Arg 34 )hGLP-1(7-36)NH 2 ;
42. (Arg 34 , Aib 35 )hGLP-1(7-36)NH 2 ;
43. (Arg 34 , β-Ala)hGLP-1(7-36)NH 2 ;
44. (D-Ala 8 , Arg 26 )hGLP-1(7-36)NH 2 ;
45. (D-Ala 8 , Arg 26 , Aib 35 )hGLP-1(7-36)NH 2 ;
46. (D-Ala 8 , Arg 26 , β-Ala 35 )hGLP-1(7-36)NH 2 ;
47. (D-Ala 8 , Arg 26,34 )hGLP-1(7-36)NH 2 ;
48. (D-Ala 8 , Arg 26,34 , Aib 35 )hGLP-1(7-36)NH 2 ;
49. (D-Ala 8 , Arg 26,34 , Ala 35 )hGLP-1(7-36)NH 2 ;
50. (D-Ala 8 , Arg 34 )hGLP-1(7-36)NH 2 ;
51. (D-Ala 8 , Arg 34 , Aib 35 )hGLP-1(7-36)NH 2 ;
52. (D-Ala 8 , Arg 34 , β-Ala 35 )hGLP-1(7-36)NH 2 ;
53. (Gly 8 , Arg 26 )hGLP-1(7-36)NH 2 ;
54. (Gly 8 , Arg 26 , Aib 35 )hGLP-1(7-36)NH 2 ;
55. (Gly 8 , Arg 26 , βAla 35 )hGLP-1(7-36)NH 2 ;
56. (Gly 8 , Arg 26,34 )hGLP-1(7-36)NH 2 ;
57. (Gly 8 , Arg 26,34 , Aib 35 )hGLP-1(7-36)NH 2 ;
58. (Gly 8 , Arg 26,34 , Ala 35 )hGLP-1(7-36)NH 2 ;
59. (Gly 8 , Arg 34 )hGLP-1(7-36)NH 2 ;
60. (Gly 8 , Arg 34 , Aib 35 )hGLP-1(7-36)NH 2 ;
61. (Gly 8 , Arg 34 , β-Ala 35 )hGLP-1(7-36)NH 2 ;
62. (N-Me-D-Ala 8 , Arg 26,34 )hGLP-1(7-36)NH 2 ;
63. (N-Me-D-Ala 8 , Arg 26,34 , Aib 35 )hGLP-1(7-36)NH 2 ;
64. (N-Me-D-Ala 8 , Arg 26,34 , β-Ala 35 )hGLP-1 (7-36)NH 2 ;
65. (Ser 8 , Arg 26 )hGLP-1(7-36)NH 2 ;
66. (Ser 8 , Arg 26 , Aib 35 )hGLP-1(7-36)NH 2 ;
67. (Ser 8 , Arg 26 , β-Ala 35 )hGLP-1(7-36)NH 2 ;
68. (Ser 8 , Arg 26,34 )hGLP-1(7-36)NH 2 ;
69. (Ser 8 , Arg 26,34 , Aib 35 )hGLP-1(7-36)NH 2 ;
70. (Ser 8 , Arg 26,34 , β-Ala 35 )hGLP-1(7-36)NH 2 ;
71. (Ser 8 , Arg 34 )hGLP-1(7-36)NH 2 ;
72. (Ser 8 , Arg 34 , Aib 35 )hGLP-1(7-36)NH 2 ;
73. (Ser 8 , Arg 34 , β-Ala 35 )hGLP-1(7-36)NH 2 ;
74. (Val 8 , Arg 26 )hGLP-1(7-36)NH 2 ;
75. (Val 8 , Arg 26 , Aib 35 )hGLP-1(7-36)NH 2 ;
76. (Val 8 , Arg 26 , β-Ala 35 )hGLP-1(7-36)NH 2 ;
77. (Val 8 , Arg 26,34 )hGLP-1(7-36)NH 2 ;
78. (Val 8 , Arg 26,34 , Aib 35 )hGLP-1(7-36)NH 2 ;
79. (Val 8 , Arg 26,34 , β-Ala 35 )hGLP-1(7-36)NH 2 ;
80. (Val 8 , Arg 34 )hGLP-1(7-36)NH 2 ;
81. (Val 8 , Arg 34 , Aib 35 )hGLP-1(7-36)NH 2 ;
82. (Val 8 , Arg 34 , β-Ala 35 )hGLP-1(7-36)NH 2 .
Physical data for a representative sampling of the compounds exemplified herein are given in the following Table 1.
TABLE 1
Mol. Wt.
Mol. Wt.
Purity
Ex. No.
Calculated
MS(ES)
(HPLC)
1
3356.77
3356.6
99%
6
3381.74
3381.3
97%
22
3367.75
3367.77
99%
23
3328.72
3328.5
99%
24
3395.74
3395.5
99%
32
3406.84
3406.4
99%
33
3367.75
3367.77
99%
34
3328.72
3328.5
99%
Experimental Procedures
A. Determination of GLP-1 Receptor Affinity
Compounds useful to practice the present invention can be tested for their ability to bind to the GLP-1 receptor using the following procedure.
Cell Culture:
RIN 5F rat insulinoma cells (ATCCO CRL-2058, American Type Culture Collection, Manassas, Va.), expressing the GLP-1 receptor, were cultured in Dulbecco's modified Eagle's medium (DMEM) containing 10% fetal calf serum, and maintained at about 37° C. in a humidifed atmosphere of 5% CO 2 /95% air.
Radioligand Binding:
Membranes were prepared for radioligand binding studies by homogenization of the RIN cells in 20 ml of ice-cold 50 mM Tris-HCl with a Brinkman Polytron (Westbury, N.Y.) (setting 6, 15 sec). The homogenates were washed twice by centrifugation (39,000 g/10 min), and the final pellets were resuspended in 50 mM Tris-HCl, containing 2.5 mM MgCl 2 , 0.1 mg/ml bacitracin (Sigma Chemical, St. Louis, Mo.), and 0.1% BSA. For assay, aliquots (0.4 ml) were incubated with 0.05 nM ( 125 I)GLP-1(7-36) (˜2200 Ci/mmol, New England Nuclear, Boston, Mass.A), with and without 0.05 ml of unlabeled competing test peptides. After a 100 min incubation (25° C.), the bound ( 125 I)GLP-1(7-36) was separated from the free by rapid filtration through GF/C filters (Brandel, Gaithersburg, Md.), which had been previously soaked in 0.5% polyethyleneimine. The filters were then washed three times with 5 ml aliquots of ice-cold 50 mM Tris-HCl, and the bound radioactivity trapped on the filters was counted by gamma spectrometry (Wallac LKB, Gaithersburg, Md.). Specific binding was defined as the total ( 125 I)GLP-1(7-36) bound minus that bound in the presence of 1000 nM GLP1(7-36) (Bachem, Torrence, Calif.).
B. Determination of Solubility vs pH
Advantageously, compounds for use in the present invention are relatively insoluble in aqueous solutions having approximately neutral or physiological pH values and relatively soluble in aqueous solutions having acidic or basic pH values. Preferably compounds for use in the present invention have an aqueous solubility lower than 1 mg/mL, more preferably lower than 0.5 mg/mL, at pH between approximately 6 and approximately 8 and at about temperatures between approximately 4° C. and approximately 40° C.
B.1. Determination of Compound Solubility vs pH in Buffered Saline
Compounds that may advantageously be used to practice the invention can be and were tested to determine their solubility in PBS at different pHs and temperatures using the following procedure.
A stock PBS buffered solution was made by dissolving one packet of pre-mixed powder (SIGMA, Product No.: P-3813) in one liter of de-ionized water to yield 10 mM phosphate-buffered saline with 138 mM NaCl, 2.7 mM KCl, and a pH of 7.4. PBS buffers with different pH values were made by adjusting the pH of this stock solution with phosphoric acid and/or sodium hydroxide.
2 mg samples of the compound of Example 1 were weighed into glass vials. Into each vial was added a 50 μl aliquot of PBS buffer at a certain pH. The solution was vortexed, and if necessary sonicated, until clear. For each pH tested the total volume of buffer needed to dissolve 2 mg of the compound was recorded and the solubility was calculated.
Peptide solutions that were clear at room temperature (20-25° C.) were placed in a refrigerator (4° C.) overnight and the solubility of the peptide at 4° C. was then examined.
B.2. Determination of Compound Solubility vs pH in Saline
Compounds that may advantageously be used to practice the invention can be and were tested to determine their solubility in saline at different pH values and temperatures using the following procedure.
A stock saline solution was prepared by dissolving 9 grams of NaCl in one liter of de-ionized water. Saline solutions with different pH values were made by adjusting the pH of this stock solution with HCI and/or NaOH.
2 mg samples of the compound of example 1 were weighed into glass vials. Into each vial was added a 50 μl aliquot of saline solution at a certain pH. The vial was vortexed and, if necessary, sonicated until clear. For each tested pH the total volume of saline needed to dissolve 2 mg of the compound was recorded and the solubility was calculated.
Solutions that were clear at room temperature (20-25° C.) were placed in a refrigerator (4° C.) overnight and the solubility at 4° C. then examined.
B.3. Determination of Compound Solubility in Saline at pH 7.0
Compounds that may advantageously be used to practice the invention can be and were tested to determine their solubility at room temperature in saline having pH=7 using the following procedure.
Saline solution was prepared by dissolving 9 grams of NaCl in one liter of de-ionized water. 2 mg each of (Aib 8 , Arg 26,34 , β-Ala 35 )hGLP-1(7-36)NH 2 (example 6), (Aib 8,35 , Arg 26,34 )hGLP-1(7-36)NH 2 (example 24), and (Aib 8 35, Arg 26,34 , 2Nal 31 )hGLP-1(7-36)NH 2 (example 32) were weighed into separate glass vials respectively and 1 mL aliquots of of saline were added, with vortexing and sonication, until clear. The total volume of saline used to dissolve 2 mg of peptide was recorded and the solubility at room temperature was calculated.
B.4. Determination of Compound Solubility in Saline at various pH
Compounds that may advantageously be used to practice the invention can be and were tested to determine their solubility at room temperature in saline solutions having various pH values using the following procedure.
A stock saline solution was prepared by dissolving 9 grams of NaCl in one liter of de-ionized water. Saline solutions having various pH values were obtained by treating aliquots of this stock saline solution with HCl and NaOH.
2 mg samples of (Aib 8,35 , Arg 2 , Phe 3 )hGLP-1 (7-36)NH 2 (example 23) and of (Aib 8,35 , Phe 31 , Arg 34 )hGLP-1(7-36)NH 2 (example 34) were weighed into glass vials, respectively. Aliquots of 50 μl of a saline buffer at a certain pH were added. The solution was vortexed and sonicated until clear. The total volume of buffer used to dissolve 2 mg of peptide was recorded and the solubility was calculated.
C. Determination of Aqueous Solubility of Compound vs Zinc Concentration
Compounds that may advantageously be used to practice the invention can be and were tested to determine their solubility in pH 7 water at different zinc concentrations using the following procedure.
A stock zinc solution was prepared by dissolving ZnCl 2 in de-ionized water to a concentration of 100 mg/ml and adjusting the pH to 2.7 using HCl. Solutions having various ZnCl 2 concentrations (“Zn Test Solutions”) were prepared by making appropriate dilutions of the stock solution.
1 mg of the compound of Example 1 was dissolved in 250 μl of each Zn Test Solution to yield a solution having 4 mg/ml of the Example 1 compound. The pH of this solution was then adjusted using 0.2 N NaOH until white precipitates were observed to form. The precipitation solution was centrifuged and the mother liquor analyzed using HPLC. The UV absorption area of test compound peak was measured and the concentration of the test compound in the mother liquor was determined via comparison to a calibration curve.
As a representative example of a compound that may be used to practice the invention, the compound of Example 1 was tested in the immediately foregoing assay and the following results were obtained (aqueous saline, pH 7.0, room temperature):
TABLE 2 ZnCl 2 concentration Solubility (μg/mL) (mg/mL) 0 0.0539 80 0.0059 500 0.0056 1000 0.0097 1500 0.0097 2500 0.0110
D. Preparation of Peptide/Zinc Solution Having pH=4.0
A 0.5 mg/ml ZnCl 2 solution was prepared by dilution of a solution of 100 mg/ml ZnCl 2 in an HCl solution having pH 2.7 water. 1 mg of the compound of Example 1 was dissolved in 250 μl of this solution to yield a clear solution having 4 mg/ml of the compound and 0.5 mg/ml Zn at pH 4.
E. Preparation of Peptide/Zinc Suspension/Gel Having pH=7.0
A particle suspension or gel of a test compound at pH 7.0 for use in in vivo pharmacodynamic (“PD”) studies may be made using the following procedure.
Approximately 250 μL of the clear solution made in Preparation D., above, (pH 4, 0.5 mg/ml Zn, 4 mg/ml compound of Example 1) is neutralized to pH 7.0 using approximately 25 μL 0.2 N NaOH.
F. Determination of pl Using IEF Gels
Invitrogen's Novex IEF pH3-10 gels were used to measure the pi of GLP-1 peptides.
Peptidyl compounds to be tested were dissolved in water to a concentration of 0.5 mg/ml. For each such compound, 5 ii of the resulting solution was mixed with 5 μl of Novex® Sample Buffer 2X (comprised of 20 mM Arginine free base, 20 mM Lysine free base and 15% Glycerol) and the resulting 10 μl sample solution was loaded onto the gel along with a protein standard sample.
Running buffers were also obtained from Invitrogen and the gel was run according to manufacture's instructions, generally as follows: 100 V constant for 1 hour, followed by 200 V constant for 1 hour, followed by 500 V constant for 30 minutes.
The gel was then fixed in 12% TCA containing 3.5% sulfosalicylic acid for 30 minutes, and then stained for 2 hours with Colloidal Coomassie Blue according to the instructions found on the Novex® Colloidal Blue Kit thereafter, then de-stained in water overnight.
The gel was scanned and analyzed by the program Fragment Analysis 1.2. pl's of unknown peptides were calculated relative to the pl's of standard compounds having pl values of: 10.7, 9.5, 8.3, 8.0, 7.8, 7.4, 6.9, 6.0, 5.3, 5.2, 4.5, 4.2, and 3.5.
Preferred compounds that may be used to practice the invention have pl values of approximately 6.0 to approximately 8.5, more preferred approximately 6.5 to approximately 8.0, even more preferred approximately 7.0 to approximately 7.8. Surprisingly, compositions of the invention which are particularly well adapted for use were found to have pl's approximating physiologic pH.
G. In Vivo Assays
Compositions of the present invention can be and were tested to determine their ability to promote and enhanced effect in vivo using the following assays.
G.1. Experimental Procedure:
The day prior to the experiment, adult male Sprague-Dawley rats (Taconic, Germantown, N.Y.) that weighed approximately 300-350g were implanted with a right atrial jugular cannula under chlorohydrate anesthetic. The rats were then fasted for 18 hours prior to the injection of the appropriate test composition or vehicle control at time 0. The rats continued to be fasted throughout the entire experiment.
At time zero the rats were injected subcutaneously (sc) either with (a) the compound of Example 1 (Aib 8 , 35 , Arg 26 , 34 , Phe 31 )hGLP-1(7-36)NH 2 ) at pH 4.0 as a clear solution (i.e., the solution of Preparation D.), or (b) the compound of Example 1 at pH 7.0 as a suspension or gel (i.e., the suspension or gel of Preparation E.). In both cases the injection volume was very small (4-6 μL) and the dose of GLP-1 compound administered to the subject was 75 μg/kg. At the appropriate time after the sc injections a 500 μl blood sample was withdrawn via the intravenous (iv) cannula and the rats were given an iv glucose challenge to test for the presence of enhanced insulin secretion. The times of the glucose challenge were 0.25, 1, 6, 12 and 24 hours post-compound injection. After the initial blood sample was withdrawn glucose (1 g/kg) was injected iv and flushed in with 500 μl heparinized saline (10U/mL). Thereafter, 500 μl blood samples were withdrawn at 2.5, 5, 10 and 20 minutes post-glucose injection. Each of these was immediately followed by an iv injection of 500 μl heparinized saline (10U/mL) through the cannula. The blood samples were centrifuged, plasma was collected from each sample and the samples were stored at −20° C. until they were assayed for insulin content. The amount of insulin in each sample was determined using a rat insulin enzyme-linked immunosorbant assay (ELISA) kit (American Laboratory Products Co., Windham, N.H.).
Results:
Surprisingly, with both the clear solution and suspension or gel form of the compound of Example 1 a sustained insulin-enhancing activity was observed that was inducible by glucose injection over the full 24 hours of the experiment.
G.2. Experimental Procedure:
The assay was performed as in G.1., with the exception that at time zero the rats were injected subcutaneously (sc) with a solution of (Aib 8,35 )hGLP1(7-36)NH 2 prepared according to Preparation D., above, or with vehicle control. As in G.1. the injection volume was very small (4-6 μL) and the dose of GLP-1 compound administered to the subject was 75 μg/kg.
Results:
A sustained insulin-enhancing activity was observed that was inducible by glucose injection over the full 24 hours of the experiment.
G.3. Experimental Procedure:
The general procedure was the same as that provided in G.1. In this case the compound of Example 1 prepared according to Preparation D, or a vehicle control, was injected subcutaneously (“sc”) at time zero. The time points for the glucose challenge were 1, 6, 12, 24, 48 and 72 hours post-injection. The glucose injection via the iv cannula and subsequent blood sampling were performed as in experiment G.1. Because of the extended fasting period, vehicle and glucose-only controls were included at each time point.
Results:
A sustained insulin-enhancing activity that was inducible by glucose for at least 48 hours after subcutaneous injection of the test composition was observed. In addition, as in experiment G.1. no initial high level of insulin enhancement in response to glucose was observed.
H. In Vivo Assays
Compositions of the present invention can be and were tested to determine their ability to promote extended release of active compound in vivo using assays H.1-H.4., described below. As a representative example of compounds that may be used to practice the invention, the compound of Example 1, (Aib 8 , 35 , Arg 26 , 4 , Phe 31 )hGLP-1(7-36)NH 2 , was formulated into the various exemplary formulations described in Table 3, below, and subjected to assays H.1.-H.4.
Compositions for use in the assays below were made according to the following general procedure:
Stock solutions of 100 mg/ml ZnCl 2 were made by dissolving zinc chloride (Merck, Mollet del Valles, Barcelona, Spain) in sterile water for injection (Braun, Rubi, Spain) which had been adjusted to pH 2.7 using HCl. Solutions containing zinc at various concentrations, e.g., 0.1 mg/ml, 0.5 mg/ml, 2 mg/ml, etc., were obtained by dilution of the stock solution. Solutions containing zinc at lower concentrations, e.g., 10 μg/ml, 20 μg/ml, 30 μg/ml, were prepared in an analogous manner by dilution of a stock solution comprising 1 mg/ml ZnCl 2 .
An appropriate amount of a compound to be assayed, e.g., the peptide of Example 1, was weighed and dissolved in the appropriate volume of each resulting zinc solution to yield a clear solution having a desired concentration of the compound; e.g., 4 mg/ml. The resulting solutions were then micro-filtered and, if necessary, stored in light-protected vials before administration.
The concentration of test compound in the plasma of the test subjects may be determined by a number of methods known in the art. In one convenient method the concentration of a compound, e.g., the compound of Example 1, is determined via radioimmunoassay employing a rabbit derived antibody to the test compound in competition with a known quantity of test compound that has been radio-iodinated with, e.g., 125 I.
H.1. Pharmacokinetic Study 1
The effect of zinc on the bioavailability of a bioactive compound administered to a subject using a composition according to the invention can be and was determined as follows.
Following the procedures described above, four aqueous compositions were formulated to have 4 mg/mL of the Compound of Example 1 at pH=2.7, and 0.0, 0.1, 0.5, and 2.0 mg/ml of ZnCl 2 , respectively. See Table 3, Examples H1a, H1b, H1c and H1d. Each of the four compositions was administered subcutaneously to 16 Sprague-Dawley rats (Charles River Laboratories, Wilmington, Mass., USA). The average age of the rats was approximately 8-9 weeks, and the average weight was approximately 260-430 g. The rats were provided food and water ad libitum. The plasma levels of the compound of Example 1 after injection (dose=75 microg/kg compound of Example 1) are depicted in FIG. 1 .
H.2. Pharmacokinetic Study 2
The effect of injection volume on the bioavailability of a bioactive compound administered to a subject using a composition according to the invention can be and was determined as follows.
Following the procedures described above, three aqueous compositions were formulated to have 3000, 300 and 75 microg/mL, respectively, of the Compound of Example 1, at a pH of 2.7 and Zn concentration of 0.5 mg/ml. See Table 3, Examples H2a, H2b, and H2c. Each of the three compositions was administered subcutaneously to 16 Sprague-Dawley rats (Charles River Laboratories, Wilmington, Mass., USA). The average age of the rats was approximately 8-10 weeks and the average weight was approximately 330-460 g. The rats were fasted overnight prior to commencement of the study. The volume of injection was selected to provide each rat with 75 micorg/kg dose of the compound of Example 1. (0.025 ml/kg, 0.25 ml/kg, and 1 ml/kg, respectively.) The plasma levels of the compound of Example 1 after injection are depicted in FIG. 2 .
H.3. Pharmacokinetic Study 3
The effect of zinc on the bioavailability of a bioactive compound administered to a subject using a composition according to the invention can be and was determined as follows.
Following the procedures described above, three aqueous compositions were formulated to have 4 mg/mL of the Compound of Example 1 at pH=2.7, and 10, 20 and 30 microg/mL of zinc, respectively. See Table 3, Examples H3a, H3b, and H3c. Each of the three compositions was administered subcutaneously to 16 Male albino Sprague-Dawley rats (St. Feliu de Codines, Barcelona, ES). These rats were fasted overnight prior to commencement of the study. The plasma levels of the compound of Example 1 after injection (dose=75 microg/kg compound of Example 1) are depicted in FIG. 3 .
H.4. Pharmacokinetic Study 4
The effect of zinc and bioactive compound concentrations on the bioavailability of the bioactive compound when administered to a subject using a composition according to the invention can be and was determined as follows.
Following the procedures described above, two aqueous compositions were formulated. The first solution comprised 1.45 mg/ml of the compound of Example 1 and 30 micorg/ml Zinc, the second comprised 1.45 mg/ml of the compound of Example 1 but without zinc. Both solutions had pH=2.7. See Table 3, Example H4a and H4b. Each solution was administered subcutaneously to male Beagle dogs (Isoquimen, Barcelona, Spain) ranging in age from approximately 54-65 months and in weight from approximately 16-21 kg. The dogs were fasted overnight prior to commencement of the study. Additionally, the second solution containing only active compound was administered intravenously. All injections provided doses of 25 microg/kg. The plasma levels of the Compound of Example 1 after injection are depicted in FIG. 4 .
TABLE 3 Summary of compositions tested Example Components Amount Units H1a Active Compound: Example 1 4 mg Solution pH = 2.7 1 mL H1b Active Compound: Example 1 4 mg Solution 0.1 mg/mL ZnCl 2 in WFI 1 mL (pH = 2.7) H1c Active Compound: Example 1 4 mg Solution 0.5 mg/mL ZnCl 2 in WFI 1 mL (pH = 2.7) H1d Active Compound: Example 1 4 mg Solution 2 mg/mL ZnCl 2 in WFI 1 mL (pH = 2.7) H2a Active Compound: Example 1 3 mg Solution 0.5 mg/mL ZnCl 2 in WFI 1 mL H2b Active Compound: Example 1 300 μg Solution 0.5 mg/mL ZnCl 2 in WFI 1 mL H2c Active Compound: Example 1 75 μg Solution 0.5 mg/mL ZnCl 2 in WFI 1 mL Solution NaOH 7 M 8 μL H3a Active Compound: Example 1 4 mg Solution 10 microg/ml ZnCl 2 in WFI 1 ml H3b Active Compound: Example 1 4 mg Solution 20 microg/ml ZnCl 2 in WFI 1 ml H3c Active Compound: Example 1 4 mg Solution 30 microg/ml ZnCl 2 in WFI 1 ml H4a Active Compound: Example 1 1.45 mg WFI 1 Ml H4b Active Compound: Example 1 1.45 mg/Ml Solution 30 microg/ml ZnCl 2 in WFI 1 ml WFI = sterile water for injection (BRAUN, Rubi, Spain)
I. In Vivo Assays
I.1. Pharmacokinetic Study: Semi-solid composition
The ability of semi-solid aqueous compositions of the invention to provide a biologically significant plasma concentration of peptide over a further extended period of time after administration to a subject can be and was determined as follows.
An aqueous semi-solid composition of the Compound of Example 1 was made by homogenizing an amount of the Compound of Example 1 (acetate salt) with sufficient sterile water for injection to provide a semi-solid, paste-like composition which comprised approximately 25% of the peptide (e.g., 0.250 mg/mg). The composition was loaded into 0.3 mL syringes fitted with 19/0.6 (0.35 mm) UNIMED needles. Approximately 60 mg of the semi-solid composition (containing approximately 15 mg of peptide) was administered to each of 10 male Sprague-Dawley rats (Harlan Iberica, Barcelona, Spain). The average age of the rats was approximately 10 weeks, and the average weight was approximately 220-330 g. The rats were fasted approximately 14 hours prior to commencement of the study, however they were provided with water ad libitum. The rats were provided with food and water ad libitum after administration of the test composition. The plasma levels of the compound of Example 1 after injection are depicted in FIG. 5 .
I.2. Pharmacokinetic Study: 1 mg Microtablet
The ability of a solid composition of the invention, without zinc, diluent, or other excipient, also to provide a biologically significant plasma concentration of peptide over a further extended period of time after administration to a subject can be and was determined as follows.
Samples of such weight of the acetate salt of the Compound of Example 1 as to provide approximately 1 mg of the peptide were added to a standard tableting die and compressed to form solid microtablets. The microtablets were loaded into ICO plunger syringes fitted with a 1.2/1.0 (0.25 mm) needles; i.e., having a 1 mm internal diameter. The mircotablets were administered to each of 10 male Sprague-Dawley rats (Charles River Laboratories). The age of the rats ranged from approximately 10-12 weeks, and the weight ranged from approximately 320-480 g. The rats were fasted approximately 14 hours prior to commencement of the study, however they were provided with water ad libitum. The rats were provided with food and water ad libitum after administration of the test composition. The plasma levels of the compound of Example 1 after injection are depicted in FIG. 6 .
I.pb 3 . Pharmacokinetic Study: 15 mg Microtablet
Substantially the same procedure was employed as provided for study 1.3., above, with the exception that the microtablets were formulated to contain 15 mg of the Compound of Example 1. The age of the rats ranged from approximately 11-13 weeks, and the weight ranged from approximately 300-480 g. The plasma levels of the compound of Example 1 after injection are depicted in FIG. 7 .
In the figures depicting the results of the foregoing in vivo examples the points plotted represent the mean values of the tested populations.
The peptides used in this invention advantageously may be provided in the form of pharmaceutically acceptable salts. Examples of such salts include, but are not limited to, those formed with organic acids (e.g., acetic, lactic, maleic, citric, malic, ascorbic, succinic, benzoic, methanesulfonic, toluenesulfonic, or pamoic acid), inorganic acids (e.g., hydrochloric acid, sulfuric acid, or phosphoric acid), and polymeric acids (e.g., tannic acid, carboxymethyl cellulose, polylactic, polyglycolic, or copolymers of polylactic-glycolic acids). A typical method of making a salt of a peptide of the present invention is well known in the art and can be accomplished by standard methods of salt exchange. Accordingly, the TFA salt of a peptide of the present invention (the TFA salt results from the purification of the peptide by using preparative HPLC, eluting with TFA containing buffer solutions) can be converted into another salt, such as an acetate salt by dissolving the peptide in a small amount of 0.25 N acetic acid aqueous solution. The resulting solution is applied to a semi-prep HPLC column (Zorbax, 300 SB, C-8). The column is eluted with (1) 0.1N ammonium acetate aqueous solution for 0.5 hrs., (2) 0.25N acetic acid aqueous solution for 0.5 hrs. and (3) a linear gradient (20% to 100% of solution B over 30 min.) at a flow rate of 4 ml/min (solution A is 0.25N acetic acid aqueous solution; solution B is 0.25N acetic acid in acetonitrile/water, 80:20). The fractions containing the peptide are collected and lyophilized to dryness.
As is well known to those skilled in the art, the known and potential uses of GLP-1 is varied and multitudinous (See, Todd, J. F., et al., Clinical Science, 1998, 95, pp. 325-329; and Todd, J. F. et al., European Journal of Clinical Investigation, 1997, 27, pp.533-536). Thus, the administration of the compounds of this invention for purposes of eliciting an agonist effect can have the same effects and uses as GLP-1 itself. These varied uses of GLP-1 may be summarized as follows, treatment of: Type I diabetes, Type II diabetes, obesity, glucagonomas, secretory disorders of the airway, metabolic disorder, arthritis, osteoporosis, central nervous system diseases, restenosis, neurodegenerative diseases, renal failure, congestive heart failure, nephrotic syndrome, cirrhosis, pulmonary edema, hypertension, and disorders wherein the reduction of food intake is desired. GLP-1 analogues of the present invention that elicit an antagonist effect from a subject can be used for treating the following: hypoglycemia and malabsorption syndrome associated with gastroectomy or small bowel resection.
Accordingly, the present invention includes within its scope pharmaceutical compositions as defined herein comprising, as an active ingredient, at least one of the compounds of formula (I).
The dosage of active ingredient in the formulations of this invention may be varied; however, it is necessary that the amount of the active ingredient be such that a suitable dosage is obtained. The selected dosage depends upon the desired therapeutic effect, on the route of administration, and on the duration of the treatment, and normally will be determined by the attending physician. In general, an effective dosage for the activities of this invention is in the range of 1×10 −7 to 200 mg/kg/day, preferably 1×10 −4 to 100 mg/kg/day, which can be administered as a single dose or divided into multiple doses.
The formulations of this invention are preferably administered parenterally, e.g., intramuscularly, intraperitoneally, intravenously, subcutaneously, and the like.
Preparations according to this invention for parenteral administration include sterile aqueous or non-aqueous solutions, suspensions, gels, or emulsions, provided that the desired in vivo release profile is achieved. Examples of non-aqueous solvents or vehicles are propylene glycol, polyethylene glycol, vegetable oils, such as olive oil and corn oil, gelatin, and injectable organic esters such as ethyl oleate. Such dosage forms may also contain adjuvants such as preserving, wetting, emulsifying, and dispersing agents. They may be sterilized by, for example, filtration through a bacteria-retaining filter, by incorporating sterilizing agents into the compositions, by irradiating the compositions, or by heating the compositions. They can also be manufactured in the form of sterile solid compositions which can be dissolved in sterile water, or some other sterile injectable medium immediately before use.
Unless defined otherwise, 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. Also, all publications, patent applications, patents and other references mentioned herein are incorporated by reference.
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The present invention is directed to peptide analogues of glucagon-like peptide-1, the pharmaceutically-acceptable salts thereof, to methods of using such analogues to treat mammals and to pharmaceutical compositions useful therefor comprising said analogues.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is cross-referenced to and claims the benefit from U.S. Provisional Patent Application 60/712,355 filed Aug. 29, 2005, which is hereby incorporated by reference in its entirety for all that it discloses.
FIELD OF THE INVENTION
[0002] The invention relates generally to telerobotics. More particularly, the invention relates to feedback control devices and methods in telerobotic systems.
BACKGROUND
[0003] Telerobotics allows users to indirectly manipulate and interact with environments via master and slave robotic mechanisms. It enables operation at a distance and can also scale human forces and motions to achieve stronger, larger, or smaller interfaces. Applications range from space exploration to minimally invasive surgery. Vision is typically the dominant feedback modality in these systems, but the addition of haptic feedback provides more complete information to the user and can improve their ability to perform complex tasks.
[0004] High frequency feedback to a user is commonly recognized as vital to achieving a realistic telerobotic experience. However, high frequency feedback continues to be a challenge for most telerobotic systems. Difficulties such as contact instabilities have led researchers to sidestep stability issues using alternate modalities such as audio and vibrotactile displays.
[0005] Among the force feedback architectures, one could distinguish two existing philosophies. First, position-position approaches use slave tracking errors to feed back computed forces. Typically, they connect master and slave with a single PD controller imitating a spring and damper. This method is passive and provides robust stability without any knowledge of the environment. Furthermore, in this approach the critical high frequency forces are masked out of the feedback and the operator experiences a soft, compliant feel.
[0006] Realizing that human perception peaks at several hundred Hertz, the opposing philosophy utilizes a position-force architecture. It feeds measured contact forces directly back to the user, with high frequency signals intact. This violates passivity by hiding the slave's inertia and often has limited stability, especially in contact with stiff environments. Though researchers have tried to improve stability margins, these systems are fundamentally sensitive to lag and delays.
[0007] The presence of even small time delays, typically found in the communication channel between the master and slave sites, poses a serious stability problem for force feedback telerobots. Most delay capable controllers ultimately achieve stability through prediction across the delay and/or by severely restricting the bandwidth of the system. Prediction of interactions with a truly unknown environment itself proves problematic. Limiting the system bandwidth deprives the user of very important high frequency feedback information. Even wave variable controllers with guaranteed stability focus on low frequency interactions. For a description of wave variable controllers the reader is referred to Niemeyer et al. (Niemeyer G and Slotine J J E (2004), a paper entitled “ Telemanipulation with time delays” and published in the International Journal of Robotics Research 23(9):873-890).
[0008] Accordingly, there is a need in the art to develop new methods and systems to overcome the shortcomings in the art and integrate high frequency feedback in telerobotic systems to enhance users' telerobotic experience.
SUMMARY OF THE INVENTION
[0009] The present invention provides telerobotic systems with integrated high frequency feedback to enhance users' telerobotic experience. In one embodiment the invention is a telerobotic system including a master, a slave and a wave controller interfacing the master and slave device. The wave controller is characterized by receiving position or velocity information from the slave and encoding position or velocity information in a wave transformation. The encoded position or velocity information is then decoded for feedback to the master. The position or velocity information received from the slave device is low frequency information, and in a preferred example this information has a frequency content up to about 10 Hz.
[0010] The wave controller further receives force or acceleration information from the slave. The received force or acceleration information is used to extract and shape high frequency force or acceleration information, which in one example is defined as matching the acceleration between the master and the slave device in the high frequency range. The extracted and shaped high frequency information is then combined with either the encoded or the decoded position or velocity information. The high frequency information has a frequency content of about 10 Hz or higher or of about 10 Hz to about 1 Khz.
[0011] A wave filter could be used to shape or cancel wave reflections in the wave controller. The invention provides two types of wave filters, i.e. a infinite horizon and finite horizon wave shaping filter.
[0012] In another embodiment, the invention is a telerobotic system including a master, a slave and a controller interfacing the master and the slave device. In this system, the controller is characterized by providing a first feedback force to the master device and a second force feedback to the slave device. The first feedback force has a component being dependent on one of the velocities of the master device or the slave device, or a combination of both velocities. The second feedback force has a component being dependent on one of the velocities of the master device or the slave device, or a combination of both velocities. A key aspect of this controller is that the first feedback force and the second feedback force together do not dissipate or generate power in the master device and the slave device. This particular controller is also characterized by having gyroscopic forces with an asymmetry between the gain of the master velocity to the slave force and the gain of the slave velocity to the master force.
[0013] The telerobotic systems with high frequency feedback are useful for teleoperations with delay as well as with no-delay between the communication channels of the master and slave device, while maintaining contact stability.
BRIEF DESCRIPTION OF THE FIGURES
[0014] The objectives and advantages of the present invention will be understood by reading the following detailed description in conjunction with the drawing, in which:
[0015] FIG. 1 shows that interactions may be separated into a bidirectional manipulation band and a unidirectional perception band.
[0016] FIGS. 2-3 show each a block diagram representation of an augmented wave controller according to the present invention.
[0017] FIGS. 4-5 show each a block diagram representation with wave shaping according to the present invention.
[0018] FIG. 6 shows a bond graph representation of the augmented wave controller according to the present invention.
[0019] In the figures and text abbreviations and indices are defined as:
u=forward wave traveling from master to slave ν=backward wave traveling from slave to master T=communication delay F=force {dot over (x)}=velocity {umlaut over (x)}=acceleration m=mass b=wave impedance S(s)=wave shaping element M(s)=feedback scaling/shaping element H(s)=high pass filter L(s)=low pass filter λ=bandwidth of L(s) γ=bandwidth of H(s) s/(s+γ) implementation of H(s) λ/(s+λ) implementation of L(s) I=Inertial element R=Resistive element C=Capacitive element B=Damping term K=Spring term s=Laplace operator S e =Effort source GY=Gyrator element η=perception band scale factor (any positive number where 1 could be considered normal or any value ranging from 0 to 100)
[0045] Subscripts are used and defined as:
m=master s=slave h=hand env or e=environment (except in S e ) eq=equivalent c=controller f=filtered p=proportional term d=derivative term
[0055] Combinations of subscripts are used and combine the individual terms like e.g. mc is master-controller.
DETAILED DESCRIPTION OF THE INVENTION
[0000] Human Perception and Sensor Selection
[0056] As humans, we interact with our environment in a very asymmetric manner. While the bandwidth of human movements is limited to under 10 Hz, forces from DC to 1 kHz are important for our perception of the environment. We intentionally use motions such as tapping, stroking, and scratching that elicit high frequency cues for perceiving properties such as hardness and texture.
[0057] We can thus separate interactions with an environment into two discrete frequency bands as shown in FIG. 1 ; i.e. a manipulation band and a perception band. The manipulation band includes the low frequency range up to approximately 10 Hz. It is fundamentally bidirectional, containing both motion (position and velocity) and force signals. The perception band is unidirectional and includes frequencies above 10 Hz up to about 1 KHz.
[0000] Augmented Wave Controller
[0058] Recognizing the inherent stability of a low bandwidth passive controller and the perceptual importance of high frequency feedback, the present invention provides a controller that will combine both of these concepts. The augmented wave controller shown in FIGS. 2-3 incorporates high frequency information from a slave tip accelerometer ( FIG. 2 ) or a force sensor at the slave side ( FIG. 3 ) into a passive wave controller. The augmented controller retains the bidirectional low frequency manipulation band connection and adds a unidirectional high frequency perception band feedback path using the acceleration or force information. The examples provided describe an individual degree of freedom, modeling the master and slave devices as pure masses m m and m s respectively.
[0059] At both the master and slave locations we utilize the wave transformation to compute a force command, which is applied directly to the devices, according to
F m c = b x . m - 2 b v m F sc = - b x . s + 2 b u s
[0060] These force commands provide local velocity feedback as part of the wave transformation. The energy removed by this term drives the wave signals and is returned with the incoming wave so that the system does not feel damped. Using the wave transformation to compute forces eliminates the need for further control elements and provides the most direct coupling between the master and slave.
[0061] Alternatively, the wave command can be decoded into a desired velocity, which is followed by a local tracking controller.
[0062] In addition to the regular feedback path, the slave tip acceleration {umlaut over (x)}, or environment force F e is measured explicitly by an accelerometer or force sensor respectively and the high frequency portion of the signal is incorporated into the returning wave after passing through a shaping process.
[0063] In the example of FIG. 2 , slave tip acceleration is incorporated into the returning wave after passing through a scaling element M (s) and a high pass filter H (s). A final shaping by the wave impedance 1/√(2b) matches the signal against the units of the wave variables.
[0064] The slave acceleration {umlaut over (x)} s is routed through the element M (s) to obtain an equivalent force F eq that is eventually applied to the master motors. The transfer function M (s) maps acceleration to force and hence carries the units of mass. For one to one scaling between the environment force and the master force, M (s) is set to the mass of the slave m s . To match accelerations in the perception band between the master and slave, M (s) needs to equal the mass of the master m m . Assuming a more complete model of the master device we can further improve perception by matching acceleration of the slave end effector and the user's fingertips. In this case, M (s) would invert the dynamic relationship between master motor force and master handle acceleration. It would counteract any high frequency distortion from the master's internal dynamics to more closely tie the user to the environment.
[0065] The equivalent force F eq is processed by a high pass filter H (s) to isolate the perception band signals and avoid interference between the two feedback paths. Nevertheless, the additional feedback path injects high frequency energy into the system and violates passivity. While the extra energy is desired for feedback, we must ensure it remains unidirectional and cannot create a closed-loop instability. As such, a low pass filter L (s) is placed in the forward wave path to dissipate any reflected high frequency energy. By tuning L (s), H (s), and M (s) appropriately, we can balance energy amplification and dissipation to ensure system stability. The end result is an asymmetric controller designed to match the interaction requirements of the user.
[0066] Augmentation based upon a force sensor, as shown in the example of FIG. 3 , follows the same steps as those used with an accelerometer with the exclusion of the shaping element M (s). Here, F e is measured directly and then routed through the remainder of the scaling and shaping elements. One additional implementation uses the same scaling and shaping concepts discussed supra but applies the high frequency feedback directly to the master device, without formally integrating it into the wave channel.
[0067] While this description so far has focused to the case where unity force and position scaling are desired between master and slave within the manipulation band, extension to scaled teleoperation applications would be readily understood by one skilled in the art.
[0068] To ensure stability of the augmented wave controller, the elements L (s), H (s), and M (s) must be tuned appropriately. Specifically, these elements are typically tuned to result in the two-port including the master, slave, and controller satisfying LLewellyn's criterion for unconditional stability. A preferred implementation uses
M ( s )=m s ,
ℒ ( s ) = λ s + λ where λ = b m s , and
[0069] H(s) as one of the following options:
ℋ ( s ) = s s + λ where γ = λ
for accelerometer based architecture.
ℋ ( s ) = s 2 ( s + λ ) 2 where γ = λ
for force sensor based architecture.
ℋ ( s ) = s s + 2 λ where γ = 2 * λ
for force sensor based architecture with improved performance and a less rigorous stability proof.
Shaping Wave Reflections
[0070] Wave reflections are known to occur in the transmission element of telerobotic system and can pose significant distractions to the operator. They may be understood in the context of undamped resonances or standing wave phenomena. The traditional wave transmission allows passive bidirectional signal transmission and creates a lossless communications element regardless of delay. It stores the energy associated with the wave signals for the duration of their transmission and displays both inertial and spring-like aspects, with associated kinetic and potential energy. As such, a system based on the wave transmission may be interpreted as an undamped oscillator, with a natural frequency approximately inversely proportional to the delay time. The wave reflections are thus the response of this oscillator to user inputs.
[0071] An alternate interpretation is based on standing wave phenomena, where reflections on boundaries can superimpose and interfere constructively to create sustained oscillations. Similar to standing wave phenomena, the particular boundary conditions determine the exact resonant frequency. Irrespective of their interpretation, wave reflections can disorient the user and their slow decay may force the user to wait considerable time before resuming operations.
[0072] For small delays, this resonance can be suppressed with a simple low-pass filter in the forward wave path. With slightly longer communication delays, in the 100 ms range, the wave reflection resonance occurs at a low enough frequency that compensation with a simple low pass filter begins to limit the manipulation bandwidth of the system. To focus additional damping more effectively at the resonant frequency of the wave channel, the invention further provides shaping the waves such that the wave reflections cancel at this frequency.
[0073] We examined both infinite horizon and finite horizon wave shaping filters ( FIGS. 4-5 ). In the infinite horizon wave shaping in FIG. 4 , the wave command is halved but also recycled and reintroduced into the system after an additional delay of 2 T. FIG. 5 shows a block diagram for the finite horizon wave shaping that delays half of the commanded wave an additional 2 T before it is sent to the slave. Both of these wave shaping schemes can still be viewed as wave filters. They are just slightly smarter filters that place more of-the damping where it is actually needed and less where it is not. The transfer functions for these two filters are given as
G infinite ( s ) = 1 2 - ⅇ - 2 sT G finite ( s ) = 1 + ⅇ - 2 sT 2 .
[0074] The magnitude portions of the bode plots show that both of these filters attenuate at the resonant frequency of the wave reflection and it's harmonics.
[0075] One advantage of wave shaping filters over a traditional notch filter is that the designer does not need to know the actual value of the time delay. The required additional 2 T delay can easily be generated by sending the commands on one extra round trip to the slave site and back through the normal communication channel. Assuming that this extra data bandwidth does not adversely affect the communication channel, this will result in a filter that automatically tunes itself to the wave reflection resonance.
[0076] Both of these wave shaping filters showed promising results for damping the wave reflection resonance for delays up to several hundred milliseconds. Allowing more of the manipulation band commands through the forward path than a low pass filter at these delays, the user benefits from better tracking and a less sluggish feel. DC components of wave reflections are returned to the user and generate appropriate steady state behavior.
[0000] Stabilization Control Through Gyration
[0077] Working in wave space provides the designer with the opportunity to easily and intuitively manipulate power flows and analyze passivity. However, most people have developed much more experience and intuition in the more commonly used power variables. By expanding the wave transformations and solving the wave loop algebraically, we are able to write the augmented wave controller with a particular selection of filters in power variables as
F sc = 2 b λ s Δ x . + b Δ x . - b x . m + λ s + γ F e
F m c = 2 b λ s Δ x . + b Δ x . ︸ PD - b x . s ︸ GY + λ s + γ F e ︸ LF F e + s s + γ F e ︸ H F F e
where the relative velocity of the devices is written as
Δ {dot over (x)}={dot over (x)} m −{dot over (x)} s .
[0078] At this point it should be noted that while the augmented wave controller expressed in wave variables is tolerant to arbitrary communication delays, the augmented controller represents only the special case of no delay and does not retain the provable tolerance to delay.
[0079] Examining this augmented controller we see that the first two terms represent a traditional PD controller with gains K p =2bλ and K d =b. However, the third term in the controller clearly distinguishes this design from traditional approaches. It does not provide damping, but instead a gyroscopic force (GY) connecting the two devices. This force transfers power between master and slave without dissipating energy and is inherent to the wave design. It is one of the sources of the augmented wave controller's asymmetry and highlights how designs in wave space can result in new control architectures.
[0080] Continuing to combine aspects of both position-position (pos-pos) and position-force (pos-force) architectures, the LF F e term applies the low frequency portion of the environment force to both the master and slave with a DC gain of one half (for γ=2λ). This effective low frequency force control renders the environment to the user with twice the DC stiffness of the PD terms alone. The controller's most noticeable asymmetry arises from the high frequency environment forces fed to the user in the final term of F mc , i.e. HF F e .
[0081] To examine power flows in this expression of the augmented wave controller, we construct its bond graph model in FIG. 6 . The bonds drawn in sold lines represent the embedded traditional PD controller. With the exception of the human user, this network represents an interconnection of passive elements and is therefore itself passive. The addition of the dashed bonds through the gyrator provides a second path for energy to flow between the master and slave that parallels the PD elements. While not a familiar element in force feedback controllers, a gyrator conserves power and preserves the passivity of the network. Accordingly, the addition of the gyrator alone does not significantly alter the high frequency transmission characteristics of the controller.
[0082] To improve the high frequency force rendering of the controller, we connect the dotted bonds to effort sources carrying the measured environment forces that are applied to the master and slave. According to the augmented wave controller expressed in power variables, these effort sources are computed by the controller as
F es = λ s + γ F e
F em = λ s + γ F e + s s + γ F e
[0083] These bonds represent the possibility of injecting or absorbing arbitrary amounts of energy into the system and are one of the basic causes of non-passivity and contact instabilities that often arise in traditional pos-force architectures.
[0084] The present invention has now been described in accordance with several exemplary embodiments, which are intended to be illustrative in all aspects, rather than restrictive. Thus, the present invention is capable of many variations in detailed implementation, which may be derived from the description contained herein by a person of ordinary skill in the art. Controller performance, passivity analysis, contact stability analysis and other details are described in the various appendices filed with the provisional application to which this application claims the benefit from. As indicated supra the provisional application with its appendices are hereby incorporated by reference in its entirety. All such variations are considered to be within the scope and spirit of the present invention as defined by the following claims and their legal equivalents.
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Telerobotic systems with integrated high frequency feedback to enhance users' telerobotic experience are provided. The controller of the telerobotic system is characterized by combining high frequency information with low frequency position or velocity information. The controller is useful for teleoperations with delay and no-delay between the communication channels of the master and slave device.
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BACKGROUND
[0001] The “background” description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description which may not otherwise qualify as prior art at the time of filing, are neither expressly or impliedly admitted as prior art against the present invention.
[0002] A conventional vacuum cleaner may include a head portion that is in contact with a surface to be cleaned, a tube or flexible hose or a combination thereof to connect the head portion to a main body, and an air suction mechanism housed in the main body. When the suction mechanism is switched on, the tube provides a suction flow path from the head portion to the main body, so dirt, dust and other debris may be removed from the surface to be cleaned. The main body typically includes a dirt bag or other container to collect the debris.
[0003] The suction mechanism in the main body is conventionally generated by an electric motor driving a fan. A suction flow path connects the low pressure side of the fan to the head portion. Conventionally, an exhaust flow path connects the high pressure side of the fan to a filtered exhaust to establish an exhaust air flow from the high pressure side of the fan to outside the main body.
[0004] As similarly above, vacuum cleaners typically use a suction nozzle that is movable across a surface to be cleaned. The suction created at an inlet in the nozzle results in the removal of free dirt particles accumulated on the surface. However, ground in dirt is frequently encountered when cleaning carpets or other textured surfaces, and reliance on suction for removal of such ground-in dirt has proven to be unsatisfactory.
[0005] The head portion of a vacuum cleaner is conventionally equipped with a mechanical agitator, mimicking a sweeping function. The agitator may be in the form of a stationary brush or a rotating brush which rolls as the head portion is moved against the cleaning surface. Alternatively, the brush may be mechanically driven by an electric motor which is primarily used for the mechanical agitator. Alternatively, the brush may be mechanically driven by a belt to connect to the electric motor within the main body which is primarily used for the suction mechanism.
[0006] The mechanical agitator is sometimes undesirable due to the nature of the surface to be cleaned. One disadvantage of a mechanical agitator is damage to the surface being cleaned. Delicate material or surfaces prohibit the use of a mechanical brush as it might cause damage to the surface. One remedy may be to substitute the mechanical agitator with a touchless agitation mechanism such as a sonic agitator which relies on fluctuation in air flow through the nozzle opening to dislodge dirt particles. Although sonic agitators avoid physical damage to a carpet often caused by mechanical agitators, they are not as effective in dislodging dirt on the surface of a carpet pile. At the same time, mechanical agitators are not as effective in removing particles embedded deeply in the carpet pile. Also, mechanical agitators tend to push dirt particles down into the carpet, thereby making it more difficult to effectively clean the carpet.
SUMMARY
[0007] Another remedy may be to instead use a touchless agitator where the debris is agitated by a pressured air flow blown to the surface to be cleaned. This option also provides for better dusting when the surface to be cleaned has hard to reach dusty grooves, an example of which is a keyboard. The touchless agitation mechanism may also be used in conjunction with the conventional mechanical agitator for improved debris removal.
[0008] To provide the pressured air flow for the touchless agitation mechanism, the touchless agitation mechanism may be provided by a separate motor or drive mechanism driving a fan, wherein a blowing flow path connects the high pressure side of the fan to the head portion.
[0009] Embodiments include an apparatus, which includes a housing including a suction portion having a suction source connected to a motor connected to a power source; a suction pipe connected to the housing and the vacuum suction portion; a head portion connected to the suction hose via an inlet opening; and a set of rotating fans connected to a drive mechanism and disposed in the head portion. The set of rotating fans is further disposed adjacent to the inlet opening, and the set of rotating fans are configured to synchronously push or pull air to or from a surface to be cleaned when the vacuum suction portion is in operation.
[0010] Embodiments also include an apparatus, which includes a base; a head portion connected to the base via a suction pipe; a suction inlet in the head portion; and a set of rotating fans connected to a drive mechanism and disposed in the head portion adjacent to the suction inlet. The set of rotating fans are configured to synchronously push or pull air to or from a surface to be cleaned.
[0011] The foregoing paragraphs have been provided by way of general introduction, and are not intended to limit the scope of the following claims. The described embodiments, together with further advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] A more complete appreciation of the disclosure 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:
[0013] FIG. 1 is an illustrative view of a head portion of a vacuum cleaner according to an embodiment of the invention.
[0014] FIGS. 2A and 2B are illustrative views of a roller-activated switch according to an embodiment of the invention.
[0015] FIG. 3 is an illustrative view of a vacuum cleaner having a plug-in head portion according to an embodiment of the invention.
[0016] FIGS. 4A and 4B are illustrative views a vacuum cleaner having a battery-powered head portion according to an embodiment of the invention.
[0017] FIG. 5 is an illustrative view of a head portion of a vacuum cleaner according to an embodiment of the invention.
[0018] FIGS. 6A to 6D are illustrative views of a head portion having shutters of a vacuum cleaner according to an embodiment of the invention.
[0019] FIG. 7 is an illustrative view of a head portion of a vacuum cleaner according to an embodiment of the invention.
[0020] FIGS. 8A and 8B are illustrative views of a head portion of a vacuum cleaner according to an embodiment of the invention.
[0021] FIGS. 9A and 9B are illustrative views of a head portion of a vacuum cleaner according to an embodiment of the invention.
[0022] FIG. 10 is an illustrative view of a head portion of a vacuum cleaner according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0023] Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views.
[0024] FIG. 1 is an illustrative view of a head portion 100 of a vacuum cleaner. FIG. 1 shows head portion 100 including roller mechanism 105 , a set of rotating powered fans 110 , vacuum inlet 115 , and suction pipe or hose 120 . In certain embodiments, the set of rotating powered fans 110 are adjacent to and flank the vacuum inlet 115 although the rotating fans 110 could be located above or below the vacuum inlet 115 or elsewhere on the head portion 100 . In certain embodiments, roller mechanism 105 may be configured to be operable as a switch or control mechanism which synchronously operates or turns on both fans 110 and a suction device (as shown in FIG. 3 at 320 ) simultaneously. For example, roller mechanism 105 may be electrically coupled to both the fans 110 and the suction device 320 to operate as a mutual switch, thereby causing suction and insufflation to be synched.
[0025] Further, roller mechanism 105 may be configured to act as a pressure-sensitive switch in which a predetermined amount of pressure will cause both fans 110 and the suction device to operate at the same time, as discussed above. In some embodiments, roller mechanism 105 may be configured to also change the speed of fans 110 when a predetermined amount of pressure is placed upon roller mechanism 105 . For example, if an operator wishes or needs increased agitation of the surface to be cleaned, then by increasing pressure applied towards head portion 100 may affect an increase in insufflation (blowing) by fans 110 .
[0026] Further, fans 110 may be configured with a reversible motor (not shown) for insufflation or blowing of air towards a surface to be cleaned thereby effecting a more efficient cleaning of the surface.
[0027] In some embodiments, head portion 100 may be configured as a removable detachment from suction hose 120 for cleaning purposes or the like.
[0028] FIGS. 2A and 2B are illustrative views of a roller-activated pressure switch 200 of roller mechanism 105 . In some embodiments, roller-activated switch 200 may be configured to control and/or activate fans 110 . In certain embodiments, switch 200 may be configured to control the rotational speed and/or direction of fans 110 via a reversible motor (not shown). In addition, in certain embodiments, the rotational direction of fans 110 may be controlled via a separate switch or control (as shown in FIG. 5 at 525 ) disposed on or near the handle of the vacuum cleaner within easy reach of an operator. Further, in certain embodiments, the rotational speed may be directly or indirectly proportional to the amount of pressure placed on roller mechanism 105 .
[0029] The high pressure side of fans 110 may be changed by changing the rotational direction of fans 110 , thus effecting whether an operator wishes to blow/push air or suction/pull air near the surface to be cleaned.
[0030] FIG. 2A shows roller mechanism 105 configured in a pressure switch arrangement including springs 205 disposed between poles of the switch 200 , an arm holder 215 of the roller 105 , where the holder 215 includes an area slip 220 which allows roller axle 225 to freely move in translation therein when pressure is applied. In FIG. 2A , roller mechanism 105 and switch 200 are shown in a position spaced-apart from the surface 230 to be cleaned and therefore switch 200 is in an open position at electrical contacts 210 . FIG. 2B shows roller mechanism 105 in a position in contact with the surface 230 to be cleaned and therefore switch 200 is in a closed position at electrical contacts 210 .
[0031] Alternatively, embodiments of the invention are not limited to the pressure switch arrangement shown in FIGS. 2A and 2B and may be a combination of elements which come into contact with the surface to be cleaned in order to activate fans 110 without departing from the scope of the invention.
[0032] FIG. 3 is an illustrative view of a vacuum cleaner 300 having a plug-in head portion 305 . In some embodiments, vacuum cleaner 300 may include a plug-in head portion 305 connected to a hose handle 310 . Handle 310 may be connected to a suction hose 315 connected to a suction device 320 . Suction device 320 may be electrically wired (at 325 ) to a power source (not shown). Head portion 305 may include an electrical contact 330 electrically wired (at 335 ) to the same or another power source (not shown) configured to power fans 110 .
[0033] Alternatively, FIGS. 4A and 4B are illustrative views of a vacuum cleaner 400 having a battery-powered head portion 405 . In some embodiments, vacuum cleaner 400 may include a battery-powered head portion 405 connected to a hose handle 410 . Handle 410 may be connected to a suction hose 415 connected to a suction device 420 . Suction device 420 may be electrically wired (at 425 ) to a power source (not shown), such as a standard electrical outlet. Referring to FIG. 4B , head portion 405 may include an internal rechargeable battery power source 430 configured to power fans 110 . Head portion 405 may be configured such that battery power source 430 is fixed or removable for easy replacement when needed. Battery power source 430 may be configured to be chargeable from electrical wire 425 when plugged into a power source (not shown), such as a standard electrical outlet or via a separate electrical wire and plug-in arrangement, as would be understood by one of ordinary skill in the art.
[0034] Alternatively, in some embodiments, fans 110 may be incorporated into either vacuum cleaner 300 or vacuum cleaner 400 such that fans 110 are directly powered by the vacuum cleaner ( 300 , 400 ) itself via wires ( 325 , 425 ).
[0035] FIG. 5 is an illustrative view of a head portion 500 for a vacuum cleaner. In certain embodiments, head portion 500 may include separate air ducts 505 , 510 in communication with fans 110 to a main air duct 515 . Air ducts 505 , 510 may be configured to allow for the pulled (suction) air to enter a vacuum cleaner debris container (not shown). Further, air ducts 505 , 510 may be configured to include air flow valve control elements 520 disposed at or near fans 110 configured to control the direction of air flow either to main air duct 515 in the case of pulling (suction) air via fans 110 or from outside air in the case of insufflation (blowing) of air via fans 110 . Air flow valve control elements 520 may be configured to open in the case of pulling air via fans 110 and thereby allowing air to flow towards main air duct 515 . Further, air flow valve control elements 520 may be configured to close in the case of blowing air via fans 110 and thereby preventing air to flow from main air duct 515 . In addition, air flow valve control elements 520 may include an outside air vent (not shown) to provide fresh air in the case of the blowing air fans 110 . Switch 525 may be disposed at a distal end of main air duct 515 proximal an operator and switch 525 may be configured to control whether fans 110 are pulling (suction) or performing insufflation (blowing) by reversing the rotational direction of fans 110 .
[0036] FIGS. 6A to 6D are illustrative views of a head portion 600 of a vacuum cleaner including roller mechanism 605 , fans 610 , and fan shutters 615 . Head portion 600 further includes a suction inlet 620 and a suction hose 625 . In some embodiments, in the instance of the roller mechanism 605 , disposed in head portion 600 , comes into contact with or engages a surface, such as a floor or carpet, shutters 615 may be configured to open, as shown in FIGS. 6A and 6B to allow fans 610 to perform in a manner as described above with regard to FIGS. 2A and 2B . For example, a spring-loaded switch mechanism (as similarly shown in FIGS. 2A and 2B ) may be coupled to roller mechanism 605 to operably cause shutters 615 to open when roller mechanism 605 contacts or engages a surface, thereby allowing an airstream from fans 610 . In the instance of the roller mechanism 605 lifting from or disengaging a surface, shutters 615 may be configured to close, thereby blocking the airstream from fans 610 , as shown in FIGS. 6C and 6D . For example, when roller mechanism 605 disengages the surface, the spring-loaded switch mechanism (as similarly shown in FIGS. 2A and 2B ) may be configured to cause shutters 615 to close, as shown in FIGS. 6C and 6D .
[0037] Shutters 615 may provide the advantages of preventing any possible upheaval of dust or debris via blowing fans 610 by closing off the air stream from blowing fans 610 when removing head portion 600 from a surface. Further, shutters 615 may also provide some safety advantages by limiting access to the rotating fans 610 when not in a normal operation position parallel to a surface to be cleaned. This may even be an advantage when the fans 610 are powering down but still in rotation.
[0038] FIG. 7 is an illustrative view of a head portion 700 of a vacuum cleaner showing fans 705 , turbines 710 , axis arms 715 , suction hose 720 , fan duct 725 , suction inlet 730 , and housing portion 735 . In FIG. 7 , turbines 710 take advantage of the suction airflow of the vacuum cleaner to use the air stream to power fans 705 . For example, turbines 710 may be operably connected to fans 705 via axis arms 715 , so that the rotation of turbines 710 leads to the rotation of axis arms 715 , which in turn rotate fans 705 to initiate the insufflation process. Further, turbines 710 may be disposed adjacent to the walls of housing portion 735 to prevent impeding airflow to suction hose 720 and turbines 710 and have an axis of rotation perpendicular to the axis of rotation of fans 705 . In addition, the use of the suction airflow to power fans 705 via turbines 710 may lead to overall power savings. Thus, there may be a reduced need or no need at all to power fans 705 disposed in head portion 700 by other means, such as, the wired electrical power configuration or battery powered configuration, discussed above.
[0039] FIGS. 8A and 8B are an illustrative view of a head portion 800 of a vacuum cleaner showing fans 805 , turbine mechanism 810 which may include turbine blades 812 , axis arms and gears ( 807 , 809 , 814 , 815 ), suction hose 820 , fan duct 825 , suction inlet 830 , and housing portion 835 . In FIGS. 8A and 8B , turbine blades 812 take advantage of the suction airflow of the vacuum cleaner to use the air stream to power fans 805 . For instance, turbine blades 812 may be operably connected to fans 805 via axis arms 807 , 809 , 814 , 815 , so that the rotation of turbine blades 812 leads to the rotation of axis arms 807 , 809 , 814 , 815 , which in turn rotate fans 805 to initiate the insufflation process. Further, turbine mechanism 810 may be disposed adjacent to the walls of housing portion 835 to prevent impeding airflow to suction hose 820 and turbine blades 812 have an axis of rotation perpendicular or orthogonal to the axis of rotation of fans 805 . In addition, the use of the suction airflow to power fans 805 via turbine blades 812 may lead to overall power savings. Thus, there may be a reduced need or no need at all to power fans 805 disposed in head portion 800 by other means, such as, the wired electrical power configuration or battery powered configuration, discussed above.
[0040] FIGS. 9A and 9B are illustrative views of a head portion 900 of a vacuum cleaner showing fans 905 , turbine mechanism 910 which may include turbine blades 909 , axis arms and gear couplings ( 907 , 911 , 913 ), suction hose 920 , fan duct 925 , suction inlet 930 , and housing portion 935 . In FIG. 9B , gear couplings and axis arms 907 and 913 may be configured to align with a rotational axis of fans 905 and turbine blades 909 , respectively. Further, axis arm 911 may be configured to horizontally align in rotational communication with fans 905 via turbine blades 909 . In FIGS. 9A and 9B , turbine blades 909 takes advantage of the suction airflow of the vacuum cleaner to use the air stream to power fans 905 . In other words, turbine mechanism 910 may include a plurality of separate turbine blades 909 configured to rotate when a suction airflow occurs within housing portion 935 , and turbines blades 909 may be coupled to fans 905 . For example, turbine mechanism 910 may be operably connected to fans 905 via axis arms 907 , 911 , 913 , so that the rotation of turbine blades 909 leads to the rotation of axis arms 907 , 911 , 913 which in turn rotate fans 905 to initiate the insufflation process. Further, turbine blades 909 may be disposed in parallel with respect to fans 905 and horizontally with respect to the air stream of the vacuum cleaner. In addition, turbine blades 909 may further be disposed slightly to the air stream to prevent impeding airflow to suction hose 920 .
[0041] FIG. 10 is an illustrative view of a head portion 1000 of a vacuum cleaner showing fans 1005 , forward rotational brushes 1010 , rearward rotational brushes 1015 , suction hose 1020 , fan duct 1025 , suction inlet 1030 , and housing portion 1035 . In FIG. 10 , forward rotational brushes 1010 are configured to rotate towards suction inlet 1030 and rearward rotational brushes 1015 are also configured to rotate towards suction inlet 1030 . Thus, forward rotational brushes 1010 and rearward rotational brushes 1015 rotate in opposing directions towards suction inlet 1030 to assist in sweeping a surface and pushing air with dust or debris towards suction inlet 1030 and thereby into the vacuum cleaner to be inhaled or suctioned by the air stream.
[0042] Brushes 1010 and 1015 may be driven by a conventional drive mechanism (not shown) or by other driving means, for example, brushes 1010 and 1015 may be configured to be coupled to wheels 105 , 605 , for example, to provide the proper rotational direction of brushes 1010 and 1015 , that is, forward rotational brushes 1010 and rearward rotational brushes 1015 , rotate in opposing directions towards suction inlet 1030 to assist in sweeping a surface and pushing air with dust or debris towards suction inlet 1030 . In other words, when wheels 105 , 605 rotate, then in turn brushes 1010 and 1015 rotate as well. Alternatively, brushes 110 and 1015 may be configured to be coupled to drive belts, for example, to provide the rotation, as discussed above.
[0043] Thus, the foregoing discussion discloses and describes merely exemplary embodiments of the present invention. As will be understood by those skilled in the art, the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Accordingly, the disclosure of the present invention is intended to be illustrative, but not limiting of the scope of the invention, as well as other claims. The disclosure, including any readily discernible variants of the teachings herein, define, in part, the scope of the foregoing claim terminology such that no inventive subject matter is dedicated to the public.
[0044] The above disclosure also encompasses the embodiments noted below.
[0045] (1) An apparatus, comprising: a housing including a suction portion having a suction source connected to a motor connected to a power source; a suction pipe connected to the housing and the suction portion; a head portion connected to the suction hose via an inlet opening; and a set of rotating fans connected to a drive mechanism and disposed in the head portion, wherein the set of rotating fans is further disposed adjacent to the inlet opening, and the set of rotating fans are configured to synchronously push or pull air to or from a surface to be cleaned when the suction portion is in operation.
[0046] (2) The apparatus according to (1), further comprising: a roller mechanism disposed in the head portion, wherein the roller mechanism is attached to an arm holder having an area slip configured for translational motion of the roller mechanism, wherein the arm holder is attached to an electric switch having electric contacts separated by at least one compression spring, the electric switch is configured to turn on the set of rotating fans based on pressure applied to the head portion and the at least one compression spring.
[0047] (3) The apparatus according to (1) or (2), wherein the drive mechanism includes at least one turbine disposed in an air stream of the inlet opening and configured to rotate the set of rotating fans via a rotational axis arm in communication with a rotational arm of the set of rotating fans.
[0048] (4) The apparatus according to (1) to (3), wherein the at least one turbine is further disposed adjacent a wall of the suction pipe and the at least one turbine has an axis of rotation orthogonal to an axis of rotation of the set of rotating fans.
[0049] (5) The apparatus according to (1) to (4), wherein the at least one turbine is further disposed in parallel to the set of rotating fans and parallel to the air stream, where the at least one turbine includes a horizontally aligned axis arm in rotational communication with the set of rotating fans.
[0050] (6) The apparatus according to (1) to (5), further comprising: at least one roller brush disposed in the head portion adjacent the inlet opening, wherein the at least one roller brush being configured to rotate in a direction toward the inlet opening.
[0051] (7) The apparatus according to (1) to (6), wherein the rotational direction of the set of rotating fans is configured to be reversible via an electric switch spaced apart from the head portion.
[0052] (8) The apparatus according to (1) to (7), wherein a rotational direction of the set of rotating fans is configured to be reversible based on a predetermined amount of pressure applied to the roller mechanism upon contact with the surface to be cleaned.
[0053] (9) The apparatus according to (1) to (8), further comprising: an air duct disposed adjacent to the set of rotating fans; and at least one valve disposed at a distal end within the air duct and adjacent to the set of rotating fans, wherein the at least one valve is configured to direct air flow during synchronous pulling or pushing air via the set of rotating fans and the suction source.
[0054] (10) The apparatus according to (1) to (9), wherein a rotational speed of the set of rotating fans is configured to change based on a predetermined amount of pressure applied to the roller mechanism upon contact with the surface to be cleaned.
[0055] (11) The apparatus according to (1) to (10), wherein the electric switch is further configured to trigger opening and closing of a set of shutters configured to either allow an airstream from the set of fans when opened or to block the airstream from the set of fans when closed.
[0056] (12) An apparatus, comprising: a base; a head portion connected to the base via a suction pipe; a suction inlet in the head portion; and a set of rotating fans connected to a drive mechanism and disposed in the head portion adjacent to the suction inlet, wherein the set of rotating fans are configured to synchronously push or pull air to or from a surface to be cleaned.
[0057] (13) The apparatus according to (12), further comprising: a roller mechanism disposed in the head portion, wherein the roller mechanism is attached to an arm holder having an area slip configured for translational motion of the roller mechanism, wherein the arm holder is attached to an electric switch having electric contacts separated by at least one compression spring, the electric switch is configured to turn on the set of rotating fans based on pressure applied to the head portion and the at least one compression spring.
[0058] (14) The apparatus according to (12) or (13), wherein the drive mechanism includes at least one turbine disposed in an air stream of the suction inlet and configured to rotate the set of rotating fans via a rotational axis arm in communication with a rotational arm of the set of rotating fans.
[0059] (15) The apparatus according to (12) to (14), wherein the at least one turbine is further disposed adjacent a wall of the suction pipe and the at least one turbine has an axis of rotation orthogonal to an axis of rotation of the set of rotating fans.
[0060] (16) The apparatus according to (12) to (15), wherein the at least one turbine is further disposed in parallel to the set of rotating fans and parallel to the air stream, where the at least one turbine includes a horizontally aligned axis arm in rotational communication with the set of rotating fans.
[0061] (17) The apparatus according to (12) to (16), further comprising: at least one roller brush disposed in the head portion adjacent the inlet opening, wherein the at least one roller brush being configured to rotate in a direction toward the suction inlet.
[0062] (18) The apparatus according to (12) to (17), wherein the rotational direction of the set of rotating fans is configured to be reversible via an electric switch spaced apart from the head portion.
[0063] (19) The apparatus according to (12) to (18), wherein the rotational direction of the set of rotating fans are configured to be reversible based on the amount of pressure applied to the roller mechanism at the surface to be cleaned.
[0064] (20) The apparatus according to (12) to (19), further comprising: an air duct disposed adjacent to the set of rotating fans; and at least one valve disposed at a distal end within the air duct and adjacent to the set of rotating fans, wherein the at least one valve is configured to direct air flow during synchronous pulling or pushing air via the set of rotating fans and the suction inlet.
[0065] (21) The apparatus according to (12) to (20), wherein a rotational speed of the set of rotating fans is configured to change based on a predetermined amount of pressure applied to the roller mechanism upon contact with the surface to be cleaned.
[0066] (22) The apparatus according to (12) to (21), wherein the electric switch is further configured to trigger opening and closing of a set of shutters configured to either allow an airstream from the set of fans when opened or to block the airstream from the set of fans when closed.
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Embodiments include a vacuum head portion and a combined suction and blowing mechanism configured to agitate and remove debris. A set of powered fans provide an external pressured air source to provide pressured air for the blowing mechanism. The vacuum head portion may include blowing and suction nozzles arranged with the blowing nozzles flanking the suction nozzles. The set of powered fans may be driven an electric motor or via air turbines disposed in an air stream of the suction nozzles. The blowing nozzles may be in parallel rows adjacent to the suction nozzles. The blowing mechanism may be operated to act as a suction device by reversing the rotational direction of the set of powered fans via a switching mechanism to create a negative pressure or suction to assist the suction nozzles. The vacuum head portion may be formed as a removable detachment to the vacuum cleaner.
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BACKGROUND
[0001] This invention relates generally to mortise locks, and more particularly to latch assemblies and locking mechanisms for use in reversible mortise locks.
[0002] A mortise lock is designed to fit into a mortised recess formed in the edge of a door which is opposite to the edge of the door that is hinged to the door frame. The mortise lock generally includes a rectangular housing, or case, which encloses the lock components. The principal lock component is a beveled latch bolt which projects beyond the edge of the door and into an opening in the door frame to latch the door in a closed position. The latch bolt is moveable to a retracted position inside the case to permit opening of the door by operation of a latch operator, such as a door knob or lever handle.
[0003] Mortise locks are typically configured so that the latch operators mounted on the inside and outside surfaces of the door can operate independently. The outside latch operator can either be rotated to retract the latch bolt, or locked against rotation to prevent retraction of the latch bolt. Preferably, the inside latch operator can always be rotated to retract the latch bolt. The locking of the outside latch operator is usually controlled by a manual actuator, such as, for example, push buttons or a pivoted toggle, which is exposed at the edge of the mortise lock near the latch. The manual actuator has an associated link within the mortise lock case which, in one position of the manual actuator, engages a moveable portion of the outside latch operator inside the lock case so as to prevent rotation of the latch operator. In a second position, the link disengages from the moveable portion thus permitting rotation of the outside latch operator. The inside latch operator is usually unaffected by the manipulation of the manual actuator and remains rotatable at all times.
[0004] Adjustments must be made to the mortise lock depending on whether the lock is mounted in a left-hand or right-hand door. A mortise lock mounted in a left-hand door must be rotated 180° about a vertical axis for mounting in a right-hand door. Consequently, the latch bolt must also be rotated 180° about a horizontal axis so that the beveled face of the latch faces the door-closing direction. In addition, the inside and outside latch operators of the left-hand door mounted lock become the outside and inside latch operators, respectively, of the right-hand door mounted lock. Therefore, a change must be made if the latch operator controlled by the locking mechanism happens to be the inside latch operator when the lock is installed.
[0005] The necessary adjustments to the mortise lock can be accomplished without opening the case. Typically, the latch bolt can be pulled partially out of the housing, usually against the force of a spring, rotated 180° and then allowed to be pulled back into the housing by the spring. However, this arrangement can lead to tampering after the lock is installed since the latch bolt can be reversed even when the mortise lock is in the door, which would prevent the door from the closing. Moreover, the conventional mechanisms for reversing the operation of the locking mechanism are complicated and difficult to manipulate.
[0006] For the foregoing reasons, there is a need for a latch assembly for use in a reversible mortise lock which includes a latch bolt that cannot be reversed after the lock is installed in a door. Reversal of the latch bolt for use with a door of the opposite hand should be easily accomplished in the field. Further, any corresponding changes in the locking mechanism to effect locking of the outside latch operator should also be uncomplicated. The new latch assembly and locking mechanism should be straightforward in manufacture and use.
SUMMARY
[0007] Therefore, it is an object of the present invention is to provide a reversible mortise lock wherein the latch assembly cannot be reversed when the lock is installed on the door.
[0008] A further object of the present invention is to provide a new latch assembly and locking mechanism for a mortise lock which are simple to reverse in the field prior to installation in the door.
[0009] According to the present invention, a mortise lock includes a latch assembly comprising a latch bolt having a first portion adapted to project from an opening in the lock housing in an extended position of the latch bolt while a second portion of the latch bolt remains within the lock housing. The latch bolt is removable from the lock housing through the opening. A securing member inside the housing is releasably attached to the second portion of the latch bolt. The securing member comprises a securing element having a blocking surface and means for biasing the securing element and blocking surface into engagement with the second portion of the latch bolt for releasably securing the latch bolt to the moving member. The securing element further comprises a disengaging surface which when moved against the force of the biasing means releases the second portion of the latch bolt from the securing member so that the latch bolt may be removed from the lock housing.
[0010] In further accord with the present invention, a mortise lock of the type having a latch bolt normally projecting from the lock housing and means including a moveable member in the lock housing connected to a door knob or lever handle for moving the latch bolt to a retracted position in the housing, has a locking mechanism comprising a blocking element in the housing and means for moving the blocking element between a locked position and an unlocked position relative the moveable member. The blocking element has an opening adapted to receive a portion of the moveable member when the blocking element is in the locked position for allowing the moveable member to move and the door knob or lever handle to rotate. A stop is removably positioned in the opening of the blocking element for preventing movement of the moveable member when the blocking element is in the locked position.
[0011] Also in accord with the present invention, a mortise lock comprises a housing and a latch bolt removably mounted in the housing through an opening in the housing. A securing member is disposed inside the housing for movement relative to the housing. The securing member comprises a securing element having a blocking surface and means for biasing the blocking surface into engagement with the latch bolt for releasably securing the latch bolt to the securing member. The securing element further comprises a surface which when pressed moves the securing element against the force of the biasing means for releasing the latch bolt from the securing member so that the latch bolt may be removed from the housing. The securing member is moveable between a first position where the latch bolt is inside the housing and a second position where a portion of the latch bolt projects through the opening in the housing. Means for moving the securing member to the first position are provided, including a moveable member in the housing. A blocking element is disposed in the housing and means are provided for moving the blocking element between a locked position and an unlocked position relative to the moveable member. A stop is removably attached to the blocking element and adapted in the locked position to prevent operation of the moveable member.
[0012] An important feature of the present invention is that the releasing surface of the securing member is only accessible through the side walls of the mortise lock case. Therefore, latch bolt reversal must be performed before the lock is installed. Moreover, once the latch bolt is freed from the moveable member, the latch bolt can be completely removed from the lock housing, reversed and reinstalled. The blocking element and removable stop for locking the lock are also accessible through the side walls of the lock housing. Thus, repositioning of the stop in the blocking element is also accomplished before installation. Preferably, the stop is a threaded plug which is received in a threaded opening in the blocking element.
[0013] Reversal of the latch bolt and locking mechanism is simple to perform prior to installation of the lock. A screw driver is the only tool needed to release the latch bolt from the lock housing for reversal of the latch bolt and locking mechanism. Once the lock is installed in a door, the latch bolt cannot be reversed because the latch bolt cannot be removed from the lock.
[0014] Additional objects, features and advantages of the present invention will be apparent from the following description in which references are made to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] For a more complete understanding of the present invention, reference should now be had to the embodiments shown in the accompanying drawings and described below.
[0016] [0016]FIG. 1 is a perspective view of an embodiment of a mortise lock assembly according to the present invention;
[0017] [0017]FIG. 2 is a side elevation view of the mortise lock assembly taken along line 2 - 2 of FIG. 1;
[0018] [0018]FIG. 3 is a perspective exploded view of an embodiment of a latch assembly used in the mortise lock assembly of FIG. 1;
[0019] [0019]FIGS. 4 and 5 are opposite side elevational views of an anti-friction latch used in the latch assembly of FIG. 3;
[0020] [0020]FIGS. 6 and 7 are front and rear elevational views, respectively, of the latch tail and spring clip of FIG. 3;
[0021] [0021]FIGS. 8, 9, 10 and 11 are side elevational views of the tail plate of FIG. 3;
[0022] [0022]FIG. 12 is an exploded perspective view of an alternative embodiment of a tail plate and spring clip for use in the latch assembly of FIG. 3;
[0023] [0023]FIGS. 13 and 14 are front and rear elevational views, respectively, of the tail plate and spring clip embodiment of FIG. 12 similar to FIGS. 6 and 7;
[0024] [0024]FIG. 15 is a side elevational view of the tail plate embodiment of FIG. 12 similar to FIG. 8;
[0025] [0025]FIGS. 16 and 17 are side sectional views of the tail plate and spring clip embodiment of FIG. 12 showing the latch tail entering the tail plate taken along line 16 - 16 of FIG. 13;
[0026] [0026]FIG. 18 is a side sectional view of the tail plate and spring clip embodiment of FIGS. 16 and 17 in combination with a screw driver blade illustrating the removal of the latch tail from the tail plate;
[0027] [0027]FIG. 19 is a perspective view of a hub used in the mortise lock assembly of FIG. 1;
[0028] [0028]FIG. 20 is a sectional view of the mortise lock assembly of FIG. 2 taken along line 20 - 20 of FIG. 2 showing an embodiment of a locking mechanism used in the mortise lock assembly of FIG. 1 in an unlocked position;
[0029] [0029]FIG. 21 is side elevational view of the locking mechanism embodiment of FIG. 20 with other lock components removed;
[0030] [0030]FIGS. 22 and 23 are the same views as FIGS. 20 and 21, respectively, but showing the locking mechanism embodiment in a locked position; and
[0031] [0031]FIG. 24 is the same view of the mortise lock assembly of FIG. 2 but showing the latch bolt and deadbolt retracted into the case by actuation of a latch operator.
DESCRIPTION
[0032] The latch bolt and locking mechanism according to the present invention are for use in a mortise lock and may be used with any conventional mortise lock assembly such as, for example, the mortise lock assembly described by U.S. Pat. No. 4,118,056, the contents of which are hereby incorporated by reference. Accordingly, detailed explanations of the functioning of all of the mortise lock components are deemed unnecessary for understanding of the present invention by one of ordinary skill in the art.
[0033] Referring now to FIG. 1, a mortise lock assembly according to the present invention is shown and is generally designated by reference numeral 30 . The lock 30 comprises a generally rectangular box, or case 32 , for housing the lock components and is adapted to be received in a mortise in the free, or unhinged, edge of a door. One of the side walls of the case 32 comprises a cap 34 which is secured to and forms a closure for the case 32 .
[0034] [0034]FIG. 2 shows the lock with the cap side wall 34 removed. The case 32 includes a side wall 36 and, as seen in FIG. 2, integral top 38 , bottom 40 , front 42 and rear 44 walls. The front wall 42 has openings for a latch bolt 46 , a deadbolt 48 , an auxiliary bolt 50 and a flush-mounted toggle 52 . A face plate 54 is secured to the front wall of the case 32 and has openings which correspond to the openings in the front wall 42 . The latch bolt 46 , deadbolt 48 and auxiliary bolt 50 are shown projecting from their respective openings in the front wall 42 and face plate 54 .
[0035] An embodiment of the latch assembly for use in the mortise lock assembly of FIG. 2 is shown in FIG. 3 and designated generally at 56 . The latch assembly 56 comprises the latch bolt 46 including a bolt head 58 and an integral latch tail 60 , an anti-friction latch 62 , a coil spring 64 , a spring flange 66 , a tail plate 68 and spring clip 70 . The bolt head 58 includes a beveled face 72 and a slot 74 . A short pin 76 extends from one side of the bolt head 58 and into the slot 74 for pivotally mounting the anti-friction latch 62 .
[0036] The anti-friction latch 62 is shown in more detail in FIGS. 4 and 5. As seen in FIG. 5, one side of the anti-friction latch 62 has a groove 78 for receiving the pin 76 when the anti-friction latch 62 is slipped into the slot 74 during manufacture. The groove 78 is closed near its open end in a press operation to keep the anti-friction latch 62 in the bolt head 58 . A lever 77 extends from one side of the anti-friction latch and a stub 79 extends from the opposite side. When the latch assembly 56 is in the case (FIG. 2), the anti-friction latch 62 and the opening for the latch bolt 46 in the front wall 42 of the case 32 are configured so that the lever 77 engages behind the front wall 42 while the stub 79 engages behind the face plate 54 .
[0037] Returning to FIG. 3, the latch tail 60 extends from the rear of the bolt head 58 . The portion 61 of the latch tail 60 adjacent the bolt head 58 is thicker than the free end so that the coil spring 64 must be forced onto that portion of the latch tail thereby holding the coil spring 64 on the latch tail 60 . The free end of the latch tail 60 is rounded and includes a notch 80 longitudinally spaced from the free end. The tail plate 68 is generally cube-shaped and has a pass-through opening 82 for receiving the free end of the latch tail 60 . The spring clip 70 is a flat rectangular piece defining an irregular opening 84 and having an angled tab 86 extending from one edge of the clip 84 . The tail plate 68 has a slot 88 which intersects the tail plate opening 82 for receiving the spring clip 70 . The spring clip tab 86 fits in a groove 90 in the side of the tail plate 68 .
[0038] Each side of the tail plate 68 is shown in FIGS. 6 through 11. The tail plate 68 has a support boss 91 which sits against the case side wall 34 when the tail plate 68 is in the case 32 . The support boss 91 has a retraction surface 92 . An opposed boss 94 fits in a linear guide slot 96 in the cap side wall 14 (FIG. 1) for guiding and supporting linear movement of the tail plate 68 . Referring particularly to FIGS. 6 and 7, the tail plate 68 is shown from the front and rear, respectively, with the spring clip 70 in the slot 88 in the tail plate 68 . The irregular opening 84 in the spring clip 70 aligns with the opening 82 in the tail plate 68 . The dimensions of the spring clip 70 and the position of the slot 88 are such that the spring clip 70 partially blocks the opening 82 through the tail plate 68 . The tab 86 is braced against the surface of the groove 90 in the tail plate 68 to bias the spring clip 70 upward to this position as seen in FIGS. 6 and 7.
[0039] An alternative embodiment of the tail plate 68 a and spring clip 70 a for use in the latch assembly 56 of the present invention is shown in FIGS. 12 through 15. In this embodiment, the spring clip 70 a is L-shaped and has an irregular opening 84 a . Two coil springs 98 are disposed in depressions 100 (FIG. 15) in the tail plate surface on either side of the groove 90 a for biasing the spring clip 70 a upward to the position shown in FIGS. 13 and 14 partially blocking the opening 82 a in the tail plate 68 a . The other sides of the tail plate 68 a are configured the same as seen in FIGS. 9 - 11 .
[0040] Connection of the latch bolt 46 to the tail plate 68 a and spring clip 70 a is shown in FIGS. 16 and 17. In FIG. 16, the free end of the latch tail 60 is shown entering the opening 82 a in the tail plate 68 a . As the latch tail 60 initially enters the tail plate 68 a , the rounded end engages the edge of the opening 84 a in the spring clip 70 a forcing the clip down and compressing the springs 98 . When the latch tail notch 80 passes the spring clip 70 a , the springs 98 push the clip upward so that the edge of the opening 84 a in the clip engages behind the notch 80 in the latch tail 60 securing the latch tail in the tail plate 68 a . It is understood that the embodiments of the tail plate and spring clip in FIGS. 6 through 15 are exemplary and other structures are possible, as long as the function of the overall structure for releasably holding the latch tail in the tail plate is maintained.
[0041] As seen in FIG. 2, when the latch assembly 56 is in position in the mortise lock assembly 30 , a substantial portion of the latch bolt 46 is inside the case 32 even when the latch bolt 46 is in the extended position with a predetermined portion projecting beyond the front of the case 32 . The latch tail 60 extends rearwardly from the bolt head 58 through a guide slot formed in a boss 102 fixedly mounted between the side walls 34 , 36 for guiding and supporting the linear reciprocal movement of the latch bolt 46 . The coil spring 64 is held in compression between the bolt head 58 and the spring flange 66 , which is urged against the boss 102 , for normally biasing the latch bolt 46 outwardly to the extended position. A boss 103 on the spring flange 66 fits in a hole 104 (FIG. 1) in the cap side wall 34 for holding the flange 66 in position.
[0042] The latch bolt 46 is moveable in the openings in the front wall 42 of the case 32 and face plate 54 to the retracted position inside the case by operation of a latch operator comprising either an inside or outside knob or lever handle (not shown). In addition, the latch bolt 46 automatically retracts when the anti-friction latch 62 and the beveled face 70 of the bolt head 58 engage the door frame upon closing of the door. Initially, the anti-friction latch 62 engages the door frame pivoting the anti-friction latch on the pin 76 in the bolt head 58 . As the anti-friction latch 62 pivots, the lever 77 works against the front wall 42 of the case 32 driving the latch bolt 46 rearward into the case 32 . When the latch operator is released, or the door is in the door frame, the coil spring 64 returns the latch bolt 46 to the extended position.
[0043] According to the present invention, the latch bolt 46 is reversible for use with a door of the opposite hand. In order to reverse the latch bolt 46 , it is necessary to disconnect the latch bolt from the tail plate 68 and remove the latch bolt 46 from the lock assembly 10 . This is accomplished by first removing the face plate 54 and then manually pushing the latch bolt 46 into the case 32 . Next, the user manually depresses the spring clip 70 , which is accessible through the guide slot 96 in the cap side wall 14 . As seen in FIG. 18, by pressing on the spring clip 70 a with a screw driver 106 or other tool, the spring clip 70 a is pushed down against the force of the springs 98 thereby releasing the latch tail 60 from the spring clip 70 a and tail plate 68 a . When the latch bolt 46 is free of the tail plate 68 a , the latch bolt 46 may be pulled through the opening in the front wall 42 of the case 32 (FIG. 1), rotated 180°, inserted into the case 32 and reattached to the tail plate 68 a , as described above. The slot 96 and hole 104 in the cap side wall 34 are used for viewing to guide the latch tail 60 through the flange 66 and boss 102 and into the opening 82 a in the tail plate 68 a . Because the anti-friction latch 62 can pivot and move linearly with respect to the bolt head 58 on the pin 76 , at least to the extent of the groove 78 which has not been pressed in, the latch bolt 42 is easily manipulated during removal and reinsertion.
[0044] It is understood that other means for biasing the spring clip to the position where the spring clip partially blocks the tail plate opening are possible. For example, the spring clip embodiment shown in FIGS. 12 through 15 would work without the coil springs if the clip material was flexible enough to allow the clip to be pushed down to clear the tail plate opening. Thus, we do not intend ourselves to limit to the specific embodiments of the spring clip biasing means shown herein.
[0045] As noted above, the latch operator comprises means for retracting the latch bolt 46 including an inside or outside knob or lever handle. The retracting means comprises two independent, coaxial rollback hubs 108 which are mirror images of one another. The hubs 108 are rotatably mounted in opposed holes in the walls 34 , 36 of the case 32 below the latch assembly 56 (FIG. 2). The hub 108 which fits in the case side wall 36 is shown in FIG. 19. The hubs include a star-shaped aperture 110 for non-rotatable connection to inside and outside spindle drives (not shown) connected to the knobs or lever handles for rotating the hubs 108 . Each hub 108 has an upper rollback surface 112 which faces the rear wall 44 of the case 32 , a forwardly extending boss 114 and downwardly depending legs 116 . As seen in FIG. 2, the legs 116 engage an L-shaped bracket 118 attached to the bottom of the case 32 for preventing clockwise rotation (as seen in FIG. 2) of the hubs 108 . Two torsion springs 120 are mounted on a transverse pin 122 adjacent to the front of each hub 108 . An end of each spring 120 fits in a notch 124 (FIG. 18) in the hubs 108 for restoring the hubs to the neutral or home position when the knob or handle is released. It is understood that, as an altnerative, the mortise lock assembly may have a single hub to which both the inside and outside spindle drives are connected.
[0046] The retracting means also includes a retractor shoe 126 and a hub lever 128 . The shoe 126 is mounted for linear movement within the case 32 and has a forwardly facing bearing surface 130 for engaging the rollback surfaces 112 of the hubs 108 and a rearwardly facing bearing surface 132 . In this arrangement, the shoe 126 moves linearly rearward in response to counterclockwise rotation, as seen in FIGS. 2 and 24, of either of the rollback hubs 108 . A torsion spring 134 acts between the rear wall 44 and the retractor shoe 126 to urge the shoe toward engagement with the roll back hubs 108 .
[0047] The hub lever 128 comprises a generally flat, L-shaped lever disposed within the case 32 against the case side wall 36 . The hub lever 128 is pivotally supported on a pin 129 at its lower forward leg 136 below and in front of the hubs 108 . The upper leg 138 of the hub lever 128 extends upwardly to the rear of the hubs 108 and has a first laterally projecting tab 139 adjacent the rearward bearing surface 132 of the shoe 126 . A portion of the upper leg of 138 of the hub lever 128 is adjacent to the retraction surface 92 of the tail plate 68 . A torsion spring 143 acts between the rear wall 44 and the first tab 139 to bias the hub lever 128 into operative engagement with the retractor shoe 126 .
[0048] As seen in FIG. 24, the latch bolt 46 is retracted by rotating one of the rollback hubs 108 . Rotation of the rollback hub 108 causes the rollback surface 112 to engage the bearing surface 130 of the retractor shoe 126 moving the shoe linearly rearward. The shoe's rearward bearing surface 132 engages the first hub lever tab 139 to pivot the hub lever 128 in a counterclockwise direction as seen in FIG. 24. The portion of the upper leg of 138 of the hub lever 128 acts against the retraction surface 92 of the tail plate 68 to move the tail plate and connected latch bolt 46 to the retracted position.
[0049] The present invention is also concerned with the locking mechanism (FIG. 2) for selectively securing one or both of the retractor hubs 108 from rotation. The locking mechanism comprises an elongated slide plate 142 and the toggle 52 . Referring to FIG. 20, the rearward end 144 of the slide plate 142 has two slots 146 for receiving a portion of the hubs 108 adjacent the respective bosses 114 . Both ends 144 , 145 of the slide plate 142 have opposed lateral tabs 148 , 149 which ride in corresponding slots 150 in the side walls 34 , 36 of the case for guiding and supporting linear movement of the slide plate 142 relative to the hubs 108 . Each rear plate tab 148 has a transverse hole 152 which opens into the slots 146 . The holes 152 are preferably threaded for receiving a blocking screw 154 . The screw 154 is sufficiently long so that when the screw 154 is threaded into the tab 148 the screw extends into the slot 146 .
[0050] The slide plate 142 is cooperatively linked to the toggle 52 which is accessible through the opening in the front wall 42 and face plate 54 . Manipulation of the toggle 52 linearly reciprocates the slide plate 142 relative to the hubs 108 between an unlocked position (FIGS. 20 and 21) and a locked position (FIGS. 22 and 23). The locking mechanism is moved to the locked position by depressing the upper end of the toggle 52 thereby moving the slide plate 142 so that the rearward end 144 is positioned adjacent the hubs 108 . When the locking mechanism is in the locked position, the screw 154 is in the path of the boss 114 on one of the retractor hubs 108 thereby preventing rotation of the hub 108 . As noted above, the hub 108 preferably affected by the locking mechanism is on the outside of the door. Therefore, the screw 154 is preferably placed in the rear slide plate tab 148 corresponding to the outside hub 108 so as to prevent rotation of the outside hub and retraction of the latch bolt 46 from the outside when the lock is locked. The inside hub 108 can still turn to permit retraction of the latch bolt 46 since the hub boss 114 passes freely through the open slot 146 in the slide plate 142 . If the mortise lock is reversed for installation in a door of the opposite hand, the screw 154 is simply moved to the opposite rear tab 148 . Of course, in mortise locks using a single hub, the screw prevents rotation of both operators. Similarly, in the illustrated embodiment, a second stop screw can be used with the same effect. The locking mechanism is unlocked by depressing the lower end of the toggle 52 thereby moving the slide toward the front wall 42 of the case 32 and away from the hubs 108 (FIGS. 20 and 21).
[0051] Preferably, the mortise lock assembly includes the deadbolt 48 and the auxiliary bolt 50 .
[0052] The deadbolt 48 is selectively moved between an extended position and retracted position by operation of a key cylinder or thumb turn (not shown) in a conventional manner. The cylinder and thumb turn rotate a deadbolt lever 156 which engages the sides of a slot 158 in the rearward end 160 of the deadbolt 48 for extending or retracting the deadbolt. The upper leg 138 of the hub lever 128 has a second laterally projecting tab 162 for engaging the deadbolt lever 156 when the deadbolt 48 is in the extended position for retracting the deadbolt along with the latch bolt 46 in response to rotation of either hub 108 (FIG. 24).
[0053] A rotating stop lever 164 is provided for functionally connecting the deadbolt lever 156 and locking mechanism (FIG. 2). The lower end 166 of the stop lever 164 is positioned in a slot 168 in the stop plate 142 and the upper end 170 is arranged in the path of the deadbolt lever 156 .
[0054] When the deadbolt 48 is moved from the retracted position to the extended position the deadbolt lever 156 engages the upper end portion 170 of the stop lever 164 to rotate the lever in a clockwise direction (as seen in FIG. 2) and move the locking mechanism, including the side plate 142 and toggle 52 , to the locked position. Thus, the locking mechanism automatically moves to the locked position when the deadbolt 48 is moved to the extended position. The locking mechanism remains in this position, even when the deadbolt 48 is retracted by operation of one of the hubs 108 (FIG. 24), until the toggle 52 is actuated to move the slide plate 142 away from the hubs 108 .
[0055] Means for deadlocking the latch bolt 46 in the extended position is also provided (FIG. 2). The deadlocking means 172 comprises the auxiliary bolt 50 , a deadlocking lever 174 and an auxiliary latch lever 176 . When the door is closed, the auxiliary bolt 50 is depressed by the door frame which allows the deadlocking lever 174 to pivot in a counterclockwise direction under the biasing force of a compression spring 178 to a position where the deadlocking lever prevents manual depression of the latch bolt 46 . The deadbolt 48 also has a shoulder 180 which is adjacent the rear surface of the bolt head 58 when the deadbolt is extended also for preventing depression of the latch bolt 46 .
[0056] The previously described embodiments of the present invention have many advantages, including the provision of a reversible mortise lock which cannot be tampered with after installation. Moreover, because the latch bolt reversal relies on removal of the entire latch bolt from the case rather than partial removal, the bolt head can be as long as is practical thereby providing greater strength and security for the lock. The mortise lock incorporating the new latch assembly and locking mechanism is easily modified from outside of the lock casing with a screw driver for use with either a right-hand door or a left-hand door. In either arrangement, the latch operators are operable to open the door when the lock is unlocked. When the lock is locked, rotation of the outside latch operator is prevented, whereas the inside latch operator is still operable to open the door. With the addition of another blocking screw, the inside latch operator can also be locked against rotation.
[0057] Although the present invention has been shown and described in considerable detail with respect to only a few exemplary embodiments thereof, it should be understood by those skilled in the art that we do not intend to limit the invention to the embodiments since various modifications, omissions and additions may be made to the disclosed embodiments without materially departing from the novel teachings and advantages of the invention, particularly in light of the foregoing teachings. For example, a single rollback hub can replace the two, independent hubs so that the locking mechanism affects both the inside and outside latch operators. Accordingly, we intend to cover all such modifications, omission, additions and equivalents as may be included within the spirit and scope of the invention as defined by 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.
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A reversible mortise lock comprises a latch bolt which is removable from the housing for ease of reversal. A securing member is disposed inside the lock housing for releasbly holding the latch bolt in the housing. The securing member includes a securing element having a blocking surface biased into engagement with the latch bolt for securing the latch bolt to the securing member. The securing element has a surface accessible from outside the lock housing which when pressed releases the latch bolt from the securing member. Once the latch bolt is freed, the latch bolt can be completely removed from the lock housing, reversed and reinstalled. This releasing surface is only accessible through the side walls of the lock housing. Therefore, latch bolt reversal must be performed before the lock is installed in a door. Once the lock is installed, the latch bolt cannot be reversed because the latch bolt cannot be removed from the lock. A locking mechanism for use in the lock comprises a blocking element in the housing and a toggle for manually moving the blocking element between a locked position and an unlocked position relative to a latch operator. A stop is removably attached to the blocking element and adapted in the locked position to prevent operation of the outside latch operator. The stop is also accessible through the side walls of the lock housing and positioning of the stop in the blocking element is accomplished before installation. Preferably, the stop is a threaded plug which is received in a threaded opening in the blocking element. Thus, a screw driver is the only tool needed to release the latch bolt from the lock housing for reversal of the latch bolt and locking mechanism.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a reinforcing member for interfitting channels. In particular, the invention relates to a heat-expandable reinforcing assembly that creates a seal between two tube sections of a motor vehicle roll bar for noise reduction and reinforcement of the joint between the tube sections.
2. Description of the Prior Art
Roll bars, commonly used on motor vehicles to prevent injury to the motor vehicle operator in the event the vehicle is overturned, generally include a welded tubular construction alone or in combination with a two-piece telescopically interfitted tubular construction wherein the two pieces are held together by means of a bolt or similar fastening means. In use, the fastener may become loose or may fall out of the roll bar assembly causing the two roll bar sections to bang against one another thereby creating an annoyance to the motor vehicle operator and, more importantly, creating a hazard in that the noise of the two sections rattling against one another may prevent the motor vehicle operator from hearing emergency vehicles, car horns, or other auditory warning signals. Accordingly, there is an unsolved need in the state of art for a roll bar reinforcing assembly that provides stabilization of the roll bar sections, reduces noise associated with the banging together of the roll bar sections, and is easy and economical to install from both a labor and material standpoint.
SUMMARY OF THE INVENTION
The present invention solves the prior art problems discussed above and provides a distinct advance in the state of the art. In particular, the reinforcing member hereof enables reinforcement of a two piece roll bar for a motor vehicle thereby providing sound reduction as well as advantageously enabling finishing liquids such as anti-rust coatings to penetrate and flow through the inside of the roll bar.
The preferred embodiment includes a tubular construction comprising a pair of separate, telescopically interfitted tubular components that cooperatively present a joint therebetween as well as a reinforcing assembly that is operatively located within the interfitted components and proximal the joint. The reinforcing assembly includes a body of heat-expandable synthetic resin material that increases in volume upon heating in order to provide a seal adjacent the joint. When heated, the body engages the tubular components thereby providing a sound-reducing seal which bonds together with metal components and adds strength in the area of the expanded resin material.
The preferred reinforcing assembly is adapted to be located within a pair of telescopically interfitted tubular components in order to join and seal the joint therebetween. The preferred reinforcing assembly comprises a body of heat-expandable synthetic resin material configured for location within the tubular components adjacent the joint and a retainer coupled with the body in order to position the body within the tubular components prior to heat expansion of the body. The retainer serves to locate the synthetic resin material in proximately to the joint and preferably maintains the resin in a desired, axially centered position prior to expansion. Alternatively, the synthetic resin of the reinforcing assembly may be shaped by molding or the like into a complemental shape for receipt within the tubular construction adjacent the joint so that the two tubular components serve to aid in locating the material for expansion at the joint.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the two-piece tubular construction of the present invention showing the inner tube section in phantom lines;
FIG. 2 is top plan view of the tubular construction of FIG. 1 taken along line 2 — 2 ;
FIG. 3 is a side elevational view of the tubular construction of FIG. 1 taken along line 3 — 3 showing the reinforcing assembly and cross connector assembly prior to heat expansion in cross-section;
FIG. 4 is a side elevational view in cross-section showing the reinforcing assembly and cross connector after heat expansion;
FIG. 5 is a side elevational view of the reinforcing assembly in partial cross-section;
FIG. 6 is a side elevational view in cross-section showing the second preferred reinforcing assembly prior to heat expansion;
FIG. 7 is a side elevational view of the reinforcing assembly of FIG. 6 in partial cross-section;
FIG. 8 is a top plan view of the reinforcing assembly of FIG. 7;
FIG. 9 is a bottom plan view of the reinforcing assembly of FIG. 7;
FIG. 10 is a side elevational view in cross-section of a third embodiment of the preferred reinforcing assembly prior to heat expansion with the upper tube section removed for clarity;
FIG. 11 is a top plan view of the reinforcing assembly of FIG. 10;
FIG. 12 is a side elevational view in cross-section of a fourth embodiment of the preferred reinforcing assembly prior to heat expansion with the upper tube section removed for clarity;
FIG. 13 is a top plan view of the reinforcing assembly of FIG. 12;
FIG. 14 is a side elevational view in cross-section of a fifth embodiment of the preferred reinforcing assembly prior to heat expansion;
FIG. 15 is a side elevational view of the reinforcing assembly of FIG. 14 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, FIG. 1 illustrates a preferred roll bar connection assembly 10 in accordance with the present invention. Broadly, roll bar is made up of two elongated, interfitted tubes which cooperatively define a generally U-shaped roll bar attached to a vehicle such as an automobile. The assembly 10 is between the ends of the overall roll bar, and includes a first tube section 12 , a second tube section 14 , a cross connector assembly 16 and a reinforcing assembly 18 which is normally hidden from view. In more detail, the second tube section 14 presents a reduced diameter section 19 that telescopically interfits within the larger first tube section 12 . First tube section 12 includes a sidewall 20 having an inner face 22 , an outer face 24 , and an aperture 26 extending through sidewall 20 from inner face 22 to outer face 24 . Second tube section 14 likewise includes a sidewall 28 having diametrically opposed holes 29 therethrough, an inner face 30 , an outer face 32 , and an internal end section 34 , the sidewall 28 surrounding a through bore 33 .
Cross connector assembly 16 includes a bolt 36 having an enlarged head 36 A and a threaded shank 36 B and an internally threaded sleeve 38 configured to receive the shank 36 B of bolt 36 therein. Sleeve 38 is received within bore 33 and secured to sidewall 28 so that sleeve 38 extends transversely across the interior of sidewall 28 and is positioned in registry with aperture 26 .
Reinforcing assembly 18 includes a reinforcing member 40 formed of heat-expandable synthetic resin material and a retainer 42 . Reinforcing member 40 is generally disc-shaped prior to expansion and includes first face 44 , opposed second face 46 and circumferential rim 48 . The reinforcing member 40 thus presents a height between the first face 44 and the second face 46 in an unexpanded condition as shown in FIGS. 3 and 5 of about preferably 4 to 8 cm to a typical roll bar construction, although this amount will vary depending on the particular application and size of the tube sections. Reinforcing member 40 further includes a central perforation 50 as well as grooves 52 formed about the rim 48 of member 40 and extending between first and second faces, 44 and 46 . The member 40 thus presents a scalloped edge configuration. In addition, the reinforcing member 40 includes a narrowed neck 49 of a reduced diameter relative to rim 48 and which projects below end margin 34 and partially extends into tube section 14 to aid in locating the reinforcing member 40 as shown in FIG. 3 .
One particularly preferred composition for use as member 40 is commercialized under the name SIKAREINFORCER (Sika Corporation, Madison Heights, Mich.). In more detail, the most preferred material for use in reinforcing member 40 comprises: from about 20-30% by weight of a styrene-butadiene-styrene (SBS) block co-polymer (e.g., Fina Clear 530®); from about 5-20% by weight of a polystyrene (e.g., Fina Crystal 500® and Fina Crystal 535®); from about 30-45% by weight of a bisphenol A-based liquid epoxy resin (e.g. Araldite 6010® and Epon 71®); from about 0.5-5% by weight of a pigment such as carbon black; up to about 5% by weight butadiene acrylonitrile rubber (Nipol 1411); from about 1-10% by weight hydrated amorphous silica (HiSil 233); from about 10-20% by weight glass microspheres (Scotchlite S60); from about 0.1-5% by weight of a blowing agent such as azodicarbonamide (e.g., Celogen AZ 765®, Celogen AZ 754A®, and Celogen AZ 130®); from about 0.1-5% by weight of a catalyst such as N, N, dimethyl phenyl urea (U405); from about 0.1-5% by weight of a curing agent such as sulfur or dicyandiamide (DDA10); and up to about 5% by weight of a “kicker” such as zinc oxide to lower the blowing temperature, with all percents by weight being based upon the total weight of the material taken as 100% by weight.
A particularly preferred composition of the member 40 comprises about 12.94% polystyrene, about 23.22% SBS block copolymer, about 0.57% carbon black, about 1.90% butadiene acrylonitrile rubber, about 4.28% hydrated amorphous silica, about 38.07% bisphenol A-based liquid epoxy resin, about 14.75% glass microspheres, about 0.46% zinc oxide, about 2.85% dicyandiamide, about 0.38% N,N dimethyl phenyl urea, and about 0.57% azodicarbonamide. In certain applications where increased compressive strength and reduced foaming and expansion is desired, the foregoing may be adjusted such that the polystyrene is reduced to about 12.63%, the SBS block copolymer is reduced to about 22.59%, and the butadiene acrylonitrile rubber is increased to about 2.85%.
The member 40 can be formed by mixing the SBS block co-polymer with a small portion (about {fraction (1/40)}th of the total amount) of the bisphenol A-based liquid epoxy resin in a heated mixer until the temperature of the mixer reaches from about 240-260° F. (the temperature of the mixture within the mixer is at least about 175° F.), and the mixture is substantially homogeneous, at which time the polystyrene is added to the mixer and mixing is continued. After the polystyrene is substantially mixed with the SBS block co-polymer/epoxy resin mixture, the remainder of the bisphenol A-based epoxy resin is slowly added to the mixer, stopping and starting the mixer as necessary, with the ingredients being thoroughly mixed to obtain a substantially homogeneous mixture. The desired amount of this mixture is placed in a heated mixer (set at a temperature of about 250° F.) and mixing is commenced. While mixing, the carbon black and rubber are added to the mixer and mixing is stopped once a homogeneous mixture is obtained within the mixer. Either the silica or glass microspheres is added to the mixer, and mixing is resumed and continued until the mixture is homogeneous. This step is repeated, adding the other of the silica or glass microspheres.
The temperature of the mixer is then set to a temperature below 160° F., the blowing agent(s), catalyst(s), kicker, and curing agent(s) are added, and mixing is resumed and continued only until the mixture is homogeneous. The resulting mixture is then preferably extruded into strands (at an extruder temperature of 170-180° F. and screw rotation speeds of about 400 rpm) and cut into pellets. The pellets are then injection molded at a temperature of about 180-200° F. using injection molding equipment designed to form the desired shape of the member 40 to be attached to the retainer 42 or otherwise molded into a configuration for positioning adjacent the joint 43 between the first tube section 12 and second tube section 14 .
Retainer 42 includes an attachment member 54 , a first leg 56 and a second leg 58 . Attachment member 54 has a standard 60 , a series of aligned skirts 62 , and base 64 as shown in section in FIGS. 4 and 5. Skirts 62 are integral with standard 60 and project outwardly therefrom in axially-spaced alignment. Standard 60 projects from base 64 . Attachment member 54 extends through first face 44 into perforation 50 so that base 64 contacts first face 44 and the tip of standard 60 is generally flush with second face 46 . Legs 56 and 58 project outwardly from base 64 in a generally opposite direction from standard 60 and resiliently receive sleeve 38 for locking engagement of reinforcing assembly 18 with sleeve 38 .
In use, the reinforcing assembly 18 is positioned adjacent the internal end margin 34 of the second tube section 14 prior to intermitting of the first tube section 12 and second tube section 14 . The retainer 42 is preferably coupled to the sleeve 38 as shown in FIG. 3 . The circumferential rim 48 serves to locate the reinforcing member 40 in a substantially axially centered position. The retainer 42 serves to maintain the reinforcing assembly 18 in proper position notwithstanding movement or tumbling of the roll bar connection assembly 10 . The bolt 36 is tightened against the sidewall 20 of the first tube section 12 . The axially oriented, circumferentially spaced groves 52 and the gap between the circumferential rim 48 and the interface 22 of the first tube section 12 help to ensure that any rust protecting composition received within the first tube section 12 is permitted to drain past the reinforcing member 40 and thoroughly coat the assembly 10 . When the vehicle to which the roll bar assembly 10 is secured is painted, it is typically passed to a bake oven. Upon heating of the roll bar connection assembly 10 in a bake oven to a temperature of at least 300° F., and preferably about 325° F. for a period of about 10 minutes, the reinforcing member 40 will activate, to melt, foam and expand. The base 64 aids in directing the expanding reinforcing member 40 and resisting excessive sag thereof during melting. The resulting reinforced roll bar connection assembly 10 is then allowed to cool to ambient temperature.
In another preferred embodiment of the reinforcing assembly 18 a illustrated in FIGS. 6-9, wherein like parts are numbered in the same manner as the embodiment shown in FIGS. 1-5, a two-piece retainer 42 a is depicted which includes attachment member 54 a seated within a cup-shaped stepped bore 65 with a central opening in the base of member 40 , a first leg 56 , a second leg 58 and a projecting tubular shank 66 . Attachment member 54 a is formed of synthetic resin material such as nylon having a higher melting point than that used in the material of member 40 and includes a first arm 68 , a second arm 70 , a post 72 , and a fastener 74 formed on the end of post 72 and configured to lockingly engage post 72 and shank 66 . Arms 68 and 70 project outwardly from post 72 which extends through bore 65 until the tops of arms 68 and 70 are generally flush with second face 46 . Post 72 snap-fits within shank 66 and fastener 74 lockingly engages shaft 66 to prevent longitudinal shifting of post 72 relative to shank 66 . However, post 72 is permitted to swivel within the shank 66 , thus permitted relative rotational movement of the reinforcing member 40 relative to retainer 42 a relative to the attachment member 54 a . Legs 56 and 58 project outwardly from shank 66 in a generally opposite direction from arms 68 and 70 and resiliently receive sleeve 38 for securing coupling the reinforcing assembly 18 to the sleeve 38 . By permitting the reinforcing member 40 to rotate relative to the sleeve 38 , alignment and installation of the reinforcing assembly 18 is greatly facilitated.
A third preferred embodiment of the reinforcing assembly 18 b is shown in FIGS. 10 and 11 which is of a simplified two-piece construction for use with the roll bar connection assembly 10 . In this embodiment, reinforcing member 40 b presents two apertures 76 and 78 that extend through member 40 b from first face 44 to second face 46 . Second face 46 includes a depression 80 extending between the apertures 76 and 78 and configured to receive attachment member 81 . Attachment member 81 includes a formed wire bight 82 , first leg 84 , and a second leg 86 . Attachment member 81 couples with second face 46 of reinforcing member 40 b by inserting leg 84 into first aperture 76 and inserting second leg 86 into second aperture 78 in such a manner that legs 84 and 86 extend through reinforcing member 40 b and project outwardly from first face 44 . Depression 80 therefore receives bight 82 in locking engagement. Legs 84 and 86 each include an arcuate section 88 , 90 configured to receive sleeve 38 for locking engagement of reinforcing assembly 18 b with sleeve 38 .
FIGS. 12 and 13 illustrate a fourth preferred embodiment of the reinforcing member 18 c similar to that of FIGS. 10 and 11 except that the attachment member 92 presents legs 94 and 96 which are generally arcuate and configured to engage the inner face 30 of sidewall 28 . Thus, the legs 94 and 96 of the reinforcing member 18 c serve to frictionally engage the inner face 30 of the second tube section 14 but do not normally engage the sleeve 38 except when the member 40 moves longitudinally away therefrom.
Finally, in another preferred embodiment, as shown in FIGS. 14 and 15, reinforcing member 40 is molded into a configuration complemental to the second, inner tube section 14 whereby the member 40 c includes an enlarged upper body 98 sized to rest upon the end margin 34 of the second tube section 14 and a narrowed neck 100 configured for insertion into the bore 33 . The complemental and interfitting relationship between the member 40 c and the second tube section 14 permits the bulk of the thermally expandable reinforcing material of the body 98 of member 40 c to flow into the joint for receipt both above and below the margin 34 and in the space between the reduced diameter section 19 and the interface 22 of the first tube section 12 . In addition, if desired, the reinforcing member 40 c may be temporarily coupled with internal end section 34 of tube section 14 by affixing first face 44 to the margin 34 with glue or the like, or the first face 44 may be provided with a transversely or diametrically extending groove complemental to the outer surface of sleeve 38 whereby the reinforcing member may be supported on the sleeve 38 .
In use, reinforcing assembly 18 is coupled with sleeve 38 within second tube section 14 . Second tube section 14 is telescopically interfitted with first tube section 12 and secured in place by inserting bolt 36 into sleeve 38 thereby forming a generally U-shaped roll bar which is then coupled to a motor vehicle. The motor vehicle may be sprayed or dipped with an anti-rust solution, paint, or any other finishing solution. The liquid flows through tube sections 12 and 14 past reinforcing assembly 18 by way of grooves 52 on reinforcing member 40 and past the gap between the rim 48 and the inner face 22 of the sidewall 20 of the first tube section 12 , thereby thoroughly coating inner faces 22 and 30 of sidewalls 20 and 28 . The motor vehicle is then baked at a predetermined temperature sufficient to allow curing of the liquid thereby resulting in the expansion of reinforcing member 40 so that a seal is formed between tube sections 12 and 14 as shown in FIG. 3 . The resulting expanded material of the member 40 bonds to the sleeve 38 as well as to the tubes 12 and 14 , thus creating not only a substantially reinforced connection between the first and second tube sections, but also creates a seal which provides significant sound-reducing capabilities and prevents rattling of tube sections 12 and 14 against one another in the event bolt 36 becomes loose or is freed from sleeve 38 during operation of the motor vehicle. As may be seen in FIG. 4, during expansion of the material of the reinforcing member 40 , the material flows into the junction between the tubes 12 and 14 to provide a strong, rigid, sealing connection.
Although preferred forms of the invention have been described above, it is to be recognized that such disclosure is by way of illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments, as hereinabove set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention.
The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of their invention as pertains to any apparatus or method not materially departing from but outside the literal scope of the invention as set out in the following claims.
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A reinforcing assembly for use with roll bars adapted to be mounted to motor vehicles such as an automobile. The reinforcing assembly includes a heat-expandable synthetic resin reinforcing member and a retainer configured to attach the member to the interior of a two-piece telescopically interfitting tubular roll bar construction. Upon heating, the reinforcing member expands to form a seal between the two roll bar tube sections thereby providing sound-reduction and stability of the roll bar assembly.
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This is a continuation of prior application of Ser. No. 09/161,840, filed Sep. 28, 1998, now U.S. Pat. No. 6,172,475.
A computer program listing appendix submitted to the United States Patent and Trademark Office on a Compact Disk named Codelisting.txt. in duplicate is incorporated herewith by reference.
BACKGROUND OF THE INVENTION
This invention relates generally to movable barrier operators for operating movable barriers or doors. More particularly, it relates to garage door operators having improved safety and energy efficiency features.
Garage door operators have become more sophisticated over the years providing users with increased convenience and security. However, users continue to desire further improvements and new features such as increased energy efficiency, ease of installation, automatic configuration, and aesthetic features, such as quiet, smooth operation.
In some markets energy costs are significant. Thus energy efficiency options such as lower horsepower motors and user control over the worklight functions are important to garage door operator owners. For example, most garage door operators have a worklight which turns on when the operator is commanded to move the door and shuts off a fixed period of time after the door stops. In the United States, an illumination period of 4½ minutes is considered adequate. In markets outside the United States, 4½ minutes is considered too long. Some garage door operators have special safety features, for example, which enable the worklight whenever the obstacle detection beam is broken by an intruder passing through an open garage door. Some users may wish to disable the worklight in this situation. There is a need for a garage door operator which can be automatically configured for predefined energy saving features, such as worklight shut-off time.
Some movable barrier operators include a flasher module which causes a small light to flash or blink whenever the barrier is commanded to move. The flasher module provides some warning when the barrier is moving. There is a need for an improved flasher unit which provides even greater warning to the user when the barrier is commanded to move.
Another feature desired in many markets is a smooth, quiet motor and transmission. Most garage door operators have AC motors because they are less expensive than DC motors. However, AC motors are generally noisier than DC motors.
Most garage door operators employ only one or two speeds of travel. Single speed operation, i.e., the motor immediately ramps up to full operating speed, can create a jarring start to the door. Then during closing, when the door approaches the floor at full operating speed, whether a DC or AC motor is used, the door closes abruptly with a high amount of tension on it from the inertia of the system. This jarring is hard on the transmission and the door and is annoying to the user.
If two operating speeds are used, the motor would be started at a slow speed, usually 20 percent of full operating speed, then after a fixed period of time, the motor speed would increase to full operating speed.
Similarly, when the door reaches a fixed point above/below the close/open limit, the operator would decrease the motor speed to 20 percent of the maximum operating speed. While this two speed operation may eliminate some of the hard starts and stops, the speed changes can be noisy and do not occur smoothly, causing stress on the transmission. There is a need for a garage door operator which opens the door smoothly and quietly, with no aburptly apparent sign of speed change during operation.
Garage doors come in many types and sizes and thus different travel speeds are required for them. For example, a one-piece door will be movable through a shorter total travel distance and need to travel slower for safety reasons than a segmented door with a longer total travel distance. To accommodate the two door types, many garage door operators include two sprockets for driving the transmission. At installation, the installer must determine what type of door is to be driven, then select the appropriate sprocket to attach to the transmission. This takes additional time and if the installer is the user, may require several attempts before matching the correct sprocket for the door. There is a need for a garage door operator which automatically configures travel speed depending on size and weight of the door.
National safety standards dictate that a garage door operator perform a safety reversal (auto-reverse) when an object is detected only one inch above the DOWN limit or floor. To satisfy these safety requirements, most garage door operators include an obstacle detection system, located near the bottom of the door travel. This prevents the door from closing on objects or persons that may be in the door path. Such obstacle detection systems often include an infrared source and detector located on opposite sides of the door frame. The obstacle detector sends a signal when the infrared beam between the source and detector is broken, indicating an obstacle is detected. In response to the obstacle signal, the operator causes an automatic safety reversal. The door stops and begins traveling up, away from the obstacle.
There are two different “forces” used in the operation of the garage door operator. The first “force” is usually preset or setable at two force levels: the UP force level setting used to determine the speed at which the door travels in the UP direction and the DOWN force level setting used to determine the speed at which the door travels in the DOWN direction. The second “force” is the force level determined by the decrease in motor speed due to an external force applied to the door, i.e., from an obstacle or the floor. This external force level is also preset or setable and is any set-point type force against which the feedback force signal is compared. When the system determines the set point force has been met, an auto-reverse or stop is commanded.
To overcome differences in door installations, i.e. stickiness and resistance to movement and other varying frictional-type forces, some garage door operators permit the maximum force (the second force) used to drive the speed of travel to be varied manually. This, however, affects the system's auto-reverse operation based on force. The auto-reverse system based on force initiates an auto-reverse if the force on the door exceeds the maximum force setting (the second force) by some predetermined amount. If the user increases the force setting to drive the door through a “sticky” section of travel, the user may inadvertently affect the force to a much greater value than is safe for the unit to operate during normal use. For example, if the DOWN force setting is set so high that it is only a small incremental value less than the force setting which initiates an auto-reverse due to force, this causes the door to engage objects at a higher speed before reaching the auto-reverse force setting. While the obstacle detection system will cause the door to auto-reverse, the speed and force at which the door hits the obstacle may cause harm to the obstacle and/or the door.
Barrier movement operators should perform a safety reversal off an obstruction which is only marginally higher than the floor, yet still close the door safely against the floor. In operator systems where the door moves at a high speed, the relatively large momentum of the moving parts, including the door, accomplishes complete closure. In systems with a soft closure, where the door speed decreases from full maximum to a small percentage of full maximum when closing, there may be insufficient momentum in the door or system to accomplish a full closure. For example, even if the door is positioned at the floor, there is sometimes sufficient play in the trolley of the operator to allow the door to move if the user were to try to open it. In particular, in systems employing a DC motor, when the DC motor is shut off, it becomes a dynamic brake. If the door isn't quite at the floor when the DOWN travel limit is reached and the DC motor is shut off, the door and associated moving parts may not have sufficient momentum to overcome the braking force of the DC motor. There is a need for a garage door operator which closes the door completely, eliminating play in the door after closure.
Many garage door operator installations are made to existing garage doors. The amount of force needed to drive the door varies depending on type of door and the quality of the door frame and installation. As a result, some doors are “stickier” than others, requiring greater force to move them through the entire length of travel. If the door is started and stopped using the full operating speed, stickiness is not usually a problem. However, if the garage door operator is capable of operation at two speeds, stickiness becomes a larger problem at the lower speed. In some installations, a force sufficient to run at 20 percent of normal speed is too small to start some doors moving. There is a need for a garage door operator which automatically controls force output and thus start and stop speeds.
SUMMARY OF THE INVENTION
A movable barrier operator having an electric motor for driving a garage door, a gate or other barrier is operated from a source of AC current. The movable barrier operator includes circuitry for automatically detecting the incoming AC line voltage and frequency of the alternating current. By automatically detecting the incoming AC line voltage and determining the frequency, the operator can automatically configure itself to certain user preferences. This occurs without either the user or the installer having to adjust or program the operator. The movable barrier operator includes a worklight for illuminating its immediate surroundings such as the interior of a garage. The barrier operator senses the power line frequency (typically 50 Hz or 60 Hz) to automatically set an appropriate shut-off time for a worklight. Because the power line frequency in Europe is 50 Hz and in the U.S. is 60 Hz, sensing the power line frequency enables the operator to configure itself for either a European or a U.S. market with no user or installer modifications. For U.S. users, the worklight shut-off time is set to preferably 4½ minutes; for European users, the worklight shut-off time is set to preferably 2½ minutes. Thus, a single barrier movement operator can be sold in two different markets with automatic setup, saving installation time.
The movable barrier operator of the present invention automatically detects if an optional flasher module is present. If the module is present, when the door is commanded to move, the operator causes the flasher module to operate. With the flasher module present, the operator also delays operation of the motor for a brief period, say one or two seconds. This delay period with the flasher module blinking before door movement provides an added safety feature to users which warns them of impending door travel (e.g. if activated by an unseen transmitter).
The movable barrier operator of the present invention drives the barrier, which may be a door or a gate, at a variable speed. After motor start, the electric motor reaches a preferred initial speed of 20 percent of the full operating speed. The motor speed then increases slowly in a linearly continuous fashion from 20 percent to 100 percent of full operating speed. This provides a smooth, soft start without jarring the transmission or the door or gate. The motor moves the barrier at maximum speed for the largest portion of its travel, after which the operator slowly decreases speed from 100 percent to 20 percent as the barrier approaches the limit of travel, providing a soft, smooth and quiet stop. A slow, smooth start and stop provides a safer barrier movement operator for the user because there is less momentum to apply an impulse force in the event of an obstruction. In a fast system, relatively high momentum of the door changes to zero at the obstruction before the system can actually detect the obstruction. This leads to the application of a high impulse force. With the system of the invention, a slower stop speed means the system has less momentum to overcome, and therefore a softer, more forgiving force reversal. A slow, smooth start and stop also provide a more aesthetically pleasing effect to the user, and when coupled with a quieter DC motor, a barrier movement operator which operates very quietly.
The operator includes two relays and a pair of field effect transistors (FETs) for controlling the motor. The relays are used to control direction of travel. The FET's, with phase controlled, pulse width modulation, control start up and speed. Speed is responsive to the duration of the pulses applied to the FETs. A longer pulse causes the FETs to be on longer causing the barrier speed to increase. Shorter pulses result in a slower speed. This provides a very fine ramp control and more gentle starts and stops.
The movable barrier operator provides for the automatic measurement and calculation of the total distance the door is to travel. The total door travel distance is the distance between the UP and the DOWN limits (which depend on the type of door). The automatic measurement of door travel distance is a measure of the length of the door. Since shorter doors must travel at slower speeds than normal doors (for safety reasons), this enables the operator to automatically adjust the motor speed so the speed of door travel is the same regardless of door size. The total door travel distance in turn determines the maximum speed at which the operator will travel. By determining the total distance traveled, travel speeds can be automatically changed without having to modify the hardware.
The movable barrier operator provides full door or gate closure, i.e. a firm closure of the door to the floor so that the door is not movable in place after it stops. The operator includes a digital control or processor, specifically a microcontroller which has an internal microprocessor, an internal RAM and an internal ROM and an external EEPROM. The microcontroller executes instructions stored in its internal ROM and provides motor direction control signals to the relays and speed control signals to the FETs. The operator is first operated in a learn mode to store a DOWN limit position for the door. The DOWN limit position of the door is used as an approximation of the location of the floor (or as a minimum reversal point, below which no auto-reverse will occur). When the door reaches the DOWN limit position, the microcontroller causes the electric motor to drive the door past the DOWN limit a small distance, say for one or two inches. This causes the door to close solidly on the floor.
The operator embodying the present invention provides variable door or gate output speed, i.e., the user can vary the minimum speed at which the motor starts and stops the door. This enables the user to overcome differences in door installations, i.e. stickiness and resistance to movement and other varying functional-type forces. The minimum barrier speeds in the UP and DOWN directions are determined by the user-configured force settings, which are adjusted using UP and DOWN force potentiometers. The force potentiometers set the lengths of the pulses to the FETS, which translate to variable speeds. The user gains a greater force output and a higher minimum starting speed to overcome differences in door installations, i.e. stickiness and resistance to movement and other varying functional-type forces speed, without affecting the maximum speed of travel for the door. The user can configure the door to start at a speed greater than a default value, say 20 percent. This greater start up and slow down speed is transferred to the linearly variable speed function in that instead of traveling at 20 percent speed, increasing to 100 percent speed, then decreasing to 20 percent speed, the door may, for instance, travel at 40 percent speed to 100 percent speed and back down to 40 percent speed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a garage having mounted within it a garage door operator embodying the present invention;
FIG. 2 is an exploded perspective view of a head unit of the garage door operator shown in FIG. 1;
FIG. 3 is an exploded perspective view of a portion of a transmission unit of the garage door operator shown in FIG. 1;
FIG. 4 is a block diagram of a controller and motor mounted within the head unit of the garage door operator shown in FIG. 1;
FIGS. 5A-5D are a schematic diagram of the controller shown in block format in FIG. 4;
FIGS. 6A-6B are a flow chart of an overall routine that executes in a microprocessor of the controller shown in FIGS. 5A-5D;
FIGS. 7A-7H are a flow chart of the main routine executed in the microprocessor;
FIG. 8 is a flow chart of a set variable light shut-off timer routine executed by the microprocessor;
FIGS. 9A-9C are a flow chart of a hardware timer interrupt routine executed in the microprocessor;
FIGS. 10A-10C are a flow chart of a 1 millisecond timer routine executed in the microprocessor;
FIGS. 11A-11C are a flow chart of a 125 millisecond timer routine executed in the microprocessor;
FIGS. 12A-12B are a flow chart of a 4 millisecond timer routine executed in the microprocessor;
FIGS. 13A-13B are a flow chart of an RPM interrupt routine executed in the microprocessor;
FIG. 14 is a flow chart of a motor state machine routine executed in the microprocessor;
FIG. 15 is a flow chart of a stop in midtravel routine executed in the microprocessor;
FIG. 16 is a flow chart of a DOWN position routine executed in the microprocessor;
FIGS. 17A-17C are a flow chart of an UP direction routine executed in the microprocessor;
FIG. 18 is a flow chart of an auto-reverse routine executed in the microprocessor;
FIG. 19 is a flow chart of an UP position routine executed in the microprocessor;
FIGS. 20A-20D are a flow chart of the DOWN direction routine executed in the microprocessor;
FIG. 21 is an exploded perspective view of a pass point detector and motor of the operator shown in FIG. 2;
FIG. 22A is a plan view of the pass point detector shown in FIG. 21; and
FIG. 22B is a partial plan view of the pass point detector shown in FIG. 21 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and especially to FIG. 1, a movable barrier or garage door operator system is generally shown therein and referred to by numeral 8 . The system 8 includes a movable barrier operator or garage door operator 10 having a head unit 12 mounted within a garage 14 . More specifically, the head unit 12 is mounted to a ceiling 15 of the garage 14 . The operator 10 includes a transmission 18 extending from the head unit 12 with a releasable trolley 20 attached. The releasable trolley 20 releasably connects an arm 22 extending to a single panel garage door 24 positioned for movement along a pair of door rails 26 and 28 .
The system 8 includes a hand-held RF transmitter unit 30 adapted to send signals to an antenna 32 (see FIG. 4) positioned on the head unit 12 and coupled to a receiver within the head unit 12 as will appear hereinafter. A switch module 39 is mounted on the head unit 12 . Switch module 39 includes switches for each of the commands available from a remote transmitter or from an optional wall-mounted switch (not shown). Switch module 39 enables an installer to conveniently request the various learn modes during installation of the head unit 12 . The switch module 39 includes a learn switch, a light switch, a lock switch and a command switch, which are described below. Switch module 39 may also include terminals for wiring a pedestrian door state sensor comprising a pair of contacts 13 and 15 for a pedestrian door 11 , as well as wiring for an optional wall switch (not shown).
The garage door 24 includes the pedestrian door 11 . Contact 13 is mounted to door 24 for contact with contact 15 mounted to pedestrian door 11 . Both contacts 13 and 15 are connected via a wire 17 to head unit 12 . As will be described further below, when the pedestrian door 11 is closed, electrical contact is made between the contacts 13 and 15 closing a pedestrian door circuit in the receiver in head unit 12 and signalling that the pedestriam door state is closed. This circuit must be closed before the receiver will permit other portions of the operator to move the door 24 . If circuit is open, indicating that the pedestrian door state is open, the system will not permit door 24 to move.
The head unit 12 includes a housing comprising four sections: a bottom section 102 , a front section 106 , a back section 108 and a top section 110 , which are held together by screws 112 as shown in FIG. 2 . Cover 104 fits into front section 106 and provides a cover for a worklight. External AC power is supplied to the operator through a power cord 112 . The AC power is applied to a step-down transformer 120 . An electric motor 118 is selectively energized by rectified AC power and drives a sprocket 125 in sprocket assembly 124 . The sprocket 125 drives chain 144 (see FIG. 3 ). A printed circuit board 114 includes a controller 200 and other electronics for operating the head unit 12 . A cable 116 provides input and output connections on signal paths between the printed circuit board 114 and switch module 39 . The transmission 18 , as shown in FIG. 3, includes a rail 142 which holds chain 144 within a rail and chain housing 140 and holds the chain in tension to transfer mechanical energy from the motor to the door.
A block diagram of the controller and motor connections is shown in FIG. 4 . Controller 200 includes an RF receiver 80 , a microprocessor 300 and an EEPROM 302 . RF receiver 80 of controller 200 receives a command to move the door and actuate the motor either from remote transmitter 30 , which transmits an RF signal which is received by antenna 32 , or from a user command switch 250 . User command switch 250 can be a switch on switch panel 39 , mounted on the head unit, or a switch from an optional wall switch. Upon receipt of a door movement command signal from either antenna 32 or user switch 250 , the controller 200 sends a power enable signal via line 240 to AC hot connection 206 which provides AC line current to transformer 212 and power to work light 210 . Rectified AC is provided from rectifier 214 via line 236 to relays 232 and 234 . Depending on the commanded direction of travel, controller 200 provides a signal to either relay 232 or relay 234 . Relays 232 and 234 are used to control the direction of rotation of motor 118 by controlling the direction of current flow through the windings. One relay is used for clockwise rotation; the other is used for counterclockwise rotation.
Upon receipt of the door movement command signal, controller 200 sends a signal via line 230 to power-control FET 252 . Motor speed is determined by the duration or length of the pulses in the signal to a gate electrode of FET 252 . The shorter the pulses, the slower the speed. This completes the circuit between relay 232 and FET 252 providing power to motor 118 via line 254 . If the door had been commanded to move in the opposite direction, relay 234 would have been enabled, completing the circuit with FET 252 and providing power to motor 118 via line 238 .
With power provided, the motor 118 drives the output shaft 216 which provides drive power to transmission sprocket 125 . Gear reduction housing 260 includes an internal pass point system which sends a pass point signal via line 220 to controller 220 whenever the pass point is reached. The pass point signal is provided to controller 200 via current limiting resistor 226 to protect controller 200 from electrostatic discharge (ESD). An RPM interrupt signal is provided via line 224 , via current limiting resistor 228 , to controller 200 . Lead 222 provides a plus five volts supply for the Hall effect sensors in the RPM module. Commanded force is input by two force potentiometers 202 , 204 . Force potentiometer 202 is used to set the commanded force for UP travel; force potentiometer 204 is used to set the commanded force for DOWN travel. Force potentiometers 202 and 204 provide commanded inputs to controller 200 which are used to adjust the length of the pulsed signal provided to FET 252 .
The pass point for this system is provided internally in the motor 118 . Referring to FIG. 22, the pass point module 40 is attached to gear reduction housing 260 of motor 118 . Pass point module 40 includes upper plate 42 which covers the three internal gears and switch within lower housing 50 . Lower housing 50 includes recess 62 having two pins 61 which position switch assembly 52 in recess 62 . Housing 50 also includes three cutouts which are sized to support and provide for rotation of the three geared elements. Outer gear 44 fits rotatably within cutout 64 . Outer gear includes a smooth outer surface for rotating within housing 50 and inner gear teeth for rotating middle gear 46 . Middle gear 46 fits rotatably within inner cutout 66 . Middle gear 46 includes a smooth outer surface and a raised portion with gear teeth for being driven by the gear teeth of outer ring gear 44 . Inner gear 48 fits within middle gear 46 and is driven by an extension of shaft 216 . Rotation of the motor 118 causes shaft 216 to rotate and drive inner gear 48 .
Outer gear 44 includes a notch 74 in the outer periphery. Middle gear includes a notch 76 in the outer periphery. Referring to FIG. 22A, rotation of inner gear 48 rotates middle gear 46 in the same direction. Rotation of middle gear 46 rotates outer gear 44 in the same direction. Gears 46 and 44 are sized such that pass point indications comprising switch release cutouts 74 and 76 line up only once during the entire travel distance of the door. As seen in FIG. 22A, when switch release cutouts 74 and 76 line up, switch 72 is open generating a pass point presence signal. The location where switch release cutouts 74 and 76 line up is the pass point. At all other times, at least one of the two gears holds switch 72 closed generating a signal indicating that the pass point has not been reached.
The receiver portion 80 of controller 200 is shown in FIG. 5 A. RF signals may be received by the controller 200 at the antenna 32 and fed to the receiver 80 . The receiver 80 includes variable inductor L 1 and a pair of capacitors C 2 and C 3 that provide impedance matching between the antenna 32 and other portions of the receiver. An NPN transistor Q 4 is connected in common-base configuration as a buffer amplifier. Bias to the buffer amplifier transistor Q 4 is provided by resistors R 2 , R 3 . The buffered RF output signal is supplied to a second NPN transistor Q 5 . The radio frequency signal is coupled to a bandpass amplifier 280 to an average detector 282 which feeds a comparator 284 . Referring to FIGS. 5C and 5B, the analog output signal A, B is applied to noise reduction capacitors C 19 , C 20 and C 21 then provided to pins P 32 and P 33 of the microcontroller 300 . Microcontroller 300 may be a Z86733 microprocessor.
An external transformer 212 receives AC power from a source such as a utility and steps down the AC voltage to the power supply 90 circuit of controller 200 . Transformer 212 provides AC current to full-wave bridge circuit 214 , which produces a 28 volt full wave rectified signal across capacitor C 35 . The AC power may have a frequency of 50 Hz or 60 Hz. An external transformer is especially important when motor 118 is a DC motor. The 28 volt rectified signal is used to drive a wall control switch, a obstacle detector circuit, a door-in-door switch and to power FETs Q 11 and Q 12 used to start the motor. Zener diode DIB protects against overvoltage due to the pulsed current, in particular, from the FETs rapidly switching off inductive load of the motor. The potential of the full-wave rectified signal is further reduced to provide 5 volts at capacitor C 38 , which is used to power the microprocessor 300 , the receiver circuit 80 and other logic functions.
The 28 volt rectified power supply signal indicated by reference numeral T in FIG. 5C is voltage divided down by resistors R 61 and R 62 , then applied to an input pin P 24 of microprocessor 300 . This signal is used to provide the phase of the power line current to microprocessor 300 . Microprocessor 300 constantly checks for the phase of the line voltage in order to determine if the frequency of the line voltage is 50 Hz or 60 Hz. This information is used to establish the worklight time-out period and to select the look-up table stored in the ROM in the microcontroller for converting pulse width to door speed.
When the door is commanded to move, either through a signal from a remote transmitter received through antenna 32 and processed by receiver 80 , or through an optional wall switch, the microprocessor 300 commands the work light to turn on. Microprocessor 300 sends a worklight enable signal from pin P 07 . The worklight enable signal is applied to the base of transistor Q 3 , which drives relay K 3 . AC power from a signal U provides power for operating the worklight 210 .
Microprocessor 300 reads from and writes data to an EEPROM 302 via its pins P 25 , P 26 and P 27 . EEPROM 302 may be a 93C46. Microprocessor 300 provides a light enable signal at pin P 21 which is used to enable a learn mode indicator yellow LED D 15 . LED D 15 is enabled or lit when the receiver is in the learn mode. Pin P 26 provides double duty. When the user selects switch S 1 , a learn enable signal is provided to both microprocessor 300 and EEPROM 302 . Switch S 1 is mounted on the head unit 12 and is part of switch module 39 , which is used by the installer to operate the system.
An optional flasher module provides an additional level of safety for users and is controlled by microprocessor 300 at pin P 22 . The optional flasher module is connected between terminals 308 and 310 . In the optional flasher module, after receipt of a door command, the microprocessor 300 sends a signal from P 22 which causes the flasher light to blink for 2 seconds.
The door does not move during that 2 second period, giving the user notice that the door has been commanded to move and will start to move in 2 seconds. After expiration of the 2 second period, the door moves and the flasher light module blinks during the entire period of door movement. If the operator does not have a flasher module installed in the head unit, when the door is commanded to move, there is no time delay before the door begins to move.
Microprocessor 300 provides the signals which start motor 116 , control its direction of rotation (and thus the direction of movement of the door) and the speed of rotation (speed of door travel). FETs Q 11 and Q 12 are used to start motor 118 . Microprocessor 300 applies a pulsed output signal to the gates of FETs Q 11 and Q 12 . The lengths of the pulses determine the time the FETs conduct and thus the amount of time current is applied to start and run the motor 118 . The longer the pulse, the longer current is applied, the greater the speed of rotation the motor 118 will develop. Diode D 11 is coupled between the 28 volt power supply and is used to clean up flyback voltage to the input bridge D 4 when the FETs are conducting. Similarly, Zener diode D 19 (see FIG. 5A) is used to protect against overvoltage when the FETs are conducting.
Control of the direction of rotation of motor 118 (and thus direction of travel of the door) is accomplished with two relays, K 1 and K 2 . Relay K 1 supplies current to cause the motor to rotate clockwise in an opening direction (door moves UP); relay K 2 supplies current to cause the motor to rotate counterclockwise in a closing direction (door moves DOWN). When the door is commanded to move UP, the microprocessor 300 sends an enable signal from pin P 05 to the base of transistor Q 1 , which drives relay K 1 . When the door is commanded to move DOWN, the microprocessor 300 sends an enable signal from pin P 06 to the base of transistor Q 2 , which drives relay K 2 .
Door-in-door contacts 13 and 15 are connected to terminals 304 and 306 . Terminals 304 and 306 are connected to relays K 1 and K 2 . If the signal between contacts 13 and 15 is broken, the signal across terminals 304 and 306 is open, preventing relays K 1 and K 2 from energizing. The motor 118 will not rotate and the door 24 will not move until the user closes pedestrian door 11 , making contact between contacts 13 and 15 .
The pass point signal 220 from the pass point module 40 (see FIG. 21) of motor 118 is applied to pin P 23 of microprocessor 300 . The RPM signal 224 from the RPM sensor module in motor 118 is applied to pin P 31 of microprocessor 300 . Application of the pass point signal and the RPM signal is described with reference to the flow charts.
An optional wall control, which duplicates the switches on remote transmitter 30 , may be connected to controller 200 at terminals 312 and 314 . When the user presses the door command switch 39 , a dead short is made to ground, which the microprocessor 300 detects by the failure to detect voltage. Capacitor C 22 is provided for RF noise reduction. The dead short to ground is sensed at pins P 02 and P 03 , for redundancy.
Switches S 1 and S 2 are part of switch module 39 mounted on head unit 12 and used by the installer for operating the system. As stated above, S 1 is the learn switch. S 2 is the door command switch. When S 2 is pressed, microprocessor 300 detects the dead short at pins P 02 and P 03 .
Input from an obstacle detector (not shown) is provided at terminal 316 . This signal is voltage divided down and provided to microprocessor 300 at pins P 20 and P 30 , for redundancy. Except when the door is moving and less than an inch above the floor, when the obstacle detector senses an object in the doorway, the microprocessor executes the auto-reverse routine causing the door to stop and/or reverse depending on the state of the door movement.
Force and speed of door travel are determined by two potentiometers. Potentiometer R 33 adjusts the force and speed of UP travel; potentiometer R 34 adjusts the force and speed of DOWN travel. Potentiometers R 33 and R 34 act as analog voltage dividers. The analog signal from R 33 , R 34 is further divided down by voltage divider R 35 /R 37 , R 36 /R 38 before it is applied to the input of comparators 320 and 322 . Reference pulses from pins P 34 and P 35 of microprocessor 300 are compared with the force input from potentiometers R 33 and R 34 in comparators 320 and 322 . The output of comparators 320 and 322 is applied to pins P 01 and P 00 .
To perform the A/D conversion, the microprocessor 300 samples the output of the comparators 320 and 322 at pins P 00 and P 01 to determine which voltage is higher: the voltage from the potentiometer R 33 or R 34 (IN) or the voltage from the reference pin P 34 or P 35 (REF). If the potentiometer voltage is higher than the reference, then the microprocessor outputs a pulse. If not, the output voltage is held low. The RC filter (R 39 , C 29 /R 40 , C 30 ) converts the pulses into a DC voltage equivalent to the duty cycle of the pulses. By outputting the pulses in the manner described above, the microprocessor creates a voltage at REF which dithers around the voltage at IN. The microprocessor then calculates the duty cycle of the pulse output which directly correlates to the voltage seen at IN.
When power is applied to the head unit 12 including controller 200 , microprocessor 300 executes a series of routines. With power applied, microprocessor 300 executes the main routines shown in FIGS. 6A and 6B. The main loop 400 includes three basic functions, which are looped continuously until power is removed. In block 402 the microprocessor 300 handles all non-radio EEPROM communications and disables radio access to the EEPROM 302 when communicating. This ensures that during normal operation, i.e., when the garage door operator is not being programmed, the remote transmitter does not have access to the EEPROM, where transmitter codes are stored. Radio transmissions are processed upon receipt of a radio interrupt (see below).
In block 404 , microprocessor 300 maintains all low priority tasks, such as calculating new force levels and minimum speed. Preferably, a set of redundant RAM registers is provided. In the event of an unforeseen event (e.g., an ESD event) which corrupts regular RAM, the main RM registers and the redundant RAM registers will not match. Thus, when the values in RAM do not match, the routine knows the regular RAM has been corrupted. (See block 504 below.) In block 406 , microprocessor 300 tests redundant RAM registers. Several interrupt routines can take priority over blocks 402 , 404 and 406 .
The infrared obstacle detector generates an asynchronous IR interrupt signal which is a series of pulses. The absence of the obstacle detector pulses indicates an obstruction in the beam. After processing the IR interrupt, microprocessor 300 sets the status of the obstacle detector as unobstructed at block 416 .
Receipt of a transmission from remote transmitter 30 generates an asynchronous radio interrupt at block 410 . At block 418 , if in the door command mode, microprocessor 300 parses incoming radio signals and sets a flag if the signal matches a stored code. If in the learn mode, microprocessor 300 stores the new transmitter codes in the EEPROM.
An asynchronous interrupt is generated if a remote communications unit is connected to an optional RS-232 communications port located on the head unit. Upon receipt of the hardware interrupt, microprocessor 300 executes a serial data communications routine for transferring and storing data from the remote hardware.
Hardware timer 0 interrupt is shown in block 422 . In block 422 , microprocessor 300 reads the incoming AC line signal from pin P 24 and handles the motor phase control output. The incoming line signal is used to determine if the line voltage is 50 Hz for the foreign market or 60 Hz for the domestic market. With each interrupt, microprocessor 300 , at block 426 , task switches among three tasks. In block 428 , microprocessor 300 updates software timers. In block 430 , microprocessor 300 debounces wall control switch signals. In block 432 , microprocessor 300 controls the motor state, including motor direction relay outputs and motor safety systems.
When the motor 118 is running, it generates an asynchronous RPM interrupt at block 434 . When microprocessor 300 receives the asynchronous RPM interrupt at pin P 31 , it calculates the motor RPM period at block 436 , then updates the position of the door at block 438 .
Further details of main loop 400 are shown in FIGS. 7A through 7H. The first step executed in main loop 400 is block 450 , where the microprocessor checks to see if the pass point has been passed since the last update. If it has, the routine branches to block 452 , where the microprocessor 300 updates the position of the door relative to the pass point in EEPROM 302 or non-volatile memory. The routine then continues at block 454 . An optional safety feature of the garage door operator system enables the worklight, when the door is open and stopped and the infrared beam in the obstacle detector is broken.
At block 454 , the microprocessor checks if the enable/disable of the worklight for this feature has been changed. Some users want the added safety feature; others prefer to save the electricity used. If new input has been provided, the routine branches to block 456 and sets the status of the obstacle detector-controlled worklight in non-volatile memory in accordance with the new input. Then the routine continues to block 458 where the routine checks to determine if the worklight has been turned on without the timer. A separate switch is provided on both the remote transmitter 30 and the head unit at module 39 to enable the user to switch on the worklight without operating the door command switch. If no, the routine skips to block 470 .
If yes, the routine checks at block 460 to see if the one-shot flag has been set for an obstacle detector beam break. If no, the routine skips to block 470 . If yes, the routine checks if the obstacle detector controlled worklight is enabled at block 462 . If not, the routine skips to block 470 . If it is, the routine checks if the door is stopped in the fully open position at block 464 . If no, the routine skips to block 470 . If yes, the routine calls the SetVarLight subroutine (see FIG. 8) to enable the appropriate turn off time (4.5 minutes for 60 Hz systems or 2.5 minutes for 50 Hz systems). At block 468 , the routine turns on the worklight.
At block 470 , the microprocessor 300 clears the one-shot flag for the infrared beam break. This resets the obstacle detector, so that a later beam break can generate an interrupt. At block 472 , if the user has installed a temporary password usable for a fixed period of time, the microprocessor 300 updates the non-volatile timer for the radio temporary password. At block 474 , the microprocessor 300 refreshes the RAM registers for radio mode from non-volatile memory (EEPROM 302 ). At block 476 , the microprocessor 300 refreshes I/O port directions, i.e., whether each of the ports is to be input or output. At block 478 , the microprocessor 300 updates the status of the radio lockout flag, if necessary. The radio lockout flag prevents the microprocessor from responding to a signal from a remote transmitter. A radio interrupt (described below) will disable the radio lockout flag and enable the remote transmitter to communicate with the receiver.
At block 480 , the microprocessor 300 checks if the door is about to travel. If not, the routine skips to block 502 . If the door is about to travel, the microprocessor 300 checks if the limits are being trained at block 482 . If they are, the routine skips to block 502 . If not, the routine asks at block 484 if travel is UP or DOWN. If DOWN, the routine refreshes the DOWN limit from non-volatile memory (EEPROM 302 ) at block 486 . If UP, the routine refreshes the UP limit from non-volatile memory (EEPROM 302 ) at block 488 . The routine updates the current operating state and position relative to the pass point in non-volatile memory at block 490 . This is a redundant read for stability of the system.
At block 492 , the routine checks for completion of a limit training cycle. If training is complete, the routine branches to block 494 where the new limit settings and position relative to the pass point are written to non-volatile memory.
The routine then updates the counter for the number of operating cycles at block 496 . This information can be downloaded at a later time and used to determine when certain parts need to be replaced. At block 498 the routine checks if the number of cycles is a multiple of 256. Limiting the storage of this information to multiples of 256 limits the number of times the system has to write to that register. If yes it updates the history of force settings at block 500 . If not, the routine continues to block 502 .
At block 502 the routine updates the learn switch debouncer. At block 504 the routine performs a continuity check by comparing the backup (redundant) RAM registers with the main registers. If they do not match, the routine branches to block 506 . If the registers do not match, the RAM memory has been corrupted and the system is not safe to operate, so a reset is commanded. At this point, the system powers up as if power had been removed and reapplied and the first step is a self test of the system (all installation settings are unchanged).
If the answer to block 504 is yes, the routine continues to block 508 where the routine services any incoming serial messages from the optional wall control (serial messages might be user input start or stop commands). The routine then loads the UP force timing from the ROM look-up table, using the user setting as an index at block 510 . Force potentiometers R 33 and R 34 are set by the user. The analog values set by the user are converted to digital values. The digital values are used as an index to the look-up table stored in memory. The value indexed from the look-up table is then used as the minimum motor speed measurement. When the motor runs, the routine compares the selected value from the look-up table with the digital timing from the RPM routine to ensure the force is acceptable.
Instead of calculating the force each time the force potentiometers are set, a look-up table is provided for each potentiometer. The range of values based on the range of user inputs is stored in ROM and used to save microprocessor processing time. The system includes two force limits: one for the UP force and one for the DOWN force. Two force limits provide a safer system. A heavy door may require more UP force to lift, but need a lower DOWN force setting (and therefore a slower closing speed) to provide a soft closure. A light door will need less UP force to open the door and possibly a greater DOWN force to provide a full closure.
Next the force timing is divided by power level of the motor for the door to scale the maximum force timeout at block 512 . This step scales the force reversal point based on the maximum force for the door. The maximum force for the door is determined based on the size of the door, i.e. the distance the door travels. Single piece doors travel a greater distance than segmented doors. Short doors require less force to move than normal doors. The maximum force for a short door is scaled down to 60 percent of the maximum force available for a normal door. So, at block 512 , if the force setting is set by the user, for example at 40 percent, and the door is a normal door (i.e., a segmented door or multi-paneled door), the force is scaled to 40 percent of 100 percent. If the door is a short door (i.e., a single panel door), the force is scaled to 40 percent of 60 percent, or 24 percent.
At block 514 , the routine loads the DOWN force timing from the ROM look-up table, using the user setting as an index. At block 516 , the routine divides the force timing by the power level of the motor for the door to scale the force to the speed.
At block 518 the routine checks if the door is traveling DOWN. If yes, the routine disables use of the MinSpeed Register at block 524 and loads the MinSpeed Register with the DOWN force setting, i.e., the value read from the DOWN force potentiometer at block 526 . If not, the routine disables use of the MinSpeed Register at block 520 and loads the MinSpeed Register with the UP force setting from the force potentiometer at block 522 .
The routine continues at block 528 where the routine subtracts 20 from the MinSpeed value. The MinSpeed value ranges from 0 to 63. The system uses 64 levels of force. If the result is negative at block 530 , the routine clears the MinSpeed Register at block 532 to effectively truncate the lower 38 percent of the force settings. If no, the routine divides the minimum speed by 4 to scale 8 speeds to 32 force settings at block 534 . At block 536 , the routine adds 4 into the minimum speed to correct the offset, and clips the result to a maximum of 12. At block 538 the routine enables use of the MinSpeed Register.
At block 540 the routine checks if the period of the rectified AC line signal (input to microprocessor 300 at pin P 24 ) is less than 9 milliseconds (indicating the line frequency is 60 Hz). If it is, the routine skips to block 548 . If not, the routine checks if the light shut-off timer is active at block 542 . If not, the routine skips to block 548 . If yes, the routine checks if the light time value is greater than 2.5 minutes at block 544 . If no, the routine skips to block 548 . If yes, the routine calls the SetVarLight subroutine (see FIG. 8 ), to correct the light timing setting, at block 546 .
At block 548 the routine,checks if the radio signal has been clear for 100 milliseconds or more. If not, the routine skips to block 552 . If yes, the routine clears the radio at block 550 . At block 552 , the routine resets the watchdog timer. At block 554 , the routine loops to the beginning of the main loop.
The SetVarLight subroutine, FIG. 8, is called whenever the door is commanded to move and the worklight is to be turned on. When the SetVarLight subroutine, block 558 is called, the subroutine checks if the period of the rectified power line signal (pin P 24 of microprocessor 300 ) is greater than or equal to 9 milliseconds. If yes, the line frequency is 50 Hz, and the timer is set to 2.5 minutes at block 564 . If no, the line frequency is 60 Hz and the timer is set to 4.5 minutes at block 562 . After setting, the subroutine returns to the call point at block 566 .
The hardware timer interrupt subroutine operated by microprocessor 300 , shown at block 422 , runs every 0.256 milliseconds. Referring to FIGS. 9A-9C, when the subroutine is first called, it sets the radio interrupt status as indicated by the software flags at block 580 . At block 582 , the subroutine updates the software timer extension. The next series of steps monitor the AC power line frequency (pin P 24 of microprocessor 300 ). At step 584 , the subroutine checks if the rectified power line input is high (checks for a leading edge). If yes, the subroutine skips to block 594 , where it increments the power line high time counter, then continues to block 596 . If no, the subroutine checks if the high time counter is below 2 milliseconds at block 586 . If yes, the subroutine skips to block 594 . If no, the subroutine sets the measured power line time in RAM at block 588 . The subroutine then resets the power line high time counter at block 590 and resets the phase timer register in block 592 .
At block 596 , the subroutine checks if the motor power level is set at 100 percent. If yes, the subroutine turns on the motor phase control output at block 606 . If no, the subroutine checks if the motor power level is set at 0 percent at block 598 . If yes, the subroutine turns off the motor phase control output at block 604 . If no, the phase timer register is decremented at block 600 and the result is checked for sign. If positive the subroutine branches to block 606 ; if negative the subroutine branches to block 604 .
The subroutine continues at block 608 where the incoming RPM signal (at pin P 31 of microprocessor 300 ) is digitally filtered. Then the time prescaling task switcher (which loops through 8 tasks identified at blocks 620 , 630 , 640 , 650 ) is incremented at block 610 . The task switcher varies from 0 to 7. At block 612 , the subroutine branches to the proper task depending on the value of the task switcher.
If the task switcher is at value 2 (this occurs every 4 milliseconds), the execute motor state machine subroutine is called at block 620 . If the task is value 0 or 4 (this occurs every 2 milliseconds), the wall control switches are debounced at block 630 . If the task value is 6 (this occurs every 4 milliseconds), the execute 4 ms timer subroutine is called at block 640 . If the task is value 1, 3, 5 or 7, the 1 millisecond timer subroutine is called at block 650 . Upon completion of the called subroutine, the 0.256 millisecond timer subroutine returns at block 614 .
Details of the 1 ms timer,subroutine (block 650 ) are shown in FIGS. 10A-10C. When this subroutine is called, the first step is to update the A/D converters on the UP and DOWN force setting potentiometers (P 34 and P 35 of microprocessor 300 ) at block 652 . At block 654 , the subroutine checks if the A/D conversion (comparison at comparators 320 and 322 ) is complete. If yes, the measured potentiometer values are stored at block 656 . Then the stored values (which vary from 0 to 127) are divided by 2 to obtain the 64 level force setting at block 658 . If no, the subroutine decrements the infrared obstacle detector timeout timer at block 660 . In block 662 , the subroutine checks if the timer has reached zero. If no, the subroutine skips to block 672 . If yes, the subroutine resets the infrared obstacle detector timeout timer at block 664 . The flag setting for the obstacle detector signal is checked at block 666 . If no, the one-shot break flag is set at block 668 . If yes, the flag is set indicating the obstacle detector signal is absent at block 670 .
At block 672 , the subroutine increments the radio time out register. Then the infrared obstacle detector reversal timer is decremented at block 674 . The pass point input is debounced at block 676 . The 125 millisecond prescaler is incremented at block 678 . Then the prescaler is checked if it has reached 63 milliseconds at block 680 . If yes, the fault blinking LED is updated at block 682 . If no, the prescaler is checked if it has reached 125 ms at block 684 . If yes, the 125 ms timer subroutine is executed at block 686 . If no, the routine returns at block 688 .
The 125 millisecond timer subroutine (block 690 ) is used to manage the power level of the motor 118 . At block 692 , the subroutine updates the RS-232 mode timer and exits the RS-232 mode timer if necessary. The same pair of wires is used for both wall control switches and RS-232 communication. If RS-232 communication is received while in the wall control mode, the RS-232 mode is entered. If four seconds passes since the last RS-232 word was received, then the RS-232 timer times out and reverts to the wall control mode. At block 694 the subroutine checks if the motor is set to be stopped. If yes, the subroutine skips to block 716 and sets the motor's power level to 0 percent. If no, the subroutine checks if the pre-travel safety light is flashing at block 696 (if the optional flasher module has been installed, a light will flash for 2 seconds before the motor is permitted to travel and then flash at a predetermined interval during motor travel). If yes, the subroutine skips to block 716 and sets the motor's power level to 0 percent.
If no, the subroutine checks if the microprocessor 300 is in the last phase of a limit training mode at block 698 . If yes, the subroutine skips to block 710 .
If no, the subroutine checks if the microprocessor 300 is in another part of the limit training mode at block 700 . If no, the subroutine skips to block 710 . If yes, the subroutine checks if the minimum speed (as determined by the force settings) is greater than 40 percent at block 704 . If no, the power level is set to 40 percent at block 708 . If yes, the power level is set equal to the minimum speed stored in MinSpeed Register at block 706 .
At block 710 the subroutine checks if the flag is set to slow down. If yes, the subroutine checks if the motor is running above or below minimum speed at block 714 . If above minimum speed, the power level of the motor is decremented one step increment (one step increment is preferably 5% of maximum motor speed) at block 722 . If below the minimum speed, the power level of the motor is incremented one step increment (which is preferably 5% of maximum motor speed) to minimum speed at block 720 .
If the flag is not set to slow down at block 710 , the subroutine checks if the motor is running at maximum allowable speed at block 712 . If no, the power level of the motor is incremented one step increment (which is preferably 5% of maximum motor speed) at block 720 . If yes, the flag is set for motor ramp-up speed complete.
The subroutine continues at block 724 where it checks if the period of the rectified AC power line (pin P 24 of microprocessor 300 ), is greater than or equal to 9 ms. If no, the subroutine fetches the motor's phase control information (indexed from the power level) from the 60 Hz look-up table stored in ROM at block 728 . If yes, the subroutine fetches the motor's phase control information (indexed from the power level) from the 50 Hz look-up table stored in ROM at block 726 .
The subroutine tests for a user enable/disable of the infrared obstacle detector-controlled worklight feature at block 730 . Then the user radio learning timers, ZZWIN (at the wall keypad if installed) and AUXLEARNSW (radio on air and worklight command) are updated at block 732 . The software watchdog timer is updated at block 734 and the fault blinking LED is updated at block 736 . The subroutine returns at block 738 .
The 4 millisecond timer subroutine is used to check on various systems which do not require updating as often as more critical systems. Referring to FIGS. 12A and 12B, the subroutine is called at block 640 . At block 750 , the RPM safety timers are updated. These timers are used to determine if the door has engaged the floor. The RPM safety timer is a one second delay before the operator begins to look for a falling door, i.e., one second after stopping. There are two different forces used in the garage door operator. The first type force are the forces determined by the UP and DOWN force potentiometers. These force levels determine the speed at which the door travels in the UP and DOWN directions. The second type of force is determined by the decrease in motor speed due to an external force being applied to the door (an obstacle or the floor). This programmed or pre-selected external force is the maximum force that the system will accept before an auto-reverse or stop is commanded.
At block 752 the 0.5 second RPM timer is checked to see if it has expired. If yes, the 0.5 second timer is reset at block 754 . At block 756 safety checks are performed on the RPM seen during the last 0.5 seconds to prevent the door from falling. The 0.5 second timer is chosen so the maximum force achieved at the trolley will reach 50 kilograms in 0.5 seconds if the motor is operating at 100 percent of power.
At block 758 , the subroutine updates the 1 second timer for the optional light flasher module. In this embodiment, the preferred flash period is 1 second. At block 760 the radio dead time and dropout timers are updated. At block 762 the learn switch is debounced. At block 764 the status of the worklight is updated in accordance with the various light timers. At block 766 the optional wall control blink timer is updated. The optional wall control includes a light which blinks when the door is being commanded to auto-reverse in response to an infrared obstacle detector signal break. At block 768 the subroutine returns.
Further details of the asynchronous RPM signal interrupt, block 434 , are shown in FIGS. 13A and 13B. This signal, which is provided to microprocessor 300 at pin P 31 , is used to control the motor speed and the position detector. Door position is determined by a value relative to the pass point. The pass point is set at 0. Positions above the pass point are negative; positions below the pass point are positive. When the door travels to the UP limit, the position detector (or counter) determines the position based on the number of RPM pulses to the UP limit number. When the door travels DOWN to the DOWN limit, the position detector counts the number of RPM pulses to the DOWN limit number. The UP and DOWN limit numbers are stored in a register.
At block 782 the RPM interrupt subroutine calculates the period of the incoming RPM signal. If the door is traveling UP, the subroutine calculates the difference between two successive pulses. If the door is traveling DOWN, the subroutine calculates the difference between two successive pulses. At block 784 , the subroutine divides the period by 8 to fit into a binary word. At block 786 the subroutine checks if the motor speed is ramping up. This is the max force mode. RPM timeout will vary from 10 to 500 milliseconds. Note that these times are recommended for a DC motor. If an AC motor is used, the maximum time would be scaled down to typically 24 milliseconds. A 24 millisecond period is slower than the breakdown RPM of the motor and therefore beyond the maximum possible force of most preferred motors. If yes, the RPM timeout is set at 500 milliseconds (0.5 seconds) at block 790 . If no, the subroutine sets the RPM timeout as the rounded-up value of the force setting in block 788 .
At block 792 the subroutine checks for the direction of travel. This is found in the state machine register. If the door is traveling DOWN, the position counter is incremented at block 796 and the pass point debouncer is sampled at block 800 . At block 804 , the subroutine checks for the falling edge of the pass point signal. If the failing edge is present, the subroutine returns at block 814 . If there is a pass point falling edge, the subroutine checks for the lowest pass point (in cases where more than one pass point is used). If this is not the lowest pass point, the subroutine returns at block 814 . If it is the only pass point or the lowest pass point, the position counter is zeroed and the subroutine returns at block 814 .
If the door is traveling UP, the subroutine decrements the position counter at block 794 and samples the pass point debouncer at block 798 . Then it checks for the rising edge of the pass point signal at block 802 . If there is no pass point signal rising edge, the subroutine returns at block 814 . If there is, it checks for the lowest pass point at block 806 . If no the subroutine returns at block 814 . If yes, the subroutine zeroes the position counter and returns at block 814 .
The motor state machine subroutine, block 620 , is shown in FIG. 14 . It keeps track of the state of the motor. At block 820 , the subroutine updates the false obstacle detector signal output, which is used in systems that do not require an infrared obstacle detector. At block 822 , the subroutine checks if the software watchdog timer has reached too high a value. If yes, a system reset is commanded at block 824 . If no, at block 826 , it checks the state of the motor stored in the motor state register located in EEPROM 302 and executes the appropriate subroutine.
If the door is traveling UP, the UP direction subroutine at block 832 is executed. If the door is traveling DOWN, the DOWN direction subroutine is executed at block 826 . If the door is stopped in the middle of the travel path, the stop in midtravel subroutine is executed at block 838 . If the door is fully closed, the DOWN position subroutine is executed at block 830 . If the door is fully open, the UP position subroutine is executed at block 834 . If the door is reversing, the auto-reverse subroutine is executed at block 836 .
When the door is stopped in midtravel, the subroutine at block 838 is called, as shown in FIG. 15 . In block 840 the subroutine updates the relay safety system (ensuring that relays K 1 and K 2 are open). The subroutine checks for a received wall command or radio command. If there is no received command, the subroutine updates the worklight status and returns. If yes, the motor power is set to 20 percent at block 844 and the motor state is set to traveling DOWN at block 846 . The worklight status is updated and the subroutine returns at block 850 . If the door is stopped in midtravel and a door command is received, the door is set to close. The next time the system calls the motor state machine subroutine, the motor state machine will call the DOWN direction subroutine. The door must close to the DOWN limit before it can be opened to the full UP limit.
If the state machine indicates the door is in the DOWN position (i.e. the DOWN limit position), the DOWN position subroutine, block 830 , at FIG. 16 is called. When the door is in the DOWN position, the subroutine checks if a wall control or radio command has been received. If no, the subroutine updates the light and returns at block 858 . If yes, the motor power is set to 20 percent at block 854 and the motor state register is set to show the state is traveling UP at block 856 . The subroutine then updates the light and returns at block 858 .
The UP direction subroutine, block 832 , is shown in FIGS. 17A-17C. At block 860 the subroutine waits until the main loop refreshes the UP limit from EEPROM 302 .
Then it checks if 40 milliseconds have passed since closing of the light relay K 3 at block 862 . If not, the subroutine returns. If yes, the subroutine checks for flashing the warning light prior to travel at block 866 (only if the optional flasher module is installed). If the light is flashing, the status of the blinking light is updated and the subroutine returns at block 868 . If not, the flashing is terminated, the motor UP relay is turned on at block 870 . Then the subroutine waits until 1 second has passed after the motor was turned on at block 872 . If no, the subroutine skips to block 888 . If yes, the subroutine checks for the RPM signal timeout. If no, the subroutine checks if the motor speed is ramping up at block 876 by checking the value of the RAMPFLAG register in RAM (i.e., UP, DOWN, FULLSPEED, STOP). If yes, the subroutine skips to block 888 . If no, the subroutine checks if the measured RPM is longer than the allowable RPM period at block 878 . If no, the subroutine continues at block 888 .
If the RPM signal has timed out at block 874 or the measured time period is longer than allowable at block 878 , the subroutine branches to block 880 . At block 880 , the reason is set as force obstruction. At block 882 , if the training limits are being set, the training status is updated. At block 884 the motor power is set to zero and the state is set as stopped in midtravel. At block 886 the subroutine returns.
At block 888 the subroutine checks if the door's exact position is known. If it is not, the door's distance from the UP limit is updated in block 890 by subtracting the UP limit stored in RAM from the position of the door also stored in RAM. Then the subroutine checks at block 892 if the door is beyond its UP limit.
If yes, the subroutine sets the reason as reaching the limit in block 894 . Then the subroutine checks if the limits are being trained. If yes, the limit training machine is updated at block 898 . If no, the motor's power is set as zero and the motor state is set at the UP position in block 900 . Then the subroutine returns at block 902 .
If the door is not beyond its UP limit, the subroutine checks if the door is being manually positioned in the training cycle at block 904 . If not, the door position within the slowdown distance of the limit is checked at block 906 . If yes, the motor slow down flag is set at block 910 . If the door is being positioned manually at block 904 or the door is not within the slow down distance, the subroutine skips to block 912 . At block 912 the subroutine checks if a wall control or radio command has been received. If yes, the motor power is set at zero and the state is set at stopped in midtravel at block 916 . If no, the system checks if the motor has been running for over 27 seconds at block 914 . If yes, the motor power is set at zero and the motor state is set at stopped in midtravel at block 916 . Then the subroutine returns at block 918 .
Referring to FIG. 18, the auto-reverse subroutine block 836 is described. (Force reversal is stopping the motor for 0.5 seconds, then traveling UP.) At block 920 the subroutine updates the 0.5 second reversal timer (the force reversal timer described above). Then the subroutine checks at block 922 for expiration of the force-reversal timer. If yes, the motor power is set to 20 percent at block 924 and the motor state is set to traveling UP at block 926 and the subroutine returns at block 932 . If the timer has not expired, the subroutine checks for receipt of a wall command or radio command at block 928 . If yes, the motor power is set to zero and the state is set at stopped in midtravel at block 930 , then the subroutine returns at block 932 . If no, the subroutine returns at block 932 .
The UP position routine, block 834 , is shown in FIG. 19 . Door travel limits training is started with the door in the UP position. At block 934 , the subroutine updates the relay safety system. Then the subroutine checks for receipt of a wall command or radio command at block 936 indicating an intervening user command. If yes, the motor power is set to 20 percent at block 938 and the state is set at traveling DOWN in block 940 . Then the light is updated and the subroutine returns at block 950 . If no wall command has been received, the subroutine checks for training the limits at block 942 . If no, the light is updated and the subroutine returns at block 950 . If yes, the limit training state machine is updated at block 944 . Then the subroutine checks if it is time to travel DOWN at block 946 . If no, the subroutine updates the light and returns at block 950 . If it is time to travel DOWN, the state is set at traveling DOWN at block 948 and the system returns at block 950 .
The DOWN direction subroutine, block 828 , is shown in FIGS. 20A-20D. At block 952 , the subroutine waits until the main loop routine refreshes the DOWN limit from EEPROM 302 . For safety purposes, only the main loop or the remote transmitter (radio) can access data stored in or written to the EEPROM 302 . Because EEPROM communication is handled within software, it is necessary to ensure that two software routines do not try to communicate with the EEPROM at the same time (and have a data collision). Therefore, EEPROM communication is allowed only in the Main Loop and in the Radio routine, with the Main loop having a busy flag to prevent the radio from communicating with the EEPROM at the same time. At block 954 , the subroutine checks if 40 milliseconds has passed since closing of the light relay K 3 . If no, the subroutine returns at block 956 . If yes, the subroutine checks if the warning light is flashing (for 2 seconds if the optional flasher module is installed) prior to travel at block 958 . If yes, the subroutine updates the status of the flashing light and returns at block 960 . If no, or the flashing is completed, the subroutine turns on the DOWN motor relay K 2 at block 962 . At block 964 the subroutine checks if one second has passed since the motor is first turned on. The system ignores the force on the motor for the first one second. This allows the motor time to overcome the inertia of the door (and exceed the programmed force settings) without having to adjust the programmed force settings for ramp up, normal travel and slow down. Force is effectively set to maximum during ramp up to overcome sticky doors.
If the one second time has not passed, the subroutine skips to block 984 . If the one second time limit has passed, the subroutine checks for the RPM signal time out at block 966 . If no, the subroutine checks if the motor speed is currently being ramped up at block 968 (this is a maximum force condition). If yes, the routine skips to block 984 . If no, the subroutine checks if the measured RPM period is longer than the allowable RPM period. If no, the subroutine continues at block 984 .
If either the RPM signal has timed out (block 966 ) or the RPM period is longer than allowable (block 970 ), this is an indication of an obstruction or the door has reached the DOWN limit position, and the subroutine skips to block 972 . At block 972 , the subroutine checks if the door is positioned beyond the DOWN limit setting. If it is, the subroutine skips to block 990 where it checks if the motor has been powered for at least one second. This one second power period after the DOWN limit has been reached provides for the door to close fully against the floor. This is especially important when DC motors are used. The one second period overcomes the internal braking effect of the DC motor on shut-off. Auto-reverse is disabled after the position detector reaches the DOWN limit.
If the motor has been running for one second, at block 990 , the subroutine sets the reason as reaching the limit at block 994 . The subroutine then checks if the limits are being trained at block 998 . If yes, the limit training machine is updated at block 1002 . If no, the motor's power is set to zero and the motor state is set at the DOWN position in block 1006 . In block 1008 the subroutine returns.
If the motor has not been running for at least one second at block 990 , the subroutine sets the reason as early limit at block 1026 . Then the subroutine sets the motor power at zero and the motor state as auto-reverse at block 1028 and returns at block 1030 .
Returning to block 984 , the subroutine checks if the door's position is currently unknown. If yes, the subroutine skips to block 1004 . If no, the subroutine updates the door's distance from the DOWN limit using internal RAM in microprocessor 300 in block 986 . Then the subroutine checks at block 988 if the door is three inches beyond the DOWN limit. If yes, the subroutine skips to block 990 . If no, the subroutine checks if the door is being positioned manually in the training cycle at block 992 . If yes, the subroutine skips to block 1004 . If no, the subroutine checks if the door is within the slow DOWN distance of the limit at block 996 . If no, the subroutine skips to block 1004 . If yes, the subroutine sets the motor slow down flag at block 1000 .
At block 1004 , the subroutine checks if a wall control command or radio command has been received. If yes, the subroutine sets the motor power at zero and the state as auto-reverse at block 1012 . If no, the subroutine checks if the motor has been running for over 27 seconds at block 1010 . If yes, the subroutine sets the motor power at zero and the state at auto-reverse. If no, the subroutine checks if the obstacle detector signal has been missing for 12 milliseconds or more at block 1014 indicating the presence of the obstacle or the failure of the detector. If no, the subroutine returns at block 1018 . If yes, the subroutine checks if the wall control or radio signal is being held to override the infrared obstacle detector at block 1016 . If yes, the subroutine returns at block 1018 . If no, the subroutine sets the reason as infrared obstacle detector obstruction at block 1020 . The subroutine then sets the motor power at zero and the state as auto-reverse at block 1022 and returns at block 1024 . (The auto-reverse routine stops the motor for 0.5 seconds then causes the door to travel up.)
The appendix attached hereto includes a source listing of a series of routines used to operate a movable barrier operator in accordance with the present invention.
While there has been illustrated and described a particular embodiment of the present invention, it will be appreciated that numerous changes and modifications will occur to those skilled in the art, and it is intended in the appended claims to cover all those changes and modifications which followed in the true spirit and scope of the present invention.
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A movable barrier operator having improved safety and energy efficiency features automatically detects line voltage frequency and uses that information to set a worklight shut-off time. The operator automatically detects the type of door (single panel or segmented) and uses that information to set a maximum speed of door travel. The operator moves the door with a linearly variable speed from start of travel to stop for smooth and quiet performance. The operator provides for full door closure by driving the door into the floor when the DOWN limit is reached and no auto-reverse condition has been detected. The operator provides for user selection of a minimum stop speed for easy starting and stopping of sticky or binding doors.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to new peptides derived from the proinflammatory cytokines Interleukin-1 beta (IL1β) and Tumor Necrosis Factor alpha (TNFα) and their use in human or veterinary therapy. The diseases targeted by these therapeutic uses can be in particular rheumatoid polyarthritis, septic shock, auto-immune diabetes, graft rejection in the host, and also acute or chronic inflammatory diseases, and more generally, diseases linked to the overproduction of IL1β or TNFα cytokines.
[0003] 2. Description of the Related Art
[0004] Active anti-cytokine immunization is an active immunotherapy strategy developed since 1990 by Zagury et al. which is based in particular on Patent Application WO 92/22577. This idea was taken up by several scientific teams which have published in international scientific journals, active immunizations against the entire IFNα protein multimerized by treatment with glutaraldehyde (Gringeri et al., JAIDS 1999; 20:358-70), a chimeric TNFα protein consisting of coupling the native TNFα protein with a T epitope of ovalbumin (Dalum et al., Nature Biotechnology, 1999; 17:666-69), against entire IL9 coupled with KLH (Richard et al., PNAS, 2000; 97:767-72) or also chimeric entire IL5 with a T epitope of tetanus toxin (Hertz et al., J. Immunol, 2001; 167:3792-99).
[0005] These approaches have confirmed the feasibility of autologous anti-cytokine immunizations, but these few successes obscure the unsuccessful tests described by certain authors: certain cytokines do not allow sufficiently protective and clinically effective antibodies to be obtained, and the same cytokine prepared in a form which is effective in one manner, will not be effective in another (Richard et al., PNAS, 2000; 97:767-72).
[0006] In trying to explain this phenomenon, the Applicant has observed that to date all the authors have used entire cytokines (optionally slightly modified), which leads to difficulties in particular at the following levels:
[0007] dilution of the immunogenic power of the antigenic determinants of interest
[0008] possible genesis of facilitating antibodies in vivo (B response).
[0009] possible genesis of autoimmune reaction to the potential T epitopes present in the entire cytokine (autoimmune T reaction).
[0010] This is why the Applicant has previously claimed families of peptides of limited size between 5 and 40 amino acids originating from cytokines and which have an antigenic power making it possible to generate antibodies against the native cytokine (Patent Application PCT/FR03/01120). EP-A-0218531 also described IL1 peptides used for the preparation of antibodies.
[0011] Citation of any document herein is not intended as an admission that such document is pertinent prior art, or considered material to the patentability of any claim of the present application. Any statement as to content or a date of any document is based on the information available to applicant at the time of filing and does not constitute an admission as to the correctness of such a statement.
SUMMARY OF THE INVENTION
[0012] The Applicant has evaluated certain peptides of the IL1β and TNFα cytokines with a size comprised between 10 and 30 residues and has demonstrated that these peptides were not only antigenic, but that they were also effective as immunogens for protecting in vivo against diseases linked to the overproduction of these cytokines. The present Application therefore claims peptides of a size comprised between 5 and 30 amino acids, originating from murine or human IL1β and TNFα cytokines or those of any other species of mammal, and their use in humans or animals (in this case veterinary use) for preventing or treating diseases linked to the overproduction of these cytokines. The present Application also claims the production of monoclonal or oligoclonal antibodies from these peptides and the use of these antibodies for therapeutic or preventive administration to humans or animals (veterinary application).
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a graph showing survival of mice immunized against peptides and subjected to septic shock.
[0014] FIG. 2 is a graph showing average clinical scores of groups of mice immunized against peptides in a model of collagen arthritis.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The cytokine peptides according to the invention originate from or are derived from the IL1β and TNFα cytokines. By “originate” is meant that their amino acid sequence is identical to that of the cytokine. By “are derived” is meant that their amino acid sequence is mostly identical to that of the cytokine but can comprise a few differences as will be seen hereafter.
[0016] The above cytokine peptides advantageously comprise more than 5, in particular more than 7, particularly more than 9 and quite particularly more than 11 amino acids.
[0017] Under other preferential conditions for implementing the invention, the above cytokine peptides comprise less than 30, advantageously less than 25, in particular less than 20, more particularly less than 18 amino acids.
[0018] The Applicant has demonstrated that the peptide area:
[0019] 80 VSRFAISYQEKVNLLS 95 (SEQ ID NO:1) of the murine TNFα cytokine makes it possible to engender antibodies by active immunization, capable of blocking TNFα-dependent septic shock in mice (Experiment 1). The corresponding sequence of the human cytokine is 75% homologous:
[0020] 80 ISRIAVSYQTKVNLLS 95 (SEQ ID NO:2)
[0021] The Applicant has also demonstrated that the peptide area:
[0022] 121 YISTSQAEHKPVFLG 135 (SEQ ID NO:3) of the murine IL1β cytokine makes it possible to engender antibodies by active immunization, capable of blocking collagen arthritis induced in mice (Experiment 2). The corresponding sequence in humans is 80% homologous:
[0000]
121
YISTSQAENMPVFLG
135
(SEQ ID NO:4)
[0023] Loetascher et al. (J Biol Chem, 1993, 268:26350-357) have shown by site specific mutagenesis experiments that the 143-147 region of TNFα could be important in the interaction with the p55 receptor of TNFα, and the present invention also claims the immunization against B epitopes of this region by means of peptides having a significant homology, be they xenogenic or mutant in relation to the human or animal cytokine sequence. The sequence corresponding to this area in humans is:
[0000]
140
DYLDFAESGQVY
150
(SEQ ID NO:5)
and in mice:
140
KYLDFAESGQVY
150
(SEQ ID NO:6)
[0024] Evans et al. (J Biol Chem, 1995, 270:11477-83) have also explained by site specific mutagenesis experiments that other regions of IL1β could be important in the interaction with the receptor, and the present invention also claims immunization against B epitopes of these regions by means of peptides having a significant homology, be they xenogenic or mutants in relation to the targeted human or animal cytokine sequence. The sequences corresponding to this area in humans are:
[0000]
3
VKSLNCTLRDSQQKSL
18
(SEQ ID NO:7)
45
SFVQGEESNDKIP
57
(SEQ ID NO:8)
89
NYPKKKMEKRFVFNKIEI
106
(SEQ ID NO:9)
143
ITDFTMQFVSS
153
(SEQ ID NO:10)
and in mice:
3
IRQLHYRLRDEQQKSL
18
(SEQ ID NO:11)
45
SFVQGEPSNDKIP
57
(SEQ ID NO:12)
89
QYPKKKMEKRFVFNKIEV
106
(SEQ ID NO:13)
142
IIDFTMESVSS
152
(SEQ ID NO:14)
[0025] It has been possible to create autologous antibodies against the latter peptides of mice by active immunization.
[0026] Experiments 1 and 2 hereafter, carried out by the Applicant, demonstrate the therapeutic ability in vivo of the anti-peptide active immunization approach with peptides of a size less than 30 residues. The Applicant claims these peptides and their derivatives for also carrying out active immunizations allowing the generation of antibodies targeting these epitopes of the TNFa and IL1b cytokines in order to block the interaction of the cytokine with its receptor.
[0027] As is known by a person skilled in the art of immunology, modifications of the natural peptide chains are possible without however modifying the nature of the immunological properties of the immunogenic peptides. Derivatives of cytokine peptides can therefore also be mentioned, which are highly homologous to these natural sequences, for example having more than 50% homology, in particular more than 70% homology, and preferably more than 80% homology or even more than 90% homology with the corresponding native peptide whilst retaining the immunological properties of this epitopic site of the native peptide. In particular homologous sequences of cytokines of other mammals can be used in order to obtain a xenogenic and not only an autologous protective reaction in an animal or human.
[0028] The cytokine peptide derivatives can contain modified residues, on condition that the modifications do not appreciably reduce the immunogenicity, either by adding chemical radicals (methyl, acetyl etc.) or by stereochemical modification (use of D series amino acids). The cytokine peptide derivatives should, like the cytokine peptides induce antibodies interacting with cytokine.
[0029] The cytokine peptide derivatives according to the invention can comprise one or more modifications in the amino acids of which they are constituted, such as deletions, substitutions, additions, or functionalizations (such as acylation) of one or more amino acids, to the extent that these modifications remain within the framework specified above (immunological characters). For example, in general the replacement of a leucine residue by an isoleucine residue does not modify such properties; the modifications should generally concern less than 40% of the amino acids, in particular less than 30%, preferably less than 20% and quite particularly less then 10% of the amino acids of the natural peptide. It is important that the antibodies induced by the modified peptides are active vis-à-vis native cytokine.
[0030] These modifications are within the scope of a person skilled in the art, who can verify the incidence of the modifications by simple tests. The immunogenicity of such modified derivatives can be evaluated by ELISA after immunization of mice, the antigen tested by ELISA being the entire cytokine or the immunizing cytokine peptide, or by cytokine-receptor bond blocking tests. The possible modifications preferably affect less than 8 amino acids, advantageously less than 6 amino acids, in particular less than 4 amino acids, and particularly 3 amino acids or less, such as 2 or 1 single amino acid.
[0031] A subject of the invention is also a compound characterized in that it contains at least one abovementioned cytokine peptide or cytokine peptide derivative. Such a compound can comprise identical peptide/derivative repetitions, or different peptide/derivative combinations, either in linear form or in the form of a candelabra structure or couplings mixed with carrier proteins. Such a compound can also be presented in cyclized form. Thus cytokine peptides or cytokine peptide derivatives according to the invention can for example be inserted into longer sequences of amino acids providing in particular a better conformation or combined with exogenous T epitopes (whether for protein or DNA immunizations).
[0032] They can advantageously be associated in a covalent manner with carrier proteins such as for example KLH.
[0033] The cytokine peptides according to the invention, due to their limited size, correspond in general to a small number of epitopes of the cytokine. When they are in particular inserted, combined or associated, the above compounds do not comprise other epitopes of said cytokine.
[0034] These cytokine peptides or cytokine derivatives can be included in any protein sequence which does not comprise homology with the other natural cytokine epitopes. For example, a cysteine can be added to the ends in order to confer a cyclic structure on the peptide. Another example is a peptide surrounded by sequences of T epitopes of the tetanus toxin. Yet another example can comprise a peptide corresponding to the sequence of the receptor binding site but where certain amino acids are replaced by their D series isomers in order to avoid their agonist effect. In fact, it can be optionally advantageous to use peptide derivatives which have no agonist activity on the receptor so that the immunogen does not interfere with the immune response.
[0035] In order to increase the immune response, these cytokine peptides or cytokine derivatives can be coupled to carrier proteins. The coupling methods and the carrier protein considered can be different according to the target peptide: they can for example be Keyhole Limpet Hemocyanin (KLH) protein and Tetanus Toxoid (TT) conjugated to the peptides by chemical methods well known to a person skilled in the art such as those of carbodiimide, glutaraldehyde or bis-diazotized benzidine coupling. The realization of these couplings can be facilitated by the addition or incorporation of amino acids into the sequence, such as for example lysines, histidines, tyrosines or cysteines. Such peptide compounds coupled to an exogenous T epitope (originating from plasmodium falciparum, KLH, etc.) whether chemically or genetically also come within the scope of the invention.
[0036] Network couplings of candelabra type or to molecules such as transferrin or ferritin can also be implemented in order to effectively stimulate the immune response.
[0037] The peptides according to the invention can in particular be produced by chemical synthesis or genetic engineering or any other suitable method. The synthesis of cyclic peptides, grafting, as needed, one or more amino acids at the end of the chain as cysteines in order to create a disulphide bridge makes it possible to recover part of the secondary structure that these peptide fragments possess in the three-dimensional structure of the protein.
[0038] The peptides according to the invention possess very useful pharmacological properties. In particular they possess remarkable anti-cytokine properties. These properties are illustrated hereafter in the experimental part. They justify the use of the peptides described above as a medicament.
[0039] This is why a subject of the invention is also medicaments characterized in that they are constituted by peptides or derivatives of the IL1β or TNFα cytokines or compounds as defined above, i.e. cytokine peptides or cytokine derivatives or immunogenic compounds as defined above for their use in a method of therapeutic treatment of the human or animal body, as well as the use of such a cytokine peptide or cytokine derivative or immunogenic compound for the preparation of a curative or preventive medicament intended for the treatment or prevention of diseases linked to an excess or to the presence of cytokines.
[0040] The medicaments according to the present invention are used for example in both the curative and preventive treatment of diseases linked to cytokine deregulation, whether rheumatoid polyarthritis, septic shock or any other disease where the blocking of IL1β or TNFα is curative. These are only a few examples, and a subject of the invention is also any treatment of the human or animal body based on active immunization (DNA or peptide) involving the peptide sequences mentioned above to the exclusion of other epitopes of the cytokines. These sequences can be modified as indicated in the present description, and the immunizations by DNA are carried out by simple translation from the genetic code.
[0041] The humoral immunity response can be evaluated by ELISA tests.
[0042] The immunogenic active ingredients according to the invention can be used as follows:
[0043] A cytokine peptide or cytokine derivative or immunogenic compound according to the present invention, is administered to a patient or to an animal, for example by sub-cutaneous or intramuscular route, in a sufficient quantity to be effective at a therapeutic level, to a subject needing such treatment. The dose administered can for example range from 1 to 1000 μg, in particular 10 to 500 μg, by sub-cutaneous route, once a month for three months, then periodically as a function of the induced serum antibodies count, for example every 2-6 months. In the same preparation two immunogenic molecules of the two cytokines can be administered if a still stronger blocking effect is to be obtained.
[0044] A subject of the invention is also the pharmaceutical compositions in particular the vaccines which contain at least one abovementioned cytokine peptide or cytokine derivative or immunogenic compound, as active ingredient.
[0045] As medicaments, a cytokine peptide or cytokine derivative or immunogenic compound of the invention can be incorporated into pharmaceutical compositions intended for any standard route in use in the field of vaccines, in particular by sub-cutaneous route, by intramuscular route, by intravenous route or by oral route. The administration can take place in a single dose or repeated once or more after a certain period of time.
[0046] This is why a subject of the present Application is also a curative or preventive pharmaceutical composition, characterized in that it comprises as active ingredient, one or more cytokine peptides or cytokine derivatives or immunogenic compounds, as defined above.
[0047] The immunogenic agent can be conditioned alone or mixed with an excipient or mixture of pharmaceutically acceptable excipients as an adjuvant. A subject of the present Application is more particularly a vaccine containing as immunogen, an abovementioned cytokine peptide or cytokine derivative or immunogenic compound.
[0048] A subject of the present invention is also a process for preparing a composition described above, characterized in that, according to methods known per se, the active ingredient or ingredients are mixed with acceptable, in particular pharmaceutically acceptable excipients.
[0049] The administration to a patient of a cytokine peptide or cytokine derivative or immunogenic compound according to the invention corresponds to an active immunotherapy.
[0050] It can also be useful to carry out passive immunotherapy, i.e. to provide a patient or a sick animal directly with the antibodies which they need. For this purpose, the peptides, derivatives and compounds defined previously can be used in order to produce monoclonal antibodies according to the usual techniques, human, murine or humanized, for example by conversion of B lymphocytes from a subject immunized by the Epstein-Barr virus or by the screening of antibody libraries. These antibodies by targeting the epitopes of the above peptides block the interaction of the cytokine with its receptor and thus make it possible to reduce the pathogenic effect of the cytokine in the disease. Oligoclonal antibodies can also be prepared by active immunization in animals such as horses for example, purified, and administered therapeutically to humans or animals.
[0051] The vaccine preparations can be packaged for the intra-nasal route in the form of gel with carbopol as excipient, nasal drops or spray and for the oral route in the form of gastroresistant capsules, sugar-coated tablets or gastroresistant granules.
[0052] In the case of DNA vaccine administered by systemic or mucosal route, the galenic presentation of the plasmid can be a suspension in a physiological liquid such as physiological PBS (phosphate buffered saline=PBS). The plasmids can be enclosed in biodegradable polymer (PLG, PLA, PCL) microspheres and administered in gastroresistant capsules for ingestion (oral route). The DNA can also be expressed in a bacterial, salmonella-type or viral-type, adenovirus or poxvirus living vector.
[0053] Finally, a subject of the present Application is a process for active immunization of patients characterized in that as immunogen, a cytokine peptide or cytokine derivative or immunogenic compound is used, as defined above, advantageously associated with a mineral, oily or synthetic immunity adjuvant.
[0054] The immunizations can be done in a standard fashion in particular by peptides or immunogenic compounds as conjugates preferably in the presence of an adjuvant, for example ISA 51 or Alum. The immunizations can be DNA-based (sequences homologous to the binding sites combined with exogenous T epitopes) using naked DNA or an expression vector containing an adapted promoter such as for example pCR3.1. The DNAs administered can be protected from the nucleases by the use of appropriate radicals (CpG etc.). In particular an initial DNA immunization can be followed by standard boosters using the peptide compounds.
[0055] The methods of treatment of the human or animal body described in this patent can include a cytokine peptide or cytokine derivative or immunogenic compound as defined above, and can include the monoclonal or oligoclonal antibodies as defined above.
[0056] The preferential conditions for using the peptides described above also apply to the other subjects of the invention referred to above.
[0057] FIG. 1 and FIG. 2 show the results of protection in vivo of the immunizations described in Experiments 1 and 2 for a TNFα peptide in TNFα-dependent septic shock and an IL1β peptide in collagen arthritis.
[0058] The experiments which follow illustrate the present invention.
EXPERIMENT 1
[0059] 4 murine TNFα peptides coupled to the KLH carrier protein, including the cyclized peptide CVSRFAISYQEKVNLLSC (SEQ ID NO:15) called TNFα-6, were tested in a model of endotoxinic shock. For this purpose, Balb/c mice were preimmunized against these peptides on days D0, D8, D16, and D40. On day D50, the mice were subjected to shock, i.e. they were injected with LPS with Galactosamine. A control was carried out on mice immunized against KLH alone.
[0060] It is noted that all the mice died after two days, except for the group immunized against the TNFα-6 peptide where the mice were protected. The protection conferred by the immunization was very significant (p=0.008).
EXPERIMENT 2
[0061] 3 murine IL1β peptides coupled to the KLH protein, including the cyclized IL1β-6 peptide of sequence YCYISTSQAEHKPVFLGC (SEQ ID NO:16), were tested in a model of collagen arthritis. For this purpose, DBA1 mice were preimmunized against these peptides on days D0, D20, D40, D60. On day D80 the mice were immunized against collagen in Freund's adjuvant, and similarly on day D95. The development of arthritis was monitored between day D100 and day D160: twice weekly, the mice were examined and a score was attributed to them as a function of the state of inflammation of their joints (0=no inflammation, 1=slight inflammation, 2=average inflammation, 3=strong inflammation).
[0062] It is noted that the control mice immunized by KLH alone exhibit strong inflammation (curve with squares) whereas the group of mice immunized against the IL1β-6 peptides (curve with diamonds) exhibit a strong protection level with respect to the control (p=0.0003, ANOVA test).
EXPERIMENT 3
[0063] 6 groups of 4 mice were immunized against 20 ug of the murine IL1β peptides IRQLHYRLRDEQQKSL (group 1) (SEQ ID NO:11), SFVQGEPSNDKIP (group 2) (SEQ ID NO:12), QYPKKKMEKRFVFNKIEV (group 3) (SEQ ID NO:13), IIDFTMESVSS (group 4) (SEQ ID NO:14), and 20 ug of the murine TNFα peptide KYLDFAESGQVY (group 5) (SEQ ID NO:6) all coupled to KLH. Group 6 corresponds to mice immunized by KLH alone. A booster was administered on days D20 and D40. On day D50 the mice were sacrificed and the antibodies directed against the native mTNFα cytokine and the native mIL1β cytokine in the serums were measured by an ELISA test.
[0064] The averages obtained for each group are indicated in the table hereafter.
[0000]
TABLE 1
Anti-TNFα response
Anti-IL1β response
Average
Average
Group 1
0.13
1.5
Group 2
0.15
1.9
Group 3
0.18
1.6
Group 4
0.12
0.8
Group 5
1.3
0.31
Group 6
0.10
0.15
[0065] It is therefore clear that these peptides are well capable of inducing antibodies recognizing the native cytokine. These antibodies are very specific since they recognize only the cytokine the sequence of which was used for the immunization.
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The present invention relates to peptides derived from the proinflammatory cytokines, interleukin-1β, (IL1β) and tumor necrosis factor α, (TNFα), and their use in human or veterinary therapy, such as to generally treat diseases linked to the overproduction of IL1β or TNFα as well as acute or chronic inflammatory diseases, rheumatoid arthritis, septic shock, autoimmune diabetes, graft rejection in the host, etc.
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TECHNICAL FIELD
[0001] The present invention relates to an auto-sampler, and more specifically, to an auto-sampler suitable for use in a liquid chromatograph system.
BACKGROUND ART
[0002] In an auto-sampler used in a liquid chromatograph system, a liquid sample contained in a sample container is drawn into and held by a sampling needle. Then, the sampling needle is transferred by a moving means to an injection port provided at a predetermined position, where the liquid sample is injected into the port.
[0003] The auto-sampler has a casing which contains various components, such as a rack for placing a plurality of sample containers placed at predetermined positions, the moving means for transferring the sampling needle in the aforementioned manner, the sample injection port, a washing tank for cleaning the sampling needle with a washing liquid, and a waste-liquid passage for discharging waste liquid after the cleaning of the sampling needle. In some cases, a container for holding a mobile phase to be supplied to a column of the liquid chromatograph is also provided.
[0004] In the auto-sampler, the sample containers and/or the air in the casing is heated or cooled to maintain the liquid samples at a constant temperature or to perform the heating or cooling of the samples according to the purpose of the analysis. When the sample containers and/or the air in the casing is cooled, the water-vapor pressure in the casing may exceed the saturated water-vapor pressure, causing water condensation on the sample containers or other objects. The condensed water can cause a problem; for example, it may be mixed in the liquid sample during the sample-drawing process and decrease the sample concentration. Therefore, in the conventional auto-samplers, the casing is hermetically sealed to prevent the penetration of water vapors from outside (for example, see Patent Literature 1), and simultaneously, the water vapors in the casing are collected by some means, such as a Peltier element for locally condensing water vapors or a desiccating agent.
CITATION LIST
Patent Literature
[0005] Patent Literature 1: JP 7-120448 A
SUMMARY OF INVENTION
Technical Problem
[0006] As the washing liquid or the mobile phase, organic solvents are frequently used, and accordingly, the waste liquid often contains organic solvents. Those solvents turn into vapors within the casing of the auto-sampler, and the vaporized waste liquid flows through the waste-liquid passage into the casing. Such vapors cannot be easily collected by a desiccating agent. The local cooling by the Peltier element is also ineffective in collecting the vapors of a solvent whose saturated vapor pressure at low temperatures is high. Allowing the solvent vapors to fill the sealed casing leads to a corrosion of the inner walls of the casing, the motor, the gears and other devices, as well as the rack.
[0007] The problem to be solved by the present invention is to provide an auto-sampler capable of preventing solvent vapors from filling the casing of the auto-sampler and causing a corrosion of the devices, walls and other objects inside the casing.
Solution to Problem
[0008] The auto-sampler according to the present invention aimed at solving the previously described problem is an auto-sampler having a casing whose inner space can be hermetically closed, including:
[0009] an opening provided in a wall of the casing; and
[0010] a gas discharger for discharging gas inside the casing through the opening to the outside of the casing.
[0011] By the auto-sampler according to the present invention, the gas which contains solvent vapors or water vapors emitted from the liquid sample or the washing liquid inside the casing can be discharged through the opening provided in a wall of the casing to the outside of the casing. Thus, the solvent vapors or the water vapors are prevented from filling the casing and causing a corrosion of the devices, walls and other objects inside the casing.
[0012] The auto-sampler according to the present invention may preferably include a concentration detector for detecting the concentration of solvent vapors in the casing and for generating a predetermined signal when the concentration has exceeded a predetermined threshold, and a first controller for activating the gas discharger upon receiving the aforementioned signal.
[0013] This system can assuredly activate the gas discharger without requiring additional manipulations by users. Furthermore, the casing is assuredly prevented from being filled with solvent vapors at a concentration equal to or higher than the predetermined level.
[0014] Alternatively, the auto-sampler may be provided with a second controller for automatically activating the gas discharger at predetermined intervals of time.
[0015] This system can also activate the gas discharger without requiring additional manipulations by users, and furthermore, the casing is prevented from being filled with solvent vapors.
[0016] The auto-sampler according to the present invention may preferably include an open/close device provided on an outer side of the opening, the open/close device being designed to maintain the opening in an open state when the gas discharger is running and to close the opening when the gas discharger is not running
[0017] For example, the open/close device may be a cover with the upper end joined to an upper portion of the opening. When the gas discharger is running, the cover is opened by the wind pressure of the gas flowing from the inside to the outside of the casing, letting the gas be discharged. When the gas discharger is not running, the cover is in its original position due to its own weight and closes the opening, thus preventing an inflow of water vapors from the outside.
[0018] The auto-sampler according to the present invention may preferably have a water-vapor collector inside the casing.
[0019] By this system, the situation where the casing is filled with water vapors is also prevented. Examples of the water-vapor collector include a Peltier element for locally condensing water vapors and a desiccating agent.
Advantageous Effects of the Invention
[0020] The auto-sampler according to the present invention can discharge solvent vapors from the inside to the outside of the casing by an operation of the gas discharger and thereby prevents the situation where the solvent vapors fill the casing and cause a corrosion of the devices, walls and other objects inside the casing.
BRIEF DESCRIPTION OF DRAWINGS
[0021] FIG. 1 is a diagram illustrating the structure of one embodiment of the auto-sampler according to the present invention.
[0022] FIG. 2 is a diagram illustrating the inner structure of an upper block of the auto-sampler of the present embodiment.
[0023] FIG. 3 is a diagram illustrating the right-side inner wall of the upper block of the auto-sampler of the present embodiment.
[0024] FIG. 4 is a diagram illustrating a system for an operation control of a fan in the auto-sampler of the present embodiment.
[0025] FIG. 5 is a diagram illustrating a variation of the auto-sampler.
DESCRIPTION OF EMBODIMENTS
[0026] FIG. 1 is a perspective view of an auto-sampler 1 of the present embodiment, with the outer right door 2 and the outer left door 3 opened to show the inside.
[0027] An optical door sensor 4 for sensing that the outer doors are open is provided in the upper portion of the auto-sampler 1 . An LED lamp 5 for producing a blinking signal to inform users of an abnormality (e.g. a malfunction in the temperature control) is attached to an upper block 10 (which will be described later). An opening 30 for allowing communication between the outside of the auto-sampler 1 and the inside of the upper block 10 is provided on the right side of the auto-sampler 1 . A shutter 31 consisting of a plurality of plates each of which has its upper end fixed is provided on the outside of the opening 30 .
[0028] The auto-sampler 1 contains the upper block 10 and a lower block 20 .
[0029] FIG. 2 shows the main components contained in the upper block 10 . This upper block 10 corresponds to the casing of the present invention.
[0030] The main components contained in the upper block 10 are as follows: a rack 13 for placing a plurality of sample containers 12 at predetermined positions; a sampling needle 14 for drawing and holding a liquid sample from one of the sample containers 12 , and for injecting the liquid sample into a predetermined injection port 17 ; a drive mechanism 15 for operating the sampling needle 14 in the aforementioned manner; rails 16 for horizontally moving the drive mechanism 15 ; the injection port 17 for injecting a liquid sample through a passage (not shown) into a column of a liquid chromatograph system; a washing tank 18 for cleaning the sampling needle 14 with a washing liquid, and a waste-liquid passage (not shown) for discharging waste liquid after the cleaning of the sampling needle 14 .
[0031] FIG. 3 shows the right-side inner wall of the upper block 10 . The right side on FIG. 3 corresponds to the front side of the auto-sampler 1 . The position of the opening 30 on the right-side wall of the upper block 10 corresponds to that of the opening 30 shown in FIG. 1 . A fan 32 for discharging the gas inside the upper block 10 through the opening 30 to the outside of the auto-sampler 1 is provided. A solvent vapor concentration detector unit 40 for detecting solvent concentrations in the upper block 10 is provided above the fan 32 . This unit is connected to an external controller 50 (not shown).
[0032] The lower block 20 contains a temperature controller for maintaining the air and the liquid samples inside the upper block 10 at a predetermined temperature, a power source for supplying power to the temperature controller and other units, as well as other devices.
[0033] The gas-discharging operation in the present embodiment is hereinafter described by means of FIG. 4 .
[0034] As already explained, in the auto-sampler 1 , the air and the sample containers 12 inside the upper block 10 are heated or cooled to maintain the auto-sampler at a constant temperature or to perform the heating or cooling of the auto-sampler. During the process, the solvents contained in the washing liquid, the waste liquid or the like vaporize and spread within the upper block 10 . Taking into account the kinds of solvents to be detected, the solvent vapor concentration detector unit 40 in the present embodiment has three detectors 41 a, 41 b and 41 c. Each detector continuously detects the concentration of the corresponding kind of solvent vapors and sends a predetermined signal to the controller 50 when the concentration has exceeded a predetermined level.
[0035] Upon receiving the predetermined signal from any of the detectors, the controller 50 energizes the fan 32 for a predetermined period of time. The energized fan 32 produces a gas flow from the inside of the upper block 10 to the outside of the auto-sampler 1 , which pushes the shutter 31 upward by wind pressure. Thus, the gas inside the upper block 10 is discharged through the opening 30 to the outside of the auto-sampler 1 . Later on, when the fan 32 is de-energized, the shutter 31 lowers due to its own weight and closes the opening 30 .
[0036] The previously described embodiment is a mere example and can be appropriately changed or modified in line with the spirit of the present invention.
[0037] The auto-sampler 1 of the present embodiment can discharge both solvent vapors and water vapors from the upper block 10 to the outside of the auto-sampler 1 . However, it is preferable to provide a water-vapor collector in the upper block 10 in order to more effectively remove water vapors. By this system, the situation where the upper block 10 is filled with water vapors is also prevented. For example, the water-vapor collector may be a Peltier element for locally condensing water vapors or a desiccating agent.
[0038] The solvent concentration detector unit 40 may be configured so that the detection signal of each kind of solvent vapors is directly sent from the sensors to the controller 50 . In this case, the controller 50 can be configured so as to energize the fan 32 when any one of the solvent-vapor concentrations derived from the detection signals received from the sensors has exceeded a reference concentration a which has been previously set in the controller 50 for each kind of solvent. It is also possible to set another reference concentration b in the controller 50 other than the reference concentration a and to configure the controller 50 so as to de-energize the fan 32 when the concentration of the solvent vapors has become lower than the reference concentration b as a result of the operation of discharging the solvent vapors from the upper block 10 by the fan 32 .
[0039] It is also possible to configure the controller 50 so as to automatically energize the fan 32 at predetermined intervals of time, in which case the solvent concentration detector unit 40 can be omitted.
[0040] In the previous embodiment, the gas inside the upper block 10 is directly discharged through the single opening 30 to the outside of the auto-sampler 1 . FIG. 5 shows another possible structure, in which a middle chamber 60 having an opening 30 a for communication with the inside of the upper block 10 and an opening 30 b for communication with the outside of the auto-sampler 1 is provided. This chamber is provided with a fan 32 a for discharging the gas inside the upper block 10 through the opening 30 a into the middle chamber 60 and a fan 32 b for discharging the gas inside middle chamber 60 through the opening 30 b to the outside of the auto-sampler 1 . A water-vapor collector 61 provided in the middle chamber 60 efficiently traps water vapors coming from the outside of the auto-sampler 1 .
REFERENCE SIGNS LIST
[0000]
1 . . . Auto-Sampler
2 . . . Outer Right Door
3 . . . Outer Left Door
4 . . . Optical Door Sensor
5 . . . LED Lamp
10 . . . Upper Block
12 . . . Sample Container
13 . . . Rack
14 . . . Sampling Needle
15 . . . Drive Mechanism
16 . . . Rails
17 . . . Injection Port
18 . . . Washing Tank
19 . . . Lower Block
30 , 30 a, 30 b . . . Opening
31 . . . Shutter
32 , 32 a, 32 b . . . Fan
40 . . . Solvent Concentration Detector Unit
41 a, 41 b, 41 c . . . Detector
50 . . . Controller
60 . . . Middle Chamber
61 . . . Water-Vapor Collector
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The present invention is an auto-sampler having a casing whose inner space can be hermetically closed, including an opening provided in a wall of the casing and a gas discharger for discharging gas inside the casing through the opening to the outside of the casing.
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BACKGROUND
[0001] The present invention relates, generally, to a diffusion sheet for use in a backlight unit of a TFT-LCD (Thin Film Transistor-Liquid Crystal Display), and, more particularly, to a diffusion sheet for a display, which can uniformly diffuse light, which is radiated from a light source lamp positioned at a side surface or the back surface of the display, while passing such light therethrough, to thus obtain clear display images.
[0002] Recently, LCDs are variously used not only as monitors for notebook computers but also as large monitors for desktop computers and monitors for television sets. Accordingly, the need for screens to be large and the luminance to be high of backlight units, serving as the light source of LCDs, is increasing. In the backlight unit, a diffusion sheet functions to diffuse light from the light source at the side surface or back surface of the display to the entire screen and to uniformly transfer such light forward by means of refraction. The backlighting process is an indirect lighting process for enhancing the brightness of a display screen in a manner such that light originating from the light source of a backlight unit, mounted to the back surface of a display, is transferred to the opposite side through a light guide plate and then reflected at a reflective plate, such as a metal deposition plate or an opaque white plate, to radiate the light forward. Thereby, the backlighting process is a light emission technique that is able to overcome the problems with the conventional front-lighting process. In the backlighting process, when the number of light sources of a backlight unit is increased in order to realize high image brightness, power consumption and heat generation rates are increased. However, since maximum light efficiency should be realized using minimum power consumption, typical techniques of manufacturing a light-diffusion sheet comprising a base sheet and a light-diffusing layer formed on at least one surface of the base sheet in order to transfer light from a light source to a liquid crystal operator have been proposed. As such, in the light-diffusion sheet, it is important to realize an efficient design for the light-diffusing layer formed on the base sheet and to improve the functions thereof through such a design.
[0003] In this regard, Japanese Patent Application No. 2002-104820 discloses a light-diffusing layer which is formed of a resin film having fine roughness on at least one surface of a transparent film. As such, this patent is characterized in that the transparent film contains a thermoplastic resin having a substituted and/or unsubstituted imido group on a side chain thereof and a thermoplastic resin having a substituted and/or unsubstituted phenyl group and a nitrile group on a side chain thereof. In addition, Korean Patent Application No. 1996-38912 discloses a method of forming a layer of a transparent resin and organic particles on a transparent plastic sheet to increase light efficiency and luminance. However, such conventional techniques suffer because they are difficult to use to actually realize high luminance and shielding of LCDs, that is, improved total light transmittance and light diffusibility, merely by varying the combination of resin and particles applicable in the light-diffusing layer.
SUMMARY
[0004] Therefore, the present invention has been made keeping in mind the above problems occurring in the prior art, and an object of the present invention is to provide a diffusion sheet for a TFT-LCD, which has increased light transmittance and light diffusibility.
[0005] In order to accomplish the above object, the present invention provides a diffusion sheet, comprising a transparent base sheet, a light-diffusing layer laminated on one surface of the base sheet, and an antiblocking layer laminated on the other surface of the base sheet, in which the base sheet satisfies Equation 1 below:
SR =|( N max −N z )/( N td −N md )|>20
N z ≦1.494 Equation 1
[0006] wherein SR is the three dimensional refraction constant of the base sheet,
[0007] N max is the greater value of either the refractive index of the sheet in a machinery direction (MD) or the refractive index of the sheet in a transverse direction (TD),
[0008] N z is the refractive index of the sheet in a thickness direction,
[0009] N td is the refractive index of the sheet in the TD, and
[0010] N md is the refractive index of the sheet in the MD.
[0011] In the diffusion sheet, the light-diffusing layer may comprise a resin and diffusion particles.
[0012] As such, the resin may be a thermosetting resin, and the diffusion particles may comprise at least one resin selected from the group consisting of acryl, polyurethane, polyvinyl chloride, polystyrene, polyacrylonitrile, polyamide, and polymethylmethacrylate, with a diameter of 0.1˜100 μm. Further, the light-diffusing layer may comprise 100 parts by weight of the resin and 0.1˜1000 parts by weight of the diffusion particles, and may be 0.2˜500 μm thick.
[0013] In addition, the antiblocking layer may comprise an antiblocking resin and antiblocking particles, the antiblocking resin being a thermosetting resin. The antiblocking particles may comprise at least one resin selected from the group consisting of acryl, polyurethane, polyvinyl chloride, polystyrene, polyacrylonitrile, polyamide, and polymethylmethacrylate, with a diameter of 0.1˜100 μm. Such an antiblocking layer may comprise 100 parts by weight of the resin and 0.01˜500 parts by weight of the antiblocking particles, and may be 0.1˜100 μm thick.
[0014] Additional features and advantages are described herein, and will be apparent from, the following Detailed Description and the figures.
BRIEF DESCRIPTION OF THE FIGURES
[0015] FIG. 1 is a cross-sectional view schematically showing a light-diffusion sheet having voids, according to the present invention; and
[0016] FIG. 2 is a schematic view showing the refractive indexes of the base sheet in predetermined directions.
DETAILED DESCRIPTION
[0017] Hereinafter, a detailed description will be given of the present invention.
[0018] In the present invention, the diffusion sheet 1 comprises a transparent base sheet 2 , a light-diffusing layer 3 laminated on one surface of the base sheet, and an antiblocking layer 4 laminated on the other surface of the base sheet, the base sheet satisfying Equation 1 below.
[0019] Although the thickness of the base sheet 2 is not particularly limited, it is preferably 10˜500 μm, and more preferably 75˜250 μm. As such, if the thickness of the base sheet 2 is less than 10 μm, a curling phenomenon may be readily caused by the resin composition constituting the light-diffusing layer 3 . On the other hand, if the thickness of the base sheet 2 exceeds 500 μm, the luminance of the LCD is decreased and the backlight unit becomes so thick as to be unsuitable for use in manufacturing a slim LCD. In this way, on one surface of the light-diffusion sheet 1 , the light-diffusing layer 3 composed of a light-diffusing resin 5 and light-diffusing particles 7 is provided.
[0020] The main characteristic of the present invention is that the relationship between refractive indexes of the base sheet in three directions is set within a predetermined range in order to maximize the transmittance of light passing through the base sheet so as to enhance the luminance of the diffusion sheet. At this time, for maximum total light transmittance and high luminance of light passing through the base sheet, the relationship between the refractive indexes of the base sheet in three directions should satisfy Equation 1 below:
SR =|( N max −N z )/( N td −N md )|>20
N z ≦1.494 Equation 1
[0021] wherein SR is the three dimensional refraction constant of the base sheet,
[0022] N max is the greater value of either the refractive index of the sheet in the MD or the refractive index of the sheet in the TD,
[0023] N z is the refractive index of the sheet in the thickness direction,
[0024] N td is the refractive index of the sheet in the TD, and
[0025] N md is the refractive index of the sheet in the MD.
[0026] When the Sr is not more than 20, the improvement of total light transmittance and luminance becomes insignificant. Further, in the case where N, exceeds 1.494, it is difficult to achieve an increase in the transmittance and luminance of the diffusion sheet, undesirably decreasing the luminance properties of the LCD.
[0027] Further, the light-diffusing layer 3 includes a light-diffusing resin 5 and light-diffusing particles 7 dispersed in the resin. Any resin may be used as the light-diffusing resin 5 as long as it is curable, and preferably, a thermosetting resin which is easily handled and available is useful. Examples of the thermosetting resin include, but are not limited to, any one selected from the group consisting of urea resin, melamine resin, phenol resin, epoxy resin, unsaturated polyester resin, alkyd resin, urethane resin, acrylic resin, polyurethane, fluorine resin, silicon resin, and polyamideimide. Moreover, the resin should be preferably colorless and transparent, since light should be transmitted therethrough. In addition to the above light-diffusing resin, a plasticizer, a stabilizer, a deterioration preventing agent, a dispersant, an antifoaming agent, or a foaming agent may be further included, if necessary.
[0028] The light-diffusing particles 7 used in the light-diffusing layer 3 comprise at least one selected from the group consisting of acrylic resin, polyurethane, polyvinyl chloride, polystyrene, polyacrylonitrile, polyamide, and polymethylmethacrylate, and are preferably in a spherical form. More preferably, the light-diffusing particles should be colorless and transparent so as to maximize the amount of light passing through the light-diffusion sheet.
[0029] The light-diffusing particles have a diameter of 0.1˜100 μm, preferably 0.1˜50 μm, and more preferably 0.1˜10 μm. If the diameter is less than 0.1 μm, the light-diffusing effect becomes insignificant. On the other hand, if the diameter exceeds 100 μm, the resin composition constituting the light-diffusing layer is difficult to apply and the particles may become detached from the laminated light-diffusing layer.
[0030] In order to manufacture a light-diffusion sheet having total light transmittance of 85˜95% by controlling the optical properties of the light-diffusing layer 3 , the ratio of light-diffusing resin 5 and light-diffusing particles 7 is adjusted. That is, the light-diffusing layer 3 is formed such that the light-diffusing particles 7 are used in an amount of 0.1˜1000 parts by weight, and preferably 10˜500 parts by weight, based on 100 parts by weight of the light-diffusing resin 5 . If the amount of light-diffusing particles 7 is less than 0.1 parts by weight, the light-diffusing effect is reduced. On the other hand, if the amount exceeds 1000 parts by weight, the light-diffusing resin composition constituting the light-diffusing layer is difficult to apply.
[0031] In the light-diffusion sheet 1 of the present invention, the thickness of the light-diffusing layer 3 is adjusted, thereby controlling the light transmittance. In particular, with the intention of manufacturing a light-diffusion sheet having total light transmittance of 85˜95%, the light-diffusing layer 3 is applied to a thickness of 0.2˜500 μm, and preferably 2˜200 μm. If the light-diffusing layer is applied to a thickness less than 0.2 μm, it has low adhesion to the sheet when applied, and the light-diffusing particles may become detached from the laminated light-diffusing layer. On the other hand, if the applied layer is thicker than 500 μm, total light transmittance is not higher than 84%, and thus a desired light-diffusion sheet cannot be manufactured.
[0032] Also, the light-diffusion sheet 1 of the present invention has an antiblocking layer 4 composed of an antiblocking resin 6 and antiblocking particles 8 .
[0033] The antiblocking resin 6 usable in the antiblocking layer 4 preferably includes the same thermosetting resin as the light-diffusing resin 5 , which is exemplified by any one selected from the group consisting of urea resin, melamine resin, phenol resin, epoxy resin, unsaturated polyester resin, alkyd resin, urethane resin, acrylic resin, polyurethane, fluorine resin, silicon resin, and polyamideimide. The antiblocking resin 6 should be colorless and transparent, since light must be transmitted therethrough.
[0034] In addition, a plasticizer, a stabilizer, a deterioration preventing agent, a dispersant, an antifoaming agent, a foaming agent or a waxing agent may be further used.
[0035] Further, the antiblocking particles 8 used in the antiblocking layer 4 , which are the same as the light-diffusing particles 7 , include any one selected from the group consisting of acrylic resin, polyurethane, polyvinyl chloride, polystyrene, polyacrylonitrile, polyamide, and polymethylmethacrylate. The antiblocking particles are preferably spherical. As well, the antiblocking particles 8 should be preferably colorless and transparent in order to maximize the amount of light passing through the light-diffusion sheet. The particles 8 have a diameter of 0.1˜100 μm, and preferably 1˜50 μm. If the diameter of antiblocking particles 8 is smaller than 0.1 μm, a blocking phenomenon, which impedes movement of a film, may occur during a manufacturing process. On the other hand, if the diameter of antiblocking particles exceeds 100 μm, the resin composition constituting the antiblocking layer is difficult to apply, and the antiblocking particles may become detached from the laminated antiblocking layer.
[0036] The antiblocking layer 4 is formed such that the antiblocking particles 8 are used in an amount of 0.01˜500 parts by weight, and preferably 0.1˜100 parts by weight, based on 100 parts by weight of the antiblocking resin 6 . If the amount of antiblocking particles 8 is less than 0.01 parts by weight, a blocking phenomenon, which impedes movement of a film, may occur during a manufacturing process. On the other hand, if the above amount exceeds 500 parts by weight, it is difficult to apply the resin composition constituting the antiblocking layer 4 .
[0037] Further, to assure high light transmittance and antiblocking function and to obtain total light transmittance of 85˜95%, the antiblocking layer 4 is applied to a thickness of 0.1˜100 μm, preferably 0.150 μm, and more preferably 0.1˜20 μm. If the antiblocking layer 4 is applied to a thickness less than 0.1 μm, it has low adhesion to the base sheet upon application, and the antiblocking particles may become detached from the laminated antiblocking layer. On the other hand, if the antiblocking layer 4 is thicker than 100 μm, total light transmittance is decreased to 84% or less, and therefore it is impossible to manufacture a desired light-diffusion sheet.
[0038] A better understanding of the present invention may be obtained in light of the following examples, which are set forth to illustrate, but are not to be construed to limit the present invention.
EXAMPLE 1
[0039] Manufacture of Light-Diffusion Sheet 1
[0040] Step 1: Formation of Base Sheet
[0041] A polyester resin was dried in a vacuum, melted, and extruded using an extruder, after which the melted hot polyester resin was formed into a sheet using a rotary cooling roll via a die. As such, the polymer was brought into close contact with the cooling roll using an electrostatic application process, thereby obtaining an undrawn polyester sheet. While the undrawn polyester sheet was passed on a roll preheated to 70˜120° C., it was drawn three times in MD, thus obtaining a uniaxially drawn polyester film. Both edges of the uniaxially drawn polyester film were held with clips, and then this film was fed into a chamber heated to 80˜150° C. such that heat was applied to the top side and underside of the film using hot air to draw the film five times in the TD. Subsequently, the film was fed into a higher temperature chamber to thermoset it at 220° C. for crystal orientation.
[0042] Step 2: Formation of Light-Diffusing Layer
[0043] A light-diffusing layer composition comprising the components shown in Table 1 below was applied on one surface of a highly transparent polyester film (XG533˜100 μm, available from Toray Saehan Inc.) as the base sheet formed in step 1 and was then dried at 110° C. for 60 sec, thus forming a light-diffusing layer 30 μm thick.
TABLE 1 Total Weight of Composition 100 g Composition Light-diffusing Acrylic Resin (A-811, 30 g Resin Aekyung Chemical Co. Ltd.) Light-diffusing Acrylic Particles (SOKEN 30 g Particles MX1000) Solvent Methylethylketone 40 g
[0044] Step 3: Formation of Antiblocking Layer
[0045] An antiblocking layer composition comprising the components shown in Table 2 below was applied on a surface of the base sheet opposite the surface having the light-diffusing layer formed in step 2 , and was then dried at 110° C. for 40 sec, thus forming an antiblocking layer 5 μm thick, thereby manufacturing a final light-diffusion sheet.
TABLE 2 Total Weight of Composition 100 g Composition Antiblocking Acrylic Resin (A-811, 28 g Resin Aekyung Chemical Co. Ltd.) Antiblocking Acrylic Particles (SOKEN 0.5 g Particles MX300) Solvent Methylethylketone 70 g Antistatic Anionic Antistatic 1.5 g Agent Agent (CHEMISTAT)
EXAMPLE 2
[0046] Manufacture of Light-Diffusion Sheet 2
[0047] A diffusion sheet was manufactured in the same manner as in Example 1, with the exception that the draw ratio/draw temperature were changed to 3.5 times/105° C. in the MD and 4.3 times/120° C. in the TD.
EXAMPLE 3
[0048] Manufacture of Light-Diffusion Sheet 3
[0049] A diffusion sheet was manufactured in the same manner as in Example 1, with the exception that the draw ratio/draw temperature were changed to 3.7 times/107° C. in the MD and 4.6 times/123° C. in the TD.
COMPARATIVE EXAMPLE 1
[0050] A diffusion sheet was manufactured in the same manner as in Example 1, with the exception that the draw ratio/draw temperature were changed to 3.2 times/100° C. in the MD and 5.0 times/120° C. in the TD.
COMPARATIVE EXAMPLE 2
[0051] A diffusion sheet was manufactured in the same manner as in Example 1, with the exception that the draw ratio/draw temperature were changed to 2.8 times/100° C. in the MD and 4.5 times/120° C. in the TD.
COMPARATIVE EXAMPLE 3
[0052] A diffusion sheet was manufactured in the same manner as in Example 1, with the exception that the draw ratio/draw temperature were changed to 2.5 times/100° C. in the MD and 3.2 times/120° C. in the TD.
EXPERIMENTAL EXAMPLE
[0053] The properties of the diffusion sheets manufactured in Examples 1˜3 and Comparative Examples 1˜3 were measured as follows. The results are shown in Table 3 below.
[0054] 1. Measurement of Refractive Index
[0055] The sample was cut to a size of 10 mm×30 mm, and was then measured with respect to the refractive indexes in respective directions (MD, TD, and thickness) using an ABBE refractor under predetermined temperature conditions (20±0.1° C.) using methyl iodide (refractive index of 1.74). In this case, measurement was performed according to ASTM-D542.
[0056] 2. Measurement of Total Light Transmittance
[0057] The light transmittance and light diffusibility of the diffusion sheet were determined according to the following procedures. While light of 550 nm was transmitted perpendicular to a 10 cm×10 cm sized light-diffusion sheet sample which had been stood upright, the amount of transmitted light was measured using an automatic digital hazemeter, available from Nippon Denshoku Industries Co., Ltd. The haze and the total light transmittance were calculated from Equation 2 below:
Haze(%)=(1−P/TT)*100
Total Light Transmittance(%)=(TT/IT)*100 Equation 2
[0058] wherein P is the amount of straight light, TT is the total amount of transmitted light, and IT is the amount of incident light.
[0059] 3. Measurement of Light Diffusibility
[0060] The light diffusibility of the light-diffusion sheet manufactured in Example 1 was measured according to the following procedures. A light-diffusion sheet sample was cut and then mounted on a light-diffusing plate of a 32″ direct type backlight unit. Then, a BM-7, which is a luminance meter available from Topcon Corporation, was provided such that the measurement angle was set to 0.2° and the interval between the backlight unit and the BM-7 was set to 25 cm, after which luminance was measured at 13 positions of lamps of the backlight unit and 12 positions between the lamps. Then, the average luminance at the positions of the lamps and the average luminance between the lamps were determined and the difference therebetween was taken as light diffusibility. Subsequently, the difference in average luminance (average luminance at the lamps—average luminance between the lamps) was classified according to the following criteria, to evaluate light diffusibility:
Δ(difference in average luminance)<1:good
Δ(difference in average luminance)>1:poor
[0061] The results are given in Table 3 below.
TABLE 3 Base Sheet Diffusion Sheet Manufacturing Total Light-Diff. Process Light Δ (cd/m 2 ) Ex. Draw Ratio Draw Temp. Properties Trans mit. (Differ. In Lum. No. (MD × TD) (MD/TD) N md N td N z SR (%) Average Lum.) Class. cd/m 2 Result 1 3.3 × 4.3 100/120 1.662 1.664 1.491 86.5 92 0.7 Good 6950 Good 2 3.5 × 4.3 105/120 1.664 1.663 1.492 171 94 0.5 Good 6985 Good 3 3.7 × 4.6 107/123 1.665 1.663 1.490 86.5 94 0.5 Good 7020 Good C. 1 3.2 × 5.0 100/120 1.648 1.673 1.496 7.08 88 0.2 Good 6530 Poor C. 2 2.8 × 4.5 100/120 1.645 1.672 1.497 6.48 88 0.4 Good 6450 Poor C. 3 2.5 × 3.2 100/120 1.642 1.651 1.498 17 87 0.5 Good 6320 Poor
[0062] As is apparent from Table 3, both the total light transmittance and the light diffusibility of the diffusion sheets of Examples 1˜3, satisfying Equation 1, were superior to those of Comparative Examples 1˜3, not satisfying Equation 1.
[0063] As described hereinbefore, the present invention provides a diffusion sheet for a TFT-LCD. According to the present invention, the sheet, having a controllable refractive index and satisfying a predetermined equation provided in the present invention, is excellent with respect to total light transmittance, light diffusibility, and luminance. Therefore, the diffusion sheet of the present invention can be used as an optical material for improving the light efficiency of a backlight unit of a TFT-LCD, and is thus considered very useful in the chemical industry field.
[0064] It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.
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Disclosed herein is a diffusion sheet for use in a backlight unit of a TFT-LCD. Specifically, this invention provides a diffusion sheet including a transparent base sheet, a light-diffusing layer laminated on one surface of the base sheet, and an antiblocking layer laminated on the other surface of the base sheet, the base sheet satisfying a refractive index represented by a predetermined equation. According to this invention, the diffusion sheet for a display can uniformly diffuse light, which is radiated from a light source lamp positioned at a side surface or the back surface of the display, while passing such light therethrough, thus obtaining clear display images, resulting in increased total light transmittance, light diffusibility, and luminance.
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BACKGROUND OF THE INVENTION
This invention is concerned with a safety mechanism for a multiphase forming machine, in which one leg of the clamp attached to the stock conveyor is isolated against said conveyor, with the other attached directly to said conveyor, and when a nut stock is not correctly held between a clamp a trigger signal will be actuated to stop the machine so as to protect the machine body, the main slide, the punches, and the die from any damage.
In a conventional multiphase forming machine like a nut forming machine, a nut stock often slips out of the clamp as a result of any defect in the clamp or because the stock does not comply with specification. The nut stock is at times driven out of the die and then pulled back into the die because of a malfunctioning back punch, with other parts of the machines continuing to run so that the next nut stock is thrust upon the preceding one and the punches do not squarely strike upon the nut stock or only one punch strikes upon it, causing the breaking of the punches, the anvil or the die. The moment produced causes rotation of the main slide, resulting in serious damage or deformation. After the breaking a punch, the nut stock that has been sent by the clamp to the die at which the punch is aimed will be forced back into its original position so that no nut is produced. When the stock conveying system fails, the continuous running of the main slide will result in the punches striking at the clamp that stays near the die, causing harm to the punches, the clamp and even the conveyor system. In view of the above, the present safety mechanism is devised.
SUMMARY OF THE INVENTION
The primary object of this invention is to eliminate defects in a conventional forming machine and to provide an automatic safety mechanism to prevent the damage of the machine and the manufacture of defective products.
Another object of this invention is to provide an automatic safety mechanism that reduces labor requirements, boosts productivity and produces a trigger signal to automatically stop the machine when the machine does not function normally so that operators may make immediate checks and upkeep.
Other objects will become apparent from the following drawings and description.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings,
FIG. 1 is a perspective view of the stock conveyor system installed with the present invention;
FIG. 2 is cross sectional view of the stock conveyor system installed with the present invention;
FIG. 3 is an exploded view of an insulated leg of the clamp in this invention; and
FIG. 4 is a view of the crank degree showing how the circuit is controlled.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With a nut-forming machine as an illustrative example, this invention is described in detail as follows:
The two legs 15, 16 of a clamp are attached to a nut-stock conveyor 11 with two elastic strips 111, 112, which in turn are fitted into said stock conveyor with bolts. The upper part of the clamp leg 16 is covered with insulating material like enamel and slipped into a pressure-resistant, protective casing 162 for contact with said conveyor 11 and elastic strip 112, while the lower half forms a circuit with a nut stock 19, held in the clamp, and a conductive spring 14. As insulated conductive rod on stick 12 pierces through conveyor 11 and conductive spring 14 is connected at one end with clamp leg 16 and at the other with conductive stick 12, riveted between said conductive stick and an insulated spacer 13. The upper end of said conductive stick 12 is fixed with a nut 17 onto an insulated spacer 20. Connected with said conductive stick is a flexible spiral wire made of phosphor bronze 18, whose other end connects with a conductive socket 183 fixed to an insulated fixture 182, which in turn is firmly attached onto the body of the machine. From said fixture 182 a wire transmits trigger signals to a control circuit.
In normal operation, the dead point, which is the point where the main slide or the punch is the farthest from the die, is taken as the point where the crank is at zero degrees. From 0° to around 92°, clockwise, is the stock conveying of the process when a nut stock is held between the clamp 15, 16 and voltage runs to the control circuit as a trigger signal through an electric current path connecting the machine body, clamp leg 15, nut stock 19, clamp leg 16, conductive spring 14, conductive stick 12 and spiral wire 18 permitting the machine to continue to run. From about 92° to 181° occurs the stage when punches make stocks into finished products as the nut stock grasped in the clamp is striken into the die by punches and slips from the clamp. As the conveyor returns to its original position, the crank rotates from about 181° to 271°, the clamp being empty and the circuit path between the body and the control circuit being open. In the stage from about 271° to 360°, the nut stock in the die is forced out of it into the clamp by the back punch. The control circuit functions only when the machine runs continuously.
During the conveying process from 0° to 92°, if the back punch fails to force the nut stock out of the die and into the clamp or if the nut stock slips off the clamp during the conveyance because of a defective or malfunctioning clamp, the control circuit receives no trigger signal and the machine automatically shuts off immediately, without returning to its original position. This prevent the over-lapping of nut stocks and the subsequent damage to said stocks in the forming process. Due to this safety mechanism the punches do not run the risk of being broken and the clamp will not be damaged when the punches strike the nut stock. There will not be any rotation of the main slide. In the stage from 180° to 271°, if the front punch breaks (e.g. because of faulty material) such so that the nut stock is not driven out of the clamp into the die (that is when said nut stock 19 remains in the clamp and is brought back) the control circuit continues to receive a trigger signal and the machine stops immediately, indicating a defective punch. This safety mechanism will also avert the possibility of nut stock 19 being forced out of the clamp by another nut stock in the die when said nut stock 19 is being brought back to its original position. In this condition the punch would be impaired and the main slide would rotate. According to this invention, as the crank axis turns, electricity is turned on or off in different stages so that the machine stops running at once in case the conveyor system fails. When said system fails to operate normally in the stock-conveying stage from 0° to 92° power will be cut off immediately when no stock is being carried. Because of this, no trigger signal is transmitted and the machine stops running at once so as to prevent empty running and possible damage to the machine. In the event of a failure of the safety mechanism bringing about a power cut (e.g. in case of defective insulation 162 or the intrusion of foreign matter resulting an electrical connection between legs 15 and 16, the machine will still can stop immediately, because the circuit will remain closed at a time when no nut stock is supposed to have exited the clamp leg (e.g. at 181°-271°). It therefore can be seen that the present invention will prevent damage to the machine and the manufacture of defective products, as well as reduce labor requirements and raise productivity because of the efficient trouble-detecting and warning capabilities.
As the nut-stock conveyor 11 has to make 180° rotation and to and from movement it can only be connected with an unmoving part by a flexible spiral wire to not interfere with its movement. According to this invention, the flexible spiral wire 18 is used to connect the socket 183 an insulated fixture 182 attached to the body of the machine and the conductive stick 12. What is worth special attention is that power connection remains effective when the conveyor 11 rotates and moves.
Various changes may be made in the details of construction without departing from the spirit and scope of the invention as defined by the appended claims.
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The present invention relates to a safety mechanism for a multiphase forming machine, in which trigger signalling is used to automatically stop the machine by means of the insulation state formed between one leg of a clamp and a stock conveyor to which the clamp is attached as well as whether a nut stock is firmly held by the clamp so as to prevent any part of the machine from being damaged or destroyed.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to an apparatus and method for providing active vibration isolation at an engine mount to prevent engine vibration from propagating from an aircraft engine into the wings and fuselage of an aircraft.
[0002] In aircraft cabins, tonal noise is generated by the fundamental frequencies of engine rotations. The generation of this noise has been an issue for many years. The tonal noise is caused by residual imbalances in the engines rotating parts, such as low and high speed turbines, fan blades, compressors, etc. Even though the imbalance from rotating parts, including shafts and blades, are closely controlled in manufacturing, due to improved manufacturing methods, the imbalance can still develop due to changes in operation, or through deterioration of the system over time. As a result, significant “once-per-revolution” vibration excitations from the rotating components are introduced into engine operations.
[0003] It is these kinds of vibrations which propagate through wing and/or fuselage structure and produce annoying low frequency tonal noise in the aircraft cabin.
[0004] This tonal noise is usually a major contributor to the overall cabin noise level. According to many noise evaluation standards, additional penalties will be applied to the overall noise level if significant tonal noise exists. These tones are usually in a low frequency range. For example, engines powering mid to larger commercial aircraft usually have less than 100 Hz low pressure (LP) system 1/rev frequency and less than 200 Hz high pressure (HP) system 1/rev frequency. For small aircraft such as regional jets, the LP system 1/rev is around 100 Hz, and the HP system 1/rev is about 300 Hz. Psychoacoustics analysis indicates that an individual can be easily fatigued if exposed to low frequency noises, especially with long time exposure, such as in the long range air travel.
[0005] It is understood that these tonal vibrations cannot be avoided. In engine manufacturing, the rotating components are balanced carefully. However, during the operation, the balance can change, introducing an imbalance into the structure. The system deterioration with service time can also introduce imbalance. The imbalance-induced vibrations transmit through the engine mount, wing structures, fuselage structures, and finally excite the cabin interior structures, such as trim panels. The vibration of the interior structure propagates the noise into the cabin.
[0006] Traditionally, “soft” (i.e. flexible or shock absorbing) engine mounts have been the least expensive and most effective way to reduce the vibration transmission. However, for large commercial aircraft, the engine vibration frequency can be as low as 45 Hz, which means that the soft mount isolator needs to be designed to have resonance much less than 45 Hz. Such a “soft” mount design results in a large displacement during the engine speed up, which is undesirable and air frame manufacturers wish to avoid. Further, the reliability and durability of soft engine mounts is an issue, as their reliability and durability are less than hard engine mounts.
[0007] Therefore, there still exists a need to reduce tonal noise generation in applications where a hard engine mount is used.
SUMMARY OF THE INVENTION
[0008] In an embodiment of the present invention, active vibration mechanisms are attached in the vicinity of the engine mounts to prevent engine vibrations from propagating into the engine mounting structure, for example, the wing or fuselage structure, depending how the engines are mounted. In an embodiment, the active vibration mechanisms are powered actuators attached to the structure in the vicinity of, or embedded within, the engine mount to inject anti-vibration movements to cancel the tonal vibrations generated by the engine. In another embodiment, the active vibration mechanisms are powered actuators attached to the structure in the vicinity of, or embedded within, the engine mount to dissipate the dynamic energy of the tonal vibrations generated by the engine.
[0009] In an embodiment of the present invention, vibration sensors are placed on the engine and/or fuselage and/or wing structure to monitor the vibration performance of the engine and engine mount structure. The data from these sensors, along with engine speed signals, are used to determine the instant fundamental frequencies of the rotating components and the engine, such as the turbine shafts, etc. These determined fundamental frequencies are then used to generate anti-vibration signals which are transmitted to the power actuators, which create anti-vibration movements or equivalent dynamic energy absorbers to cancel or alleviate the determined fundamental frequency vibrations and their higher order harmonics, as needed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The advantages, nature and various additional features of the invention will appear more fully upon consideration of the illustrative embodiment of the invention which is schematically set forth in the figures, in which:
[0011] FIG. 1 is a diagrammatical representation of a hard engine mount structure;
[0012] FIG. 2 is a graphical representation of the transmissibility of the hard mounted engine structure shown in FIG. 1 ;
[0013] FIG. 3 is a diagrammatical representation of an engine mount structure according to an embodiment of the present invention;
[0014] FIG. 4 is a graphical representation of the transmissibility of an engine mount having various vibration control strategies, including embodiments of the present invention;
[0015] FIG. 5 is a diagrammatical representation of a control system for an embodiment of the present invention;
[0016] FIG. 6 is a diagrammatical representation of a fuselage to engine mount of the present invention; and
[0017] FIG. 7 is a diagrammatical representation of a wing to engine mount of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The present invention will be explained in further detail by making reference to the accompanying drawings, which do not limit the scope of the invention in any way.
[0019] FIG. 1 depicts a hard engine mount conventionally known, and FIG. 2 shows the transmissibility of the hard engine mount, represented as vibration (dB) v. frequency (Hz). FIG. 3 depicts an engine mount 300 having an active element according to an embodiment of the present invention, while FIG. 5 depicts an engine mount according to an embodiment of the present invention, including a representation of a control system for the engine mount. FIG. 4 depicts the transmissibility (vibration v. frequency) of various engine mount configurations and methods. FIGS. 6 and 7 depict simplified representations of an engine mount to a fuselage and wing, respectively, according to embodiments of the present invention.
[0020] Turning now to FIG. 1 , a conventional hard engine mount structure 100 is represented as a single degree of freedom system. The engine mount structure 10 , which couples the engine 14 to the wing 12 (which can also be a fuselage or other structure) is represented by a spring, having a spring stiffness K, and a dashpot, having a viscous dampening coefficient C. During engine operation the engine 14 vibrates and moves relative to the wing 12 , which also has vibration and movement. The dynamic equation for this system is represented by the equation:
M{umlaut over (x)}+C ( x−y ) +K ( x−y ) =f (t) Eq.(1)
where M is the mass of the engine 14 , x is the displacement of the engine 14 and y is the displacement of the wing 12 in the single degree of freedom, additionally, the corresponding transmissibility in frequency domain can be written as
Y ( j ω ) X ( j ω ) = j C ω + K - M ω 2 + j C ω + K = j ζ ω ω 0 + ω 0 2 ω 0 2 - ω 2 + j ζ ω ω 0
where Eq . ( 2 ) ω 0 2 = K M , and ζ = C 2 M ω 0 Eqs . ( 3 ) and ( 4 )
[0021] As shown in FIG. 2 , for a hard mount, the transmissibility in the engine operation range is always larger than one, or larger than 0 dB in the logarithm scale. In cases such as these, the vibration induced by engine operations will be amplified and transmitted to the wing and/or fuselage and eventually transmitted into cabin in forms of vibration and noise.
[0022] The present invention reduces the transmissibility of the engine vibrations to the wing/fuselage by adding at least one active element in parallel to the engine mount structure. The active element is controlled based on the responses from motion/vibration sensors which are placed before and/or after the engine mount structure such that the transmissibility is reduced in the engine operation range.
[0023] FIG. 3 depicts an engine mount structure according to an embodiment of the present invention. Similar to FIG. 1 , the engine mount 30 is represented by a spring, having a spring stiffness K, and a dashpot, having a viscous dampening coefficient C. The engine mount 30 couples the engine 34 to the wing 32 (which may also be a fuselage or other structure). Additionally, the present invention includes at least one active vibration element 36 , which is coupled to a controller 38 .
[0024] In an embodiment of the present invention, the active vibration element 36 is capable of operating at a frequency comparable to the operational frequency or frequencies of the engine 34 , and is capable of delivering force sufficient to counteract and/or alleviate the engine vibrations. This allows the active vibration element 36 to sufficiently counteract the vibrations induced by the engine. In one embodiment of the present invention, the active vibration element 36 is a stack of piezoelectric elements. In alternative embodiments, other actuator types may be used, including, but not limited to, electrical actuators.
[0025] Further, as shown in FIG. 3 , at least one vibration or motion sensor 40 is mounted on the engine 34 , and at least one vibration or motion sensor 42 is mounted in the wing (or fuselage) 32 . In an alternative embodiment, a sensor 42 is only placed on the wing (or fuselage) 32 , and no sensor is placed on the engine. The sensors 40 , 42 are placed in the vicinity of the engine mount 30 so as to optimizing sensing of the vibrations. In a further embodiment, a sensor 40 is only placed on the engine 34 , and no sensor is placed in the wing (or fuselage) 32 .
[0026] In the present invention, it is contemplated that various sensor types can be used. For example, it is contemplated that accelerometers, velocity sensors, displacement sensors, strain gauges and deformation gauges, among other conventionally known sensors types, may be used on either the wing (or fuselage) 32 and/or the engine 34 . In an additional embodiment of the present invention, a different sensor type is used on the engine 34 and the wing (or fuselage) 32 to optimize sensor and system performance.
[0027] During operation, the present invention employs a reactive process to actuate the active vibration element(s) 36 to minimize the responses by the sensors 40 and 42 . The minimization of sensor responses is a result of minimization of vibrations transferred from the engine 34 to the wing (or fuselage) 32 , because of the activation of the active vibration element(s) 36 . Essentially, the sensors 40 and 42 transmit vibration data, which is used by a control system (discussed below) to active the element(s) 36 in such a way to minimize the vibration sensed by the sensors 40 and 42 . In one embodiment, the control signals to the element(s) 36 are constantly changed, based on the signals from the sensors. In a further embodiment, some of the constants and/or the transfer function may be fixed, based on the vibration performance characteristics of the structure, to reduce the overall computations necessary but to minimize vibration transmission.
[0028] The present invention will now be further explained in conjunction with the following equations.
[0029] In general, the dynamics equation for the engine mount structure 300 is changed from the equation set forth above (regarding FIG. 1 ), to:
{ M x ¨ + C ( x . + y . ) + K ( x - y ) = f ( t ) + f act ( t ) f act = α x ¨ + β x . + χ x + δ y ¨ + ɛ y . + ϕ y Eq . ( 5 )
where f act is the calculated actuator force, and the transmissibility in the frequency domain becomes:
Y ( j ω ) X ( j ω ) = - δ ω 2 + j ( C + ɛ ) ω + ( K + ϕ ) - ( M - α ) ω 2 + j ( C - β ) ω + ( K - χ ) = γ ω c 0 2 - η ω 2 + j κ ζ c 0 ω ω c 0 ω c 0 2 - ω 2 + j ζ c 0 ω ω c 0 Eq . ( 6 )
[0030] In Eq. 6, the parameters α, β, χ, δ, ε, φ are control parameters which represent the gain in the system for active vibration element(s) 36 . In an embodiment of the invention, these parameters are automatically adjusted so that the ratio Y/X is minimized. More specifically, a goal is to minimize Y, thus minimizing the vibrations transmitted to the cabin, to create undesirable noise levels.
[0031] In another embodiment, any number of these control parameters may be fixed in value, to reduce the overall computations necessary. The fixed value(s) are determined based on the historical and/or analytical vibration performance of the engine mount structure, and the desired level of vibration minimization.
[0032] Additionally, the parameters γ, η, and κ are defined as follows:
γ = K + ϕ K - χ , η = δ M - α , κ = C + ɛ C - β
where ,
ω c 0 = K - χ M - α ( Eq . 10 ) is the active mount resonance frequency , and
ζ c 0 = C - β 2 ( M - α ) ω c 0 ( Eq . 11 ) is the active mount damping ratio . Eqs . 7 , 8 and 9
[0033] In an embodiment of the present invention, the control parameters α, β, χ, δ, ε, φ are adjusted using feedback data from the wing (or fuselage) sensor 42 and using feedforward data from the engine sensor 40 . In a further embodiment, the control parameters are adjusted based on feedback data from the wing (or fuselage) sensor 42 .
[0034] In an embodiment of the present invention, both the x and y parameters are monitored to determine the proper control function(s) for the active vibration element(s) 36 . In a further embodiment, only y is monitored, using the sensor 42 , and the feedback of this sensor 42 is used to determine the proper control functions for the element(s) 36 . In an further alternative embodiment, only x is monitored (using the engine sensor 40 ) and a predetermined transfer function, which is determined based on testing and/or structural characteristics, is used to determine the proper control function(s) for the active vibration element(s) 36 . The predetermined transfer function optimizes the ratio X/Y based on the detected x and/or y values.
[0035] FIG. 4 graphically depicts vibration transmission during engine operation using various methods of vibration control, including alternative embodiments of the present invention. As shown in this figure, using negative velocity and negative position feedforward data, from an engine mount sensor 40 , the transmission coefficient function is similar the using only a hard mount, but the transmissibility in the engine operational range is lower.
[0036] Further, as shown, by using negative velocity feedback data, additional damping can be added to the resonance frequencies. Although it is recognized that this embodiment may create a moderate reduction on the operational range transmissibility, this embodiment suppresses any potential resonance amplification in the engine operational range.
[0037] In an additional embodiment, the negative velocity and negative position feedforward data are combined with negative velocity feedback to provide more transmission reduction in the operational range.
[0038] In a further alternative embodiment, positive position feedback data and negative acceleration feedback data are used to create an engine mount structure which is essentially equivalent to an engine soft mount, in that the vibration transmissibility is greatly reduced in the operation range, while maintaining the static deflection small.
[0039] It is noted that the alternatives shown above, regarding FIG. 4 , are exemplary embodiments, and the present invention contemplates various combinations of sensor types and sensor data to be used to minimize vibration transmissibility to the wing/fuselage structure.
[0040] Turning now to FIG. 5 , the operation of an embodiment of the present invention will now be described, along with an exemplary control system. The embodiment shown in FIG. 5 is an embodiment using both feedback (wing/fuselage side) data from the sensor 42 and feedforward (engine side) data from the sensor 40 . However, as discussed above, the present invention is not limited to this embodiment, as the present invention contemplates using only feedback data from the sensor 42 .
[0041] As shown and discussed above, the sensors 40 , 42 detect vibration or movement from the engine 34 and the wing (or fuselage) 32 to provide feedback and feedforward data, respectively. The signals from the sensors 40 , 42 are sent to signal conditioners 52 and 48 , respectively. In an embodiment where the sensors 40 and 42 are of different types, the signal conditioners may be different, as needed.
[0042] After the signals have been conditioned, they are converted from analog to digital, via the A/D converter 54 . Then the digital signal processor 50 gets the digitized signals and applies the required control strategies, and the control authority is determined through digital signal processing. Following the digital signal processor 50 , the D/A converter 46 converts the processed signal from digital to analog so it may be used to control the active vibration element 36 , after the signal is amplified by the power amplifier 44 .
[0043] In an embodiment of the present invention, the engine mount block structure is the major load path from the engine 34 to the wing (or fuselage) 32 , and the active vibration elements 36 are embedded in the engine mount block structure. However, it is contemplated that a different element mount structure may be used based on the specific engine mount structure and the applications of the present invention.
[0044] Examples of the varying embodiments are shown in FIGS. 6 and 7 . FIG. 6 depicts an embodiment of an engine mount block 600 of the present invention, where four active vibration elements are embedded within the mount block 600 , which is used to couple an engine with a fuselage. As shown, two active vibration elements 62 are used for controlling lateral vibrations, while two additional active vibration elements 64 are used for controlling vertical vibrations (i.e. along a line extending from the engine to the fuselage). As indicated above, the active vibration elements 62 and 64 are of an actuator type which is capable of operating at a frequency comparable to that of the engine. Further, although the elements 62 and 64 are shown embedded within the block 600 , the present invention contemplates that the elements 62 and 64 can also be placed in the vicinity of the block 600 . The construction and structure of the engine mount block 600 are not limited by the present invention.
[0045] Similar to FIG. 6 , FIG. 7 depicts an engine mount block 700 according to another embodiment, where the block 700 couples an engine to a wing structure. Again, active vibration elements are used to control vibration in both lateral 72 and vertical 74 directions.
[0046] Further, it is noted that although the FIG. 6 and FIG. 7 embodiments have been shown with four active vibration elements, where two are position for lateral and vertical vibration, respectively, the present invention is not limited to such a configuration. Specifically, the number and orientation of the active vibration elements may be optimized to achieve the maximum operational benefit based on the specific structural configuration. For example, if it is determined that a specific engine mount structure has a dominant vibration in only one direction, the active vibration element(s) may be oriented in only that one direction. Additionally and alternatively, the present invention contemplates controlling vibration and movement in all axes, depending on the vibration performance of the structure.
[0047] Although the above discussion has been primarily directed to the use of the present invention in conjunction with aircraft engines, those of ordinary skill in the art will recognize that the present invention may be used with any application where an engine or a rotating machinery creates or otherwise causes a low frequency vibration in structure to which it is mounted.
[0048] Moreover, although the above discussion has also been primarily directed to hard engine mounts, the present invention is not limited to this application, but may also be used in conjunction with soft engine mounts, in those applications where soft engine mounts are operationally acceptable.
[0049] Further, while the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.
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An engine mount structure is provided with active vibration mechanisms which are attached in the vicinity of the engine mount to prevent engine vibrations from propagating into the engine mounting structure, for example, the wing or fuselage structure of an aircraft. Additionally, sensors are provided on the engine and/or wing/fuselage structure to provide control signals to the active vibration mechanisms so that the active vibration mechanism react to the sensed data to minimize the vibration transmissibility from the engine into the wing/fuselage.
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FIELD OF THE INVENTION
The present invention relates to a sliding latch for blocking and unblocking the magazine of a pistol.
DESCRIPTION OF THE PRIOR ART
In the field of automatic firearms and, more particularly, of pistols, it is already known to employ latches for blocking and unblocking the magazine component of the pistol. Among the known latches there is one which is of the sliding type and which is seated and guided transversely with respect to the cavity receiving the magazine, so as to engage a notch provided on a lateral surface of the magazine. However, all sliding latches heretofore known have a unidirectional and irreversible use, in the sense that they may be utilized either only from left to right, in the case of right-handed individuals, or only from right to left, in the case of left-handed individuals. This limitation is an inconvenience because pistols become impractical when used by persons that shoot with the opposite hand.
It is evident that it is necessary for the manufacturer to make at the beginning a pistol which is to be used solely by either right-handed or left-handed individuals. Furthermore, the retailer and the distributor must stock almost twice the quantity of firearms, in order to be able to satisy every customer's demand.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a latch for magazines of pistols, wherein the mounting and the use of the latch are reversible, so that the pistol may be used both as a right-handed latch pistol and as a left-handed latch pistol.
It is another object of the invention to provide a reversible latch which is easily assembled and disassembled, so as to be positionally exchanged by the user himself without requirement of special mechanical knowledge or special tools.
Briefly stated, the latch of the present invention comprises a body member slidably guided in a seat of the pistol handle, so as to be transversely oriented with respect to the magazine to be blocked. The body is provided with spring-actuated means which engage under pressure between two shoulders provided at the bottom of the seat, and allow the operational displacements of the latch. The body also has two end projections one of which has thereon a push-button and the other of which has thereon an inner rib for blocking the magazine. Both end projections have sliding planes which cooperate with respective shoulders provided laterally on the handle of the pistol. These sliding planes are so arranged as to allow disassembly of the body of the latch when a push is applied thereon in the direction contrary to that exerted on the button actuating the latch.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects of the present invention will become more evident from the following detailed description thereof with reference to the accompanying drawings, illustrative but not limitative of the invention, in which:
FIGS. 1 and 2 are partially sectioned and fragmentary side elevational views of two pistols with, respectively, a left and a right latch:
FIG. 3 is a perspective view, on an enlarged scale, of the latch of the invention;
FIGS. 4 and 5 are transverse sectional views of the latch taken in the direction of arrows A--A and B--B, respectively of FIG. 3;
FIG. 6 is a transverse sectional view of the mounting of the latch in the blocking position for a right-handed pistol;
FIGS. 7 and 8 are sectional plan views of two successive phases of disassembling the latch during the step of reversing it; and
FIG. 9 is a transverse sectional view of the assembling of the latch in a left-handed used pistol.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the drawings, numeral 1 refers generally to a pistol having a handle 2 in which there is provided a cavity 3 for a magazine 4. The magazine 4 is provided with two lateral notches or slots 5 and 6 (FIG. 6), one on each side, one or the other of which notches serving to engage a latch as taught hereinafter by the invention. The latch comprises a substantially U-shaped body member 7 mounted on and guided slidably in a seat 8 provided in the handle 2 of the pistol 1. The latch's body extends transversely with respect to the cavity 3 for the magazine 4.
The body member 7 has a pair of end projections 9-10, one of which has an inner flat surface 11 and is provided with an external push-button 12, while the other projection 10 has a rib 13 on its inner surface. The rib 13 is arranged to engage one of the two lateral notches 5-6 of the magazine 4, in order to block it within the cavity 3.
Laterally of the end projections 9-10 there are two sliding planes or surfaces 14 and 15, respectively, the function of which is to cooperate with the respective shoulders 16-17 that are provided on the side surfaces of the handle 2 in alignment with the seat 8 of the latch body member 7. The sliding planes 14-15, together with their shoulders 16-17, prevent, on one hand, the latch 7 from falling into the cavity 3 for the mazagine 4, and permit, on the other hand, a perfect guiding action during the displacements of the latch 7.
At the base of end projection 10 (the one with the rib 13) and externally thereof there is an inclined or bevelled plane or surface 18 which connects with the sliding plane 15 via a pair of head-guides 19. The bevelled plane 18 serves as a means for the pressure-assembling of the latch 7, as will be described hereinafter. The head-guides 19 serve to center and guide the shoulder 16 or 17 along the sliding plane 14 or 15, during said assembling phase.
In the intermediate portion of the body member 7 there is a cavity 20 for guiding two small and opposed pistons 21-22. These pistons 21-22 are engaged by a spring 28 positioned therebetween which keeps them normally spaced from each other. The pistons 21-22 are provided with coupling and guiding surfaces to couple them with the body member 7 and they protrude from the base of the body member so as to form, with their outwardly facing surfaces two stops 23-24 which serve the purpose of engaging against two shoulders 25-26 defined by a cavity 27 provided at the base of the seat 8 of the latch body member 7.
As stated hereinabove, the latch body member 7 of the invention is reversible. In fact, it can be mounted on the handle 2 of the pistol so as to beused either from left to right as shown in FIG. 1 or from right to left as shown in FIG. 2. In the first case, the latch body member 7 is mounted so that its push button 12 is on the left hand side of the pistol 1 and its rib 13 engages the notch 5 of the right side surface of the magazine 4 (FIG. 6). The latch guide is thus insured by the sliding coupling of the sliding surface 14 with the respective shoulder 16, and of the sliding surface 15 with the respective shoulder 17.
Under these conditions, in order to effect the unblocking of the magazine, it is sufficient to exert pressure on the push button 12 in the direction opposed to that of spring 28 of pistons 21-22, the pressure being sufficient to disengage the rib 13 from the notch 5, so that the magazine 4 is free to exit from the cavity 3 of the handle 2. During this operation, the stop 23 of the piston 21 rests against the shoulder 25, while the piston 22 is displaced with respect to piston 21.
To reverse the position, and thus the use of the latch body member 7, and to have the push button 12 on the right hand side of the pistol 1 and the rib 13 in engagement with the notch 6 on the left hand side of the magazine 4, it is necessary first to extract the latch body member 7 from seat 8 and then to re-insert it facing the opposite side.
The disassembly of the latch body member 7 is done with the magazine 4 removed from cavity 3 and is achieved by exerting pressure on the end-projection 10, as shown by arrow F in FIG. 7. This will displace the latch body member 7 toward the other end projection 9 and will achieve the disengagement of the surface 15 of end projection 10 from the corresponding shoulder 17. As a result, the latch body member 7 becomes angularly oriented, as shown in FIG. 8, and can be removed, disengaging also the sliding surface 14 from the corresponding shoulder 16 of the side surface of the handle 2.
The latch body member 7 is then reassembled in the seat 8 of the handle 2 by carrying out an operation reverse to the one described hereinabove, so that the push button 12 is positioned on the right hand side of the pistol 1, as shown in FIGS. 2 and 9. The assembling of the latch body member 7 is effected by keeping it in an oblique position, as stated above, and by coupling first the surface 14 of end projection 9 with the corresponding shoulder 17, and then pushing the latch body member 7 toward the base of the seat 8.
The completion of the seating of the latch body member 7 in the seat 8 occurs snap-wise and it is aided by the bevelled surface as well as by the head-guide 19 of the latch body member 7. Elements 18 and 19, in contact with the shoulders 16, determine thusly the compression of the spring 28 of the pistons 21 and 22 and the guiding of shoulders 16 toward the sliding surfaces 15. When the surfaces 15 are in juxtaposition with the shoulders 16, the reaction of the spring 28 (in cooperation with the positioning of the pistons 21-22 between the shoulders 25-26) automatically prepositions the latch body member 7 in sliding condition for use.
From the above, it is evident that the assembly of the latch body member 7 on the handle 2 is rapidly and easily reversible and can be carried out by anyone without special tools, so as to obtain a weapon usable equally by right-handed and left-handed persons.
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A pistol is disclosed that may be used by either right or left handed individuals. A spring biased U-shaped latch is located in the pistol handle and may be reversed in position without any special skills or tools. In either position the latch temporarily blocks the removal of the magazine. A force exerted on the latch in opposition to the biasing force permits removal and reversal of the latch.
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This application is a continuation-in-part of application Ser. No. 08/324825, filed on Oct. 18, 1994 (now abandoned).
TECHNICAL FIELD
This invention relates to methods and apparatus for providing competitive, local and toll service in a national telecommunications network.
Problem
The U.S. telecommunications network is in a state of transition. During the next several years, it is expected that the monopoly held by local exchange carriers will be substantially altered and that Competitive Access Providers (CAPs) will begin to offer customer access for toll calls to the already competitive interexchange carriers, will provide local exchange service, or both. In order to accomplish this goal without creating an excessive burden on customers who wish to receive service from a CAP, it is expected that there will be a requirement that a change to a CAP need not be accompanied by a change of telephone number. Further in the long run, it is expected that customers will be able to move to another geographic location within some reasonably defined region, and, in moving, change their local carrier, the switch from which they are being served, or both. The ability to change service providers without moving is called service provider number portability; the ability to change location without changing a service provider is called geographic number or location portability. It is expected that in the not too distant future both will be required. In order to provide service in the face of service provider number portability and geographic number portability, the traditional tie between a customer's serving central office and the NPA-NXX portion of that customer's telephone number will have to be broken and alternate arrangements provided. Such alternate arrangements already exist for 700 service wherein the last seven digits of a 700 number bear no relation to the geographic location of the associated telephone customer. Other service access codes such as 500 are being planned for use with similar services. At the present time, this type of facility is limited to a small fraction of telephone customers. Accordingly, the problem in the prior art is that no sound economic arrangement has been proposed which offers geographic number portability and service provider number portability to most telephone customers.
Solution
The above problem is solved and an advance is made over the prior art in accordance with our invention wherein each local exchange carrier is provided with access to a local universal database listing all numbers for a given local region served by a local exchange carrier and wherein each interexchange carrier is provided with access to a national database listing all numbers for the nation. (Clearly, both of these databases can be implemented incrementally during a period of transition wherein for example, the national database need only store data for regions which have implemented service provider number portability and/or geographic number portability and within these regions only for office codes which have diversity in the location and/or the local exchange carrier of their subscribers.) For local calls, the local database is accessed to determine the identity of the terminating local exchange carrier and the terminating switch of the called customer while the national database is accessed to obtain similar information for toll calls. Advantageously, with this arrangement, the originating switch or a switch of an interexchange carrier can determine the identity of the local carrier serving the called customer and the switch from which that called customer is served.
In accordance with one feature of the invention, an alternate terminating carrier and terminating switch can be identified for customers who require especially reliable service so that if the preferred carrier and switch are inaccessible, the terminating customer may be reached by an alternate route. In accordance with another aspect of the invention, call detail records for individual calls include the identity of the terminating exchange carrier and switch for toll calls. The originating local carrier and switch must also be identified if the interexchange carrier is to produce the billing record for a call, in order to rate calls properly with geographic and/or service provider portability.
For local carrier switches for local or toll calls, the identity of the originating local exchange carrier and switch, or the interexchange carrier, respectively, can be optionally recorded in order to allow a single billing center to process calls from a plurality of carriers without requiring that the records of each carrier and switch be segregated.
In order to route calls in a network which has local number portability, it is necessary to have a location routing number for routing calls to the particular switch which serves the called customer. Such a location routing number is used to identify that switch so that the call may be routed there. In accordance with one feature of applicants' invention, this location routing number (LRN) comprises an area code and office code (NPA-NXX) wherein each switch of the network has a unique LRN. If a switch serves customers having several different office codes, perhaps even office codes and having different NPA codes, such a switch is identified by a single NPA-NXX code. While it may be convenient to assign an NPA-NXX code that is used by at least some of the customers served by switch, it is not necessary; because each switch must have a distinct location routing number, it may not be possible, in some cases, for some of the switches, especially smaller switches of competitive access providers. However, if the switch is identified by an NPA-NXX code of some of the telephones that it serves, routing translations can remain the same for those telephones. Advantageously, the use of an NPA-NXX code as a location routing number provides a high degree of compatibility with existing methods of routing telephone calls.
DRAWING DESCRIPTION
FIG. 1 is an overall block diagram illustrating the operation of applicant's invention;
FIG. 2 is a block diagram illustrating the arrangement for updating national and local databases;
FIGS. 3-6 are flow diagrams illustrating the operation of applicant's invention;
FIGS. 7 and 8 are diagrams illustrating the establishment of toll and local calls in accordance with applicant's invention; and
FIG. 9 illustrates the use of data for identifying a location reference number for routing calls.
DETAILED DESCRIPTION
FIG. 1 is a block diagram showing the relationship between telephone customers, local service providers (i.e., local exchange carriers) and interexchange carriers. Individual customers 1-5 serve to originate or terminate telephone traffic. Some of these customers, such as customers 1 and 4, are connected to two carriers in order to provide especially reliable service. Local exchange carriers 6-10 are connected to the customers and are connected to interexchange carriers 11-13. Each local exchange carrier includes one or more switches 17, a local universal database (LUDB) 18 and a billing recording system 19. Alternatively, a local universal database can be shared by several or all local carriers. The switches are for establishing telephone connections in the conventional way and are interconnected by the links shown in FIG. 1. The database 18 need only contain data for the telephone numbers of the region served by the local exchange carrier. Each of the local exchange carriers serving a particular region stores in its database data concerning all the numbers of the region so that in a broad sense, each of the databases contain the same data. The database for a particular region and a particular carrier is accessed through data links from each of the switches of the carrier serving that region. While FIG. 1 shows individual databases for each local exchange carrier, these databases could be shared among a plurality of such local exchange carriers; this is particularly straightforward since the databases are accessed using data links.
The local exchange carriers are connected to interexchange carriers 11, 12, . . . , 13, each of which contains one or more switches 14, and access to a national universal database (NUDB) 15 and a billing record system 16. The remarks made previously about the local database are also applied to the national database which, of course, is very much larger. This national database can be concentrated or distributed and can be shared among a plurality of interexchange carriers since it is accessed by data links from the switches that use the data of the database.
FIG. 2 shows an arrangement for updating the local and national databases. A centralized service management system 201 transmits update messages to individual carrier local number portability service management systems 202 which transmit update messages to the local databases 203 of each of the carriers 204. Similarly, the centralized service management system 201 transmits data messages to interexchange carrier local number portability service management systems 210, each of which are used to update the national databases 211 of each of the carriers 212.
Local access providers must provide update information to the centralized service management system 201. The customer's new local service provider is responsible for the update for the case in which the customer changes service providers. When a customer switches carriers, the original local carrier may be required to forward calls for a short period (a few days) until the database has been updated.
FIG. 3 is a flowchart of the routing procedure for this kind of arrangement. The local exchange carrier switch receives the call (action block 301). The local carrier switch makes a translation whether this is a local or a toll call (test 303). If geographic number (location) portability has been implemented in the region where the call is received, then in order to successfully complete test 303, the local database will return the preferred terminating local exchange carrier and the switch from which the terminating customer is served and this can be used in conjunction with the identification of the originating switch to determine whether this is a local or toll call. A call will also be a toll call if it is recognized that the local database will not contain data for that terminating customer. This can be determined, for example, from the NPA code of the terminating customer, or if geographic number (location) portability has not been implemented from the office code of the called number. If as a result of test 303 it is determined that this is a toll call, then the call is routed to the pre-subscribed interexchange carrier or if the customer specifies an interexchange carrier by dialing an appropriate code, then to the specified dialed interexchange carrier (see action block 305). The interexchange carrier receives the Automatic Number Identification (ANI) of the calling customer, and the Dialed Number (action block 307). The interexchange carrier then accesses the national database to determine the terminating carrier (and alternate where provided) and the terminating switch (and alternate where specified) (action block 309). The interexchange carrier then routes the call to an egress switch serving the preferred terminating carrier and transmits the terminating carrier and local office identification (action block 311). Test 313 determines whether the preferred carrier is available; if so, the call is completed to the called customer via that terminating carrier (action block 315). If the preferred carrier is not available (negative result of test 313), then test 317 determines whether an alternate carrier has been specified. If so, then test 319 determines whether the alternate carrier is available. If so, the call is routed to the alternate carrier for completion to the called customer (action block 321). If the alternate carrier is unavailable, then the call is blocked and given blocked call treatment (action block 323). Similarly, if no alternate carrier had been specified (negative result of test 317) then the call is also blocked (action block 323).
If the result of test 303 for determining whether this is a local or toll call is that the call is a local call, then action block 401 (FIG. 4) is entered. In action block 401 the local exchange carrier switch queries the local database to determine the preferred carrier and switch (and alternate carrier and switch if so specified). Test 403 is used to determine whether the preferred carrier is available. If so, then the call is routed to the preferred carrier, and the terminating carrier and end office identification are transmitted toward the terminating carrier (action block 405). If not, test 407 determines whether an alternate carrier has been specified. If so, test 409 determines whether the alternate carrier is available. If so, then the call is routed to the alternate carrier for completion to the called customer. If the alternate carrier is not available (negative result of test 409) or if no alternate carrier had been specified (negative result of test 407) then the call is given blocked call treatment (action block 413).
FIG. 5 is a flow diagram showing the actions performed for billing a toll call. The interexchange carrier receives the ANI and Dialed Number (action block 501). The interexchange carrier translates the incoming trunk identification to identify the originating carrier (action block 503). Alternatively, signaling information from the originating carrier can identify that carrier. The interexchange carrier then queries the national database to identify the terminating carrier and switch for the called number (action block 505) and the interexchange carrier prepares a call detail record including the ANI, Dialed Number, originating and terminating local carrier identification and switch identification, the interexchange carrier identity (in case billing records are processed for several carriers by a single processor), and elapsed time for the call (action block 507).
FIG. 6 is the billing procedure for local calls. The local carrier receives the Dialed Number and the ANI of the originating customer (action block 601). The local carrier then queries the local database to identify the terminating carrier and switch based on the Dialed Number (action block 603). The local carrier then prepares a call detail record including the ANI, Dialed Number, the terminating carrier and terminating switch identification.
For the case that the alternate terminating carrier is used, the alternate terminating carrier and switch are substituted for the preferred carrier and switch in the call detail record.
FIG. 7 illustrates a toll call and illustrates some of the ways in which the arrangement described herein has flexibility. A customer 701 has access to three different local carriers: namely, Local Exchange Carrier 711, Competitive Access Provider 713 and Cable TV provider 715. Assume that this customer elects for a particular call to use the Competitive Access Provider 713. When the toll call arrives at the ingress switch 731 of the selected interexchange carrier, the call is routed to the egress switch of interexchange carrier 733, either the ingress switch or the egress switch may query a national universal database 741 to obtain information as to the carrier and office serving the called customer. The interexchange carrier switch querying database 741 supplies the called party number (NPA-NXX-XXXX) and receives in response the identity or identities of the carrier(s) and end office(s) of the local carrier serving the called customer. It is also possible that the database is queried from an intermediate switch of the selected interexchange carrier; this might happen, for example, if the call is of a special type handled by a specialist interexchange carrier switch. At any rate, the egress switch is informed, either by the querying switch, or directly by the database if the egress switch is the querying switch, of the identity of the preferred carrier(s) and the identity of the end office for each such carrier. The call is then routed, in this case via CATV carrier 725, to the terminating customer. Note that in the terminating region there is also a Local Exchange Carrier 721 and the Competitive Access Provider 723, so that there is an alternative for completing the call to the called customer 703. In order to provide revenue to the carrier that actually processed the call, the identity of the originating and terminating local carrier, as well as the interexchange carrier, are provided either explicitly to the call detail records or implicitly because the record is made by a particular carrier.
FIG. 8 illustrates a local call and illustrates some of the ways in which the arrangement described herein has flexibility. A customer 801 has access to three different local carriers, namely local exchange carrier 811, Competitive Access Provider 813 and Cable TV provider 815. Assume that this customer elects for a particular call to use the Competitive Access Provider 813. When the local call arrives at a switch at Competitive Access Provider 813, the switch from the Competitive Access Provider 813 accesses local universal database 841 with the dialed number (NPA-NXX-XXXX) and receives in response the identity or identities of the carrier(s) and end office(s) of the local carrier serving the called customer. The Competitive Access Provider then routes the call via the preferred carrier which may be local exchange carrier 811 or Cable TV provider 815. Note that in the particular case where illustrated in the diagram wherein called customer 803 has access to all three carriers, the call can be routed via a non-preferred carrier if access via the preferred terminating carrier is blocked. In order to provide revenue to the carrier that actually processed the call, the identity of the originating and terminating local carrier are provided either explicitly to the call detail record or implicitly because the record is made by a particular carrier.
While in the preferred embodiment, the interexchange carrier accesses the national database, the originating carrier can alternatively be arranged to access that database and forward the identity of the terminating carrier(s) and switch(es) to the interexchange carrier.
For a local operator assistance call, the local carrier determines that the call is a local operator call and sends the call to a local operator assistance system which may be part of the calling party's local carrier network, or in another local network (operator systems can serve multiple local networks). The originating local carrier is identified to the operator system either by incoming trunk information or signaling. The operator system performs the requested operator service and then queries the LUDB to get the terminating carrier and terminating switch. It routes the call to the terminating carrier, passing the carrier and switch identification. The operator system makes a call detail record that includes both the originating and terminating, carrier and switch, identifications.
For a toll operator call, the local carrier determines that the call is a toll operator call and sends the call to the subscribed or dialed toll carrier operator system. The originating local carrier is identified to the toll operator assistance system either by incoming trunk information or signaling. The operator system performs the requested operator service and routes the call to a toll ingress switch. >From here, routing is the same as a toll call--the ingress toll switch queries the NUDB, etc. When the toll call is successfully routed, the terminating carrier and switch identifications are signaled in the backwards direction to the operator system to be included in the call detail record.
Essential to the implementation of Local Number Portability (LNP) is the ability to associate a network destination with a ported dialed number. This information, identified as a Location Routing Number or LRN, will necessarily indicate the specific switching entity which serves the called party and, therefore, to which the call must be routed. Clearly, the LRN will be the key element in the LNP database.
An LRN must be selected for each switching entity which terminates subscriber lines. Although LNP, and in particular, the use of an LRN will significantly impact call processing in all networks, the format of the LRN can be selected to minimize the required network changes. Specifically, it would be desirable if the use of the LRN:
allowed the continued use of current network routing methods
permitted the use of existing signaling protocols
avoided the need for new technical standards
Any number of formats might be considered for use as an LRN. For example, a simple 5 digit numeric code would allow the unique identity of up to 100,000 end offices. Alternatively, the code could be designed to include routing information indicating, for example, a region of the country in which the end office was located; or the code could be designed to include the identity of the local service provider. All of these suggestions, however, fail to satisfy the most important of the above mentioned criteria--the need to retain the current routing algorithms in all network switches. Today, routing is based upon the geographic information contained in North American Numbering Plan (NANP) numbers--specifically the first six digits of those numbers or NPA-NXX. Accordingly, the use of an LRN in a format other than NPA-NXX would create the need to develop routing based upon the new code. It appears appropriate, therefore, that the LRN retain the format of the numbering plan used to identify end offices today; that is, NPA-NXX.
In accordance with applicants' teachings, a unique LRN, in the form of NPA-NXX, is assigned to each switching entity which terminates subscriber lines. The LRNs are assigned by a code administrator, likely the same administrator responsible for local number administration. Existing end offices which are presently associated with one or more NPA-NXXs, would select one of the NPA-NXXs currently assigned to the office as the LRN. Local service providers establishing new switching entities would, naturally, request and receive an LRN from the administrator. An LRN need not contain the NPA-NXX code of any customer served by the switch identified by the LRN.
To avoid routing complexities it is important that an LRN assigned to any end office not be an NPA-NXX assigned to any other end office. For example, consider a large end office which currently uses four NPA-NXXs to identify customers served from that office. One of the four NPA-NXXs would be selected as the LRN for that office. The LRN for any other end office should not be selected from any of the three (non-LRN) codes assigned to the existing end office. This constraint eliminates the need to establish separate routing tables--or domains--to distinguish routing based upon LRNs--for those dialed numbers that have been ported--from routing based on the dialed number for those numbers that have not been ported. Rather, routing tables as they exist today, would be used to effect call completion. Finally, it is assumed that information associated with LRNs, such as service provider name, common location language identifier (CLLI) code, tandem routes, vertical and horizontal graphics coordinates, etc., would be added to the Local Exchange Routing Guide (LERG).
Equally important in the selection and use of an LRN is its compatibility with the existing signaling methods used to transmit the necessary address information required for proper call completion. Signaling messages are necessary to provide this information either directly to the terminating switch or to an intermediate or tandem office. It will be necessary to carry both the LRN as well as the dialed number (DN) along the signaling path. The LRN is clearly required for call routing and the DN is needed by the serving end office to effect the connection to the loop assigned to the called party. The following describes the methodology through which existing signaling methods can be used to forward this information.
Typically, signaling information is carried over a dedicated, common channel signaling network using the SS7 protocol. Call set-up is effected using an initial address message (IAM) which contains several parameters, each containing specific information related to the call. This signaling method is used to provide call completion in a number portable environment by simply modifying the use of existing parameters. Although the modification of the use of these parameters requires industry agreement on the addition of new codes to existing signaling parameters, it should not involve the more complex and time consuming exercise of establishing and implementing the use of an entirely new signaling parameter within the SS7 message.
Specifically, the SS7 IAM parameters that are involved are the called party number (CdPN) parameter and the Generic Address Parameter (GAP). Today, for non-featured calls the CdPN parameter is populated with the DN and call routing is performed using this number. (A non-featured call is one whose dialed directory number is used for routing the call, in contrast, for example, to 800 calls wherein the dialed number cannot be used directly for routing.) The GAP is an optional parameter designated to transport a "user provided number" and is currently used in only a few instances. It is proposed that when a ported call is processed and an LRN is received as a response from an LNP database, the LRN is populated in the CdPN parameter of the IAM. It is further proposed that the DN be transmitted in the GAP. The contents of the CdPN parameter (the LRN) will be used as necessary to route the call. Because the information is in the NPA-NXX format, routing should proceed without change. At the terminating end office the 6 digit format of the LRN can be identified by the switch to indicate a call for completion to a ported number. With that identification, the switch can be instructed to locate the number originally dialed--and necessary to identify the called party--in the GAP.
FIG. 9 illustrates the operation of applicant's invention with respect to the use of a location routing number. Telephones 901, 902, and 903 are connected to end offices 911, 912, and 913, respectively. End offices 911, and 912 are in the same local region, whereas, end office 913 is connected to end offices 911, and 912 via trunks interconnecting interexchange carrier offices 920 and 921. Access tandems 915 and 916 are used for accessing the interexchange carrier and for interconnecting the end offices to databases as shown as local universal database 951 and a national universal database 952. For each end office, a set of office codes served by that office is shown. The particular office code which is also used as the location routing number is shown in parentheses.
In the particular example shown, telephone station 415-887-1234 is connected to end office 912 having location routing number 415-267. End office 911 serves the bulk of the telephones having telephone numbers in the 415-887 office code. When telephone 901 calls telephone 902 having telephone number 415-887-1234, a check is made in local universal database 951, table 930, and an entry 931 is found, indicating that telephone 415-887-1234 is served by an end office identified by location routing number 415-267, i.e., end office 912. If no entry had been found for telephone 415-887-1234, then the call would have been routed using the 415-887 code to end office 911.
If telephone 901 calls telephone 903 having telephone number 201-334-9876, such a call is identified as being an inter-LATA (interlocal access transport area) routed to an interexchange carrier which accesses a national universal database in order to find the identity of the switch serving the terminating telephone. It is necessary to identify this switch in order to route via an exchange carrier that serves the identified switch. The national universal database 952 has an entry 942 in table 940 for telephone number 201-334-9876 and that entry indicates that the location routing number of the terminating end office is 201-789. If no entry had been found, then the 201-334 office code would have been used to route the call to end office 914 which serves the bulk of the 201-334 office code traffic.
Note that the databases need only store data for the numbers that are not served by the local switches serving the bulk of the numbers of a particular office code. Data need only be stored for the numbers of customers who have moved from such a switch to another.
Consider the toll call associated with FIG. 9 in more detail.
1. An interLATA call is generated by an end user in California to a called party in New Jersey. The dialed number is (201) 334-9876.
2. The call is recognized by the originating end office as an interLATA call and the call is forwarded to the presubscribed interexchange carrier (IC).
3. Although the IC could test to identify the DN at either the originating or terminating switch in its network assume the identification is performed at the originating IC switch. Specifically, the first 6 digits (201-334) of the DN are analyzed and identified as a potentially ported number.
4. Database query is launched to the appropriate NUDB database with the DN (201) 334-9876.
5. Because the number has been ported, the response from the NUDB database includes the LRN (201-789).
6. The call is routed based upon the LRN and the originating IC switch formulates an SS7 IAM (initial address message).
7. The CdPN parameter is populated with the LRN (201-789) and the DN (201) 334-9876 is inserted in the GAP.
8. The terminating IC switch routes the call based upon the LRN and generates a signaling message to the designated end office.
9. If the terminating end office is SS7 and "LNP capable" (LNP=Local Number Portability) (i.e. capable of recognizing the modified signaling message):
End office checks contents of CdPN parameter, recognizes the 6 digit format and identifies the call as an "LNP" call.
End office uses the information in the GAP (the DN) to route the call to the appropriate subscriber loop.
10. If the terminating end office is not LNP capable, the (n-1)st switch (i.e., the switch transmitting the signaling message) must format the signaling message so that the DN is contained in the CdPN parameter.
11. Similarly, if the EO is not SS7 compatible, the DN will be forwarded using in-band (MF) signaling.
12. If the dialed number has not been ported, the call is routed and signaling generated in the normal manner.
The dialed number is populated in the CdPN parameter
The GAP is not used
The call is routed based upon the DN contained in the CdPN parameter.
In some cases, an end office switch may serve more than one carrier, with different sets of customers, associated with different sets, telephone numbers, being served by different carriers. Under these circumstances, different trunk groups are likely to be used for the calls of the different carriers. The routing arrangement must be capable of selecting these carriers. Therefore, it is necessary to have the translations in the LUDB 951 and NUDB 952 augmented with the identities of the trunk groups or a routing index for finding such trunk groups. As shown in FIG. 5, such carriers must be identified for routing and entered in billing records.
It is to be understood that the above description is only of one preferred embodiment of the invention. Numerous other arrangements may be devised by one skilled in the art without departing from the scope of the invention. The invention is thus limited only as defined in the accompanying claims.
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In an environment of competitive local and interexchange carriers, offering number portability between local carriers-serving a common region and between switches serving that region, each local carrier accesses a regional database to determine the identify of the carrier and switch serving a local customer. In addition, interexchange carriers access a national database to determine the identity of the carrier and switch serving the customer specified by the number dialed by an originating customer. For customers requiring high reliability service, alternate carriers can be used to serve such customers in case the primary carrier is unavailable; the databases identify these alternate carriers. Advantageously, this arrangement allows a high degree of freedom of movement of customers between carriers and geographic relocation without requiring a number change.
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BACKGROUND
In digital electronic circuitry, it is common to transfer data from one clock domain to another. Data is clocked out of a register by the first domain clock, and clocked into a register by the second domain clock. Generally, the two clocks are synchronous. That is, their phase relationship is constant. In such instances, the major problem in ensuring proper data transfer from one domain to the other is ensuring that the phase relationship is within a range that allows the data to meet setup and hold timing requirements.
Persons involved in the design and manufacture of integrated circuits (ICs), especially application-specific ICs (ASIC), desire to verify that data can be properly transferred between two clock domains in the IC die. For example, in many ASICs, data is transferred between “core” logic in one region of the IC die and input/output (I/O) logic in another region of the IC die. The I/O logic can include, for example, a Serializer/De-serializer or “SerDes.” In the prior art, proper data transfer between core logic and a SerDes has been verified in tests by transferring large amounts of test data between the core logic and SerDes and comparing the input data with the output data. Although this method can indicate that the ASIC is generally operational for its intended purpose, it does not necessarily prove that the ASIC has been designed and manufactured in a manner that meets clock phase specifications, since it is possible for a data transfer to be successful despite the two clocks having a phase relationship somewhat outside of the designed-for, i.e., specified, range.
SUMMARY
The phase relationship between two clock signals in an integrated circuit (IC) is determined by transforming each of the clock signals into a data word, where bit transitions in the data word represent signal transitions in the clock signal, and comparing the two data words. For example, in an IC having a de-serializer as part of its input/output logic, the clocks can be sequentially multiplexed into the de-serializer, which transforms the clocks into parallel-format data words. The resulting words corresponding to the first and second clock signals can then be compared to determine clock signal transition differences and thus the phase relationship between the corresponding clocks signals. In some exemplary embodiments of the invention, the de-serializer can be included as part of a Serializer/De-Serializer (SerDes).
Other systems, methods, features, and advantages will be or become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the specification, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention.
FIG. 1 is a block diagram of an integrated circuit having one or more Serializer/De-serializers (SerDes).
FIG. 2 is a flow diagram illustrating a method for testing clock phase relationships in the integrated circuit of FIG. 1 .
FIG. 3A is timing diagram illustrating operation of the clock phase testing in the integrated circuit of FIG. 1 .
FIG. 3B is a continuation of FIG. 3A .
FIG. 3C is a continuation of FIG. 3B .
FIG. 4 is a diagram illustrating a comparison between two data words representing clock signals.
DETAILED DESCRIPTION
As illustrated in FIG. 1 , in one exemplary embodiment of the invention, an integrated circuit (IC) 10 , such as an application-specific integrated circuit (ASIC), includes core logic 12 and one or more Serializer/De-serializers (SerDes) 14 . SerDes 14 , which is part of the overall input/output (I/O) logic of IC 10 , is a high-speed device for efficiently inputting and outputting data to and from IC 10 through associated I/O pads (not shown for purposes of clarity). As known in the art, SerDes 14 comprises logic that converts data that exists inside the IC (e.g., in core logic 12 ) in parallel form into a serial bit stream for output from the IC, and converts a serial bit stream input to the IC into parallel form for use inside the IC. Core logic 12 operates primarily under a first clock signal (“CLK_A”), while the serializer portion of SerDes 14 that receives data from core logic 12 operates primarily under a second clock signal (“CLK_B”). For data to be transferred properly from core logic 12 to SerDes 14 , it is important that the phase relationship between the first and second clock signals be within a specified range. The present invention can be included in association with the manufacture of IC 10 , to test whether the phase relationship between the first and second clock signals is in fact within such a predetermined range.
It should be noted that FIG. 1 is not to scale, as SerDes 14 constitutes a much smaller portion of IC 10 than core logic 12 . Although not shown in detail for purposes of clarity, core logic 12 includes the conventional “functional logic” that effects whatever the primary functions of IC 10 may be in a given embodiment of the invention. IC can have any suitable primary function or functions known in the art. For example, in an embodiment in which IC 10 is primarily a microprocessor, the functional logic effects the various functions that characterize the microprocessor. Indeed, in an application-specific IC (ASIC), the “application” comprises the function or functions. Accordingly, such functional logic forms the bulk of the logic of IC 10 . One exemplary output register 16 of such functional logic or other logic of core logic 12 is shown for purposes of illustration as coupled to SerDes 14 for outputting data from IC 10 , but it should be appreciated that there can be many other such registers that are coupled to SerDes 14 or other such SerDes (not shown) for the purpose of outputting data from IC 10 . Likewise, one exemplary input register 18 of such functional logic or other logic of core logic 12 is shown for purposes of illustration as coupled to SerDes 10 for inputting data to IC 10 , but it should be noted that there can be many other such registers that are coupled to SerDes 14 or other such SerDes for the purpose of inputting data to IC 10 . The ellipses (“ . . . ”) included in the symbol representing registers 16 and 18 indicates that the register stores or holds a plurality of bits, i.e., stores a word having a width of two or more bits. For example, registers 16 and 18 can each be ten bits wide.
The serializer portion of SerDes 14 includes a register 20 that receives data (in parallel or non-serial format) from core logic 12 , and serializing logic 22 that transforms such data into a serial bit stream and provides it to an output pad of IC 10 . The de-serializer portion of SerDes 14 includes de-serializing logic 28 that transforms a serial-format data stream into a parallel-format data word, and a register 30 that receives that data word. The de-serializer portion of SerDes 14 operates in the same manner as that of the de-serializer portion of a conventional SerDes. That is, de-serializing logic 28 operates under a high-speed master clock to transform the data into parallel-format data words. Each of the first and second clocks (CLK_A and CLK_B in FIG. 1 , respectively) has a frequency that is an integer fraction of the master clock frequency. For example, in an embodiment in which the first and second clock signals are 100 MHz, the master clock signal under which de-serializing logic 28 operates can be 1 GHz. As in a conventional SerDes, de-serializing logic 28 can detect data word boundaries by looking for and synchronizing itself with a predetermined data word pattern that the data word source transmits as a header preceding the informational data words. For example, in an embodiment in which data words are ten bits in width, the source can transmit a synchronization pattern consisting of three “0” bits and seven “1” bits: “0001111111” (or any other suitable pattern that the de-serializing logic can be pre-configured to recognize). Typically, to ensure synchronization, the source successively transmits such a data word pattern two or more times as a training sequence before transmitting informational data. De-serializing logic 28 can find the boundaries between successive words of this training sequence, thereby allowing it to de-serialize the informational data that may follow the training sequence into other 10-bit data words. As the de-serializer portion of SerDes 14 produces the data words, they are transferred from register 30 in SerDes 14 to register 18 in core logic 12 . Note that registers 30 and 18 operate under yet another clock, produced by a divider 26 that divides the master clock by the above-described integer fraction. For example, divider 26 can be a divide-by-ten circuit, dividing a 1 GHz master clock down to 100 MHz.
SerDes 14 further includes multiplexing logic 24 that can selectably couple one of its several data inputs to its output. More specifically, in the illustrated embodiment multiplexing logic 24 has a control input and four data inputs: a first input (addressable through the control input as “0”) coupled to an input pad of IC 10 for receiving serial-format data from an external source (not shown); a second input (addressable through the control input as “1”) coupled to core logic 12 via the serializer portion for receiving serialized data in a loopback manner for the above-described synchronization purposes or other suitable purposes; a third input (addressable through the control input as “2”) coupled to the first clock signal; and a fourth input (addressable through the control input as “3”) coupled to the second clock signal. In response to the address applied to the control input, multiplexing logic 24 selects one of its three inputs to couple to its output.
When IC 10 is not in the test mode described below, i.e., when it is in normal operational mode, SerDes 14 can receive data words from core logic 12 , serialize the data, and transmit the serial-format data stream out of IC 10 . Similarly, in normal operation, SerDes 14 can receive a serial-format data stream from a source external to IC 10 , de-serialize the data, and provide the parallel-format data words to core logic 12 . The normal operational mode is how the functional logic of IC 10 communicates (functional or informational) data, i.e., data relating to the functions that characterize IC 10 (for example, as a microprocessor or whatever its primary function or application may be in a given embodiment), with other devices. The arrows in FIG. 1 shown directed into the “D” inputs of register 16 and out of the “Q” outputs of register 18 (shown for purposes of illustration as comprising arrays of D-type flip-flops) are intended to represent such functional data flow in the normal operational mode.
Core logic 12 further includes control logic 32 and comparison logic 34 for operating in a clock phase relationship test mode. It should be noted that although in the exemplary embodiment control logic 32 and comparison logic 34 are included in core logic 12 , in other embodiments such logic can alternatively be included in the SerDes or in any other suitable logic in IC 10 or external to IC 10 . Note that in the normal operational mode, control logic 32 applies an address of “0” to multiplexing logic 24 .
A clock phase relationship test can be performed at any suitable time, such as in conjunction with other post-production or wafer-level testing of IC 10 . In the exemplary embodiment, control logic 32 effects the test steps, and communicates control signals accordingly with other elements involved in the test, as indicated in broken line in FIG. 1 . Although not shown for purposes of clarity, control logic 32 can receive a signal from an external device (through suitable I/O communications) that causes control logic 32 to initiate the clock phase relationship test. Alternatively, the test can be initiated in any other suitable manner.
As illustrated in FIG. 2 , and with continuing reference to FIG. 1 , in the test mode, control logic 32 can apply an address of “1” that causes multiplexing logic 24 to select the loopback path, thereby coupling the serializer output of SerDes 14 to the de-serializer input of SerDes 14 , as indicated by step 36 . Core logic 12 can then be used to transmit the above-described predetermined synchronization pattern, such as “0001111111”, as indicated by step 38 . As in a conventional SerDes, transmitting such a predetermined pattern one or more times causes de-serializing logic 28 to synchronize to that pattern, outputting a (parallel-format) data word, as indicated by step 40 . For example, in an embodiment in which the data words are ten bits wide, after synchronizing to the 10-bit pattern, de-serializing logic 28 outputs a data word after every ten bits of incoming serial data.
Control logic 32 then applies an address of “2” to multiplexing logic 24 that causes multiplexing logic 24 to select the first clock signal input, as indicated by step 42 . In response to switching multiplexing logic 24 , the first clock signal passes through to de-serializing logic 28 , which accordingly receives and transforms the first clock signal into a (parallel-format) data word, as indicated by step 44 . The resulting data word representing the first clock signal is latched into register 30 and then transferred to register 18 in core logic 12 . Comparison logic 34 saves or stores the data word representing the first clock signal.
Control logic 32 then applies an address of “3” to multiplexing logic 24 that causes multiplexing logic 24 to select the second clock signal input, as indicated by step 46 . In response to switching multiplexing logic 24 , the second clock signal passes through to de-serializing logic 28 , which accordingly receives and transforms the second clock signal into a (parallel-format) data word, as indicated by step 48 . The resulting data word representing the first clock signal is latched into register 30 and then transferred to register 18 in core logic 12 .
As indicated by step 50 , comparison logic 34 then compares the data word representing the second clock signal with the (previously saved) data word representing the first clock signal. A step 52 can be performed in which an indication of the result of the comparison is output. For example, it can be output from IC 10 to an external device (e.g., test equipment). Alternatively, the indication can be further processed in core logic 12 . The indication can indicate the phase difference or, alternatively, only whether the test passed (i.e., the phase difference was within some predetermined threshold) or failed (i.e., the phase difference was not within the predetermined threshold). In most instances, it is desired for the first and second clock signals to have zero phase difference. If the first and second clock signals were to have zero phase difference, then step 52 would indicate that the corresponding data words match each other, i.e., are identical. After the test is completed, control logic 32 can return IC 10 to normal operational mode or pass control of this portion of IC 10 to other logic for further testing.
The above-described method can be further understood through the timing diagram of FIGS. 3A-C . Initially, control logic 32 applies an address of “1” to multiplexing logic 24 , which responds by selecting the core logic data input. Core logic 12 transmits the synchronization pattern (in this example, as above, “0001111111”), which passes through to the multiplexing logic output (MUX OUT). De-serializing logic 28 synchronizes to the pattern and outputs it at time 54 as a (parallel-format) data word 56 . Thereafter, de-serializing logic 28 outputs another data word every ten master clock cycles. In the illustrated example, as the pattern is transmitted twice, ten master clock cycles later, at time 58 , de-serializing logic 28 again outputs the same data word 56 ′.
Then, a few master clock cycles after time 58 , control logic 32 applies an address of “2” to multiplexing logic 24 , which responds by selecting the first clock signal (CLK_A) input. For a few master clock cycles after this switching of multiplexing logic 24 , its output (MUX OUT) is unstable or unpredictable, as indicated by “XXX”. However, after this switching transition, the first clock signal appears at the multiplexing logic output (MUX OUT) as a repeating pattern of five “1” bits alternating with five “0” bits. This pattern reflects that the first clock signal is high for five “bit-times” (of the master clock) and low for five bit-times of the master clock.
Ten master clock cycles after time 58 , de-serializing logic 28 outputs another data word 62 , but data word 62 is unpredictable (indicated by “XXXXXXXXXX”) because the multiplexing logic output was itself unstable or unpredictable during the switching transition of multiplexing logic 24 . However, another ten master clock cycles later, at time 64 , de-serializing logic 28 outputs the 10-bit portion of the first clock signal pattern that was captured or de-serialized during the previous ten master clock cycles. As the event of de-serializing logic 28 producing an output (at time 64 ) occurred between the fourth and fifth “0” bits of the first clock signal pattern, the resulting data word 66 output by de-serializing logic 28 begins with that fifth “0” bit: “0111110000”. As described above with regard to step 44 ( FIG. 2 ), comparison logic 34 saves this data word. Note that de-serializing logic 28 again outputs the same data word 66 ′ ten master clock cycles later at time 68 .
Note that control logic 32 need not switch multiplexing logic 24 at any precisely synchronized time. For example, several master cycles after time 68 , control logic 32 applies an address of “3” to multiplexing logic 24 , which responds by selecting the second clock signal (CLK_B) input. For a few master clock cycles after this switching of multiplexing logic 24 , its output remains unstable or unpredictable, as indicated by “XXXX”. However, after this switching transition, the second clock signal appears at the multiplexing logic output as the repeating pattern of five “1” bits alternating with five “0” bits. This pattern reflects that the second clock signal, like the first clock signal, is high for five bit-times and low for five bit-times.
Ten master clock cycles after time 68 , de-serializing logic 28 outputs another data word 70 at time 72 , but data word 70 is unpredictable, as is the data word 74 that is output still another ten master clock cycles later at time 76 , because the multiplexing logic output was itself unstable or unpredictable during the switching transition of multiplexing logic 24 . However, another ten master clock cycles later, at time 78 , de-serializing logic 28 outputs the 10-bit portion of the second clock signal pattern that was captured or de-serialized during the previous ten master clock cycles. As the event of de-serializing logic 28 producing an output (at time 78 ) occurred between the second and third “0” bits of the second clock signal pattern, the resulting data word 80 output by de-serializing logic 28 begins with that third “0” bit: “0001111100”. As described above with regard to step 50 ( FIG. 2 ), comparison logic 34 compares this data word 80 , representing the second clock signal, with the saved data word 66 representing the first clock signal.
The comparison is illustrated in FIG. 4 . Note that data word 66 representing the first clock signal and data word 80 representing the second clock signal are not identical, indicating that there is some detectable (non-zero) phase difference or clock skew between them. Specifically, the corresponding bit transitions representing the clock edges are offset by two bit positions. In an embodiment in which the de-serializer portion of SerDes 14 operates at 1 GHz (as in the example described above), each bit-time is 1 ns. Therefore, an offset of two bit positions indicates that there is a 2 ns phase difference between the first clock signal and second clock signal.
One or more illustrative embodiments of the invention have been described above. However, it is to be understood that the invention is defined by the appended claims and is not limited to the precise embodiments described.
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The phase relationship between two clock signals in an integrated circuit (IC) is determined by transforming each of the clock signals into a data word, where bit transitions in the data word represent signal transitions in the clock signal, and comparing the two data words. For example, in an IC having a de-serializer as part of its input/output logic, the clocks are sequentially multiplexed into the de-serializer, which transforms the clocks into parallel-format data words. The resulting words corresponding to the first and second clock signals can then be compared to determine clock signal transition differences and thus the phase relationship between the corresponding clocks signals.
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BACKGROUND
[0001] The present invention relates to schemes for user access to computer systems, and in particular to systems and methods for policy based privileged user access management.
[0002] Unless otherwise indicated herein, the approaches described in this section are not prior art to the claims in this application and are not admitted to be prior art by inclusion in this section.
[0003] For reasons relating to auditing, security, and compliance, organizations need to monitor access to critical business systems. Internal auditing typically requires that activities performed by system administrators or privileged users be monitored and reviewed. Accordingly, security or IT departments may strictly control access to sensitive areas. Moreover, compliance requirements may limit access to types of data for privacy, export control, and other reasons.
[0004] At the same time, however, businesses seek to operate with the greatest flexibility possible. For example it may be desirable to grant temporary access to business systems in order to allow the performance of emergency activities.
[0005] As applications evolve to support web and mobile access, conventional mechanisms to proxy authentication and monitor activity may no longer be sufficiently flexible to accommodate user needs. Additionally, the types of scenarios supported by emergency access systems for databases and operating systems may tend to focus on user management, rather than on end-to-end (emergency) scenarios including access and activity monitoring.
[0006] Thus, there is a need for a common approach allowing customers emergency access across various types of applications and systems supporting temporary/emergency access scenarios. Embodiments address these and other issues by providing systems and methods for policy based privileged user access management.
SUMMARY
[0007] Embodiments dynamically manage privileged access to a computer system according to policies enforced by rule engine. User input to the rule engine may determine an extent of system access, as well as other features such as intensity of user activity logging (including logging supplemental to a system activity log). Certain embodiments may provide access based upon user selection of a pre-configured ID at a dashboard, while other embodiments may rely upon direct user input to the rule engine to generate an ID at a policy enforcement point. Embodiments of methods and apparatuses may be particularly useful in granting and/or logging broad temporary access rights allowed based upon emergency conditions.
[0008] An embodiment of a computer implemented method comprises providing a Policy Enforcement Point (PEP) comprising a rule engine, providing to the (PEP), an identification (ID) to gain access to a first target system or application, and creating an authentication assertion of the ID. In response to receipt of the authentication assertion, the first system or application is caused to invoke the PEP such that the rule engine grants a user access to the first system or application according to a parameter determined by a policy. The parameter may comprise a logging level of activity of the user that is recorded in a first activity log supplemental to a second activity log of the first system or application.
[0009] An embodiment of a non-transitory computer readable storage medium embodies a computer program for performing a method comprising providing a Policy Enforcement Point (PEP) comprising a rule engine, providing to the (PEP), an identification (ID) to gain access to a first target system or application, and creating an authentication assertion of the ID. In response to receipt of the authentication assertion, the first system or application is caused to invoke the PEP such that the rule engine grants a user access to the first system or application according to a parameter determined by a policy. The parameter may comprise a logging level of activity of the user that is recorded in a first activity log supplemental to a second activity log of the first system or application.
[0010] An embodiment of a computer system comprises one or more computer processors and a non-transitory computer readable storage medium. The non-transitory computer readable storage medium comprises instructions for controlling the one or more computer processors to be operable to provide a Policy Enforcement Point (PEP) comprising a rule engine, provide to the (PEP), an identification (ID) to gain access to a first target system or application, and create an authentication assertion of the ID. In response to receipt of the authentication assertion, the first system or application is caused to invoke the PEP such that the rule engine grants a user access to the first system or application according to a parameter determined by a policy. The parameter may comprise a logging level of activity of the user that is recorded in a first activity log supplemental to a second activity log of the first system or application.
[0011] In some embodiments, access may be restricted by time and/or by portions of the first system or application available to the user.
[0012] According to certain embodiments, the ID comprises a pre-configured ID selected by the user from a list on a dashboard.
[0013] Particular embodiments may further comprise causing the PEP to dynamically select the ID in response to a user input to the rule engine.
[0014] In certain embodiments, the input may comprise a user response to a question posed by the PEP.
[0015] According to some embodiments, the PEP is in communication with a second target system or application, and the ID is specific to the first target system or application.
[0016] In particular embodiments the authentication assertion is federated across the first target system or application and the second target system or application.
[0017] The following detailed description and accompanying drawings provide a better understanding of the nature of particular embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a simplified block diagram illustrating a system according to an embodiment.
[0019] FIG. 2 is a simplified block diagram illustrating one embodiment of a system.
[0020] FIG. 2A is a simplified flow diagram showing a method of operation of the system of FIG. 2 .
[0021] FIG. 3 is a simplified block diagram illustrating another embodiment of a system.
[0022] FIG. 3A is a simplified flow diagram showing a method of operation of the system of FIG. 3 .
[0023] FIG. 4 illustrates hardware of a special purpose computing machine configured to perform policy based access management according to an embodiment.
[0024] FIG. 5 illustrates an example of a computer system.
[0025] FIG. 6 is a simplified flow diagram of an administration scenario process flow according to an embodiment.
[0026] FIG. 7 is a simplified flow diagram showing review of activity log by system/role/ or ID Owner.
DETAILED DESCRIPTION
[0027] Described herein are systems and techniques for policy based privileged user access management. In the following description, for purposes of explanation, numerous examples and specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention as defined by the claims may include some or all of the features in these examples alone or in combination with other features described below, and may further include modifications and equivalents of the features and concepts described herein.
[0028] Embodiments allow centralized management of privileged user access across different types of systems and applications. FIG. 1 shows a simplified schematic view of an embodiment an access management scheme 100 for a first target application or system 101 which includes a corresponding system activity log 105 , and a second, different target application or system 109 which includes a corresponding system activity log 111 .
[0029] In particular, privileged user sessions may be initiated from a common landing page 102 . The common landing page may be established and administered through certain administrative processes 103 , as is further discussed below in connection with FIG. 6 .
[0030] In certain embodiments, this common landing page 102 may provide an end user 104 with access a list 113 of pre-configured IDs for corresponding applications/systems that can be used to launch an emergency access session. Such an embodiment is described in detail below in connection with FIGS. 2-2A . By authenticating to the particular application/system, a link between the end user and temporary emergency access ID is maintained.
[0031] Certain embodiments may apply federation technologies. Such embodiments leverage the underlying authorization functions within different applications/systems, in order to provide temporary monitored access to privileged accounts across enterprise landscapes. The embodiment of FIG. 1 thus includes a federated authentication feature 108 that allows an emergency access ID to be used to access the relevant application or system for a temporary session.
[0032] A federated authentication feature according to embodiments, may support several protocols required to implement the type of authentication called for by the target system(s). These protocols may include federation protocols such as Security Assertions Markup Language (SAML), the OAuth™ open standard for authorization, as well as other mechanisms including Single Sign On (SSO) logon tickets, HTTP cookies, tokens, user names, passwords, certificates, etc. that can be used alone or in combination to establish a session with target application(s).
[0033] According to certain embodiments, the particular type of authentication mechanism employed may be dynamically determined through a negotiation with the target application.
[0034] In some embodiments, the authentication mechanism may be based on a pre-configured setting using the emergency access role or ID.
[0035] Embodiments may include a policy enforcement point (PEP) 106 component employing a rule engine 107 , that is responsible for applying policies that determine parameters for the activity session. Various embodiments may allow functionalities that include but not limited to policy enabled authentication, authorization, session parameter setting, and audit tracking.
[0036] One particular example of a system parameter that may be determined by a rule engine of a PEP, is the specific type of activity information which is logged by the target application/system, and/or which is logged by the activity management scheme (e.g. in a supplemental activity log). Such activity logging ensures that details of user activity are captured and able to be routed for review and approval.
[0037] Particular embodiments may provide for creation of a separate activity log 120 by the PEP, to be associated with the emergency ID and an end user ID for review. This supplemental activity log supplements an existing activity log (e.g. 105 or 111 ) of the target system. This PEP activity log may include details about each action, while the system activity log may include other relevant transaction details. To ensure that correct activity information is logged and reviewed, the session can be tagged with the emergency access ID.
[0038] The policy enforcement point component may support scenarios including dynamic assignment in which user input does not take the form of selection of a pre-configured ID. Particular embodiments can be used to support access to a target system through a dashboard that supports the dynamic assignment process based on the context of the session request, with federated authentication of a generated ID occurring downstream. Such an embodiment is described below in connection with FIGS. 3-3A .
[0039] Embodiments may include dashboard(s) providing central reporting on emergency access activity and log review processes. According to an embodiment, the workflow may support the approval routing and administrative processes 130 for review of activity logging. This is described below in connection with FIG. 7 .
[0040] As described herein, various embodiments may support access for privileged user accounts across multiple target systems and types of target systems. While each type of target application/system may have different capabilities for managing access for privileged accounts, embodiments addresses consistency and performance issues through a centralized approach that employs a PEP and rule engine operating independently of particular target technologies, applications, and systems.
EXAMPLE
Dashboard Mode (Pre-Configured ID)
[0041] FIG. 2 is a simplified block diagram illustrating one embodiment of a system.
[0042] FIG. 2A is a simplified flow diagram showing a method of operation of the system of FIG. 2 .
[0043] The particular embodiment of FIGS. 2-2A employs an input to a rule engine in the form of a pre-configured ID that is selected by a user at a dashboard. That ID has already been subjected to federated authentication assertion.
[0044] Specifically, in a first step 201 of method 200 , a user 252 authenticates to get access to emergency dashboard 254 . This dashboard has a list 255 of pre-configured systems and IDs.
[0045] In a second step 202 , the user selects an ID/system. This initiates a federated authentication assertion 256 in a third step 203 .
[0046] In a fourth step 204 , the target system 258 receives the authentication assertion and invokes the policy enforcement point 260 . This policy enforcement point applies policy for the target system and the ID, utilizing a rule engine 262 .
[0047] In particular, the PEP may provide questions to a user, and receive corresponding answers. This information may aid in providing the appropriate level of access to the user for the session.
[0048] The PEP can determine the appropriate session parameters either where a pre-configured ID is selected, or where an ID is dynamically determined. In certain embodiments, the PEP is able to evaluate the situational context of the session to apply configuration, logging, and security parameters dynamically. Dynamically determining the session, logging, and security parameters can permit the appropriate activity logging to occur during the emergency access scenarios, without affecting the system performance during typical operation.
[0049] A process to determine the session parameters may involve logical condition(s) based on attributes and other values associated with the user or system. These may be determined by a mathematical procedure, derived from questions and answers, provided by the computing device or system, based on events, incorporated in approval or review processes, and/or associated with levels of risk, etc.
[0050] In certain embodiments, the rule engine may also prompt the PEP to require the user to enter codes. An example of such a code is a reason code describing the nature of the situation necessitating system access.
[0051] At this time, the rule engine may evaluate attributes utilizing logical conditions. Such attributes include the identity of the user, the identity of an organization with which the user is affiliated, the device through which the user is attempting to gain access to the system, and/or the identity of the target system to which access is sought.
[0052] The rule engine may also apply security and other session parameters. Examples include but are not limited to authentication, time outs, the use of multiple sessions and other security constraints. Alerts to others (e.g. system administrators) may also be sent.
[0053] Logging levels are another type of session parameter which may be applied. The particular logging level for the existing system activity log 264 , as well as for the supplemental activity log 266 of the PEP, may be configured at this time.
[0054] Embodiments may allow dynamic setting of the configuration of audit, configuration, event, activity, and system logging. The parameters that are available in the target system, may vary depending on the system and application design. Embodiments can integrate with system interfaces to change the levels or configuration in order to track user activity, data changes, configuration changes, and/or other changes related to activities performed by a user to restore operation, correct data, change configuration, perform system maintenance, etc.
[0055] Types of user activity may of course vary by system, along with capabilities to track user activity. In order to support consistent activity tracking, embodiments may incorporate multiple logging capabilities using the PEP as well as existing system audit, configuration, event, and activity logs.
[0056] The following presents a list of possible audit and activity logging levels which may be applied in various embodiments:
date of user access; date and time of user access; date, time, and specific areas of the target system accessed; date, time, and every keystroke entered by the user.
[0061] Certain embodiments can include the ability to apply logging as necessary to track user activity and actions that include but are not limited to: turning on logging for specific tables or data sets within an application to track changes to values; and/or setting the level of logging within an application or system based upon a condition level. For example, condition levels may be classified according to the following:
[0000]
Level
Severity
Description
0
Emergency
System is unusable.
1
Alert
Action must be taken immediately.
2
Critical
Critical conditions.
3
Error
Error conditions.
4
Warning
Warning conditions.
5
Notice
Normal but significant condition.
6
Informational
Informational messages.
7
Debug
Debug-level messages.
[0062] Embodiments may dynamically configure the type, actions, and format of activity information. Embodiments may configure the system to track specific events (e.g. security-related), and/or critical system indicators relevant to the type of emergency access session. Embodiments may monitor changes in configuration of the application to detect specific types of security vulnerabilities and other possible fraud scenarios.
[0063] In certain embodiments, a logging level parameter may specify a logging level that is available to a system activity log. In certain embodiments, a logging level parameter may specify a logging level not available to the system activity log, but which is performed based upon instructions provided by the PEP/rules engine of the access management scheme.
[0064] In a fifth step 205 , the activity session is opened. User activities may be logged in the system activity log and by a supplemental activity log of the policy enforcement point.
EXAMPLE
Dynamic Mode (No Pre-Configured ID)
[0065] FIG. 3 is a simplified block diagram illustrating an alternative embodiment of a system. FIG. 3A is a simplified flow diagram showing a method of operation of the alternative system of FIG. 3 .
[0066] The embodiment of FIGS. 3-3A employs a session ID dynamically generated based upon user input to a rule engine. The session ID is then subjected to federated authentication assertion.
[0067] According to this embodiment, the user authenticates to get access to emergency dashboard with list of pre-configured systems and IDs. Embodiments can operate with both a pre-configured emergency access ID, as well as in a mode where an appropriate ID is determined based on a set of questions and/or evaluation of a logical condition by rule engine. Thus in a first step 301 of method 300 , the user 350 accesses the dashboard 352 to select a logical or physical system.
[0068] In a second step 302 , the policy enforcement point 354 evaluates the request. The rule engine 356 dynamically determines the list of privileged IDs based on information such as questions/answers, end user ID, attributes, organization, device, context, prior activity information, and others.
[0069] In a third step 303 , an authentication assertion 358 created based on the ID selected by the PEP. In a fourth step 304 , the target system 360 receives the assertion and invokes the policy enforcement point.
[0070] In a fifth step 305 , the policy enforcement point applies a policy for system and ID. This application of policy by the rules engine may include questions issued and answers/reason codes received from the user. User, organization, device, system, and/or other attributes may be evaluated by the rule engine using logical conditions. Security and other session parameters may be applied. Parameters include but are not limited to, authentication, time outs, alerts, and multiple session and other security constraints. A logging level parameter may be applied, and logging level configured.
[0071] In a sixth step 306 , an (emergency) session is opened. Activities may be logged in both the target application/system activity log 370 and the supplemental activity log 372 of the policy enforcement point.
EXAMPLE
Administration Scenarios
[0072] Administration scenarios for emergency access may include one or more of the following functions.
[0073] One function may be to provide an emergency access role or ID management. Specifically, emergency access roles and IDs may allow emergency users to access the features and data in the target system or application. These roles and IDs are specific to the target application. They may be incorporated into the authentication assertion in order to initiate an emergency access session.
[0074] A second function may be to provide user administration and assignment. Specifically, upon selecting and assigning a role to a user, access to the dashboard is available.
[0075] FIG. 6 is a simplified flow diagram of a process flow 600 according to an embodiment. The top row of FIG. 6 comprises steps of a process of administering emergency access roles and IDs. In a first step 601 , IDs and roles are extracted from target systems. Following a workflow and approval process 602 , in step 603 IDs and Roles are stored in a repository.
[0076] The second row of FIG. 6 shows steps for the assignment of users. Step 604 shows selection and assignment of roles to a user. Following a workflow and approval process 605 , step 606 shows storing at the Emergency Access Dashboard, a list of IDs accessible to an authenticated user. The embodiment of the access management scheme outlined in FIGS. 2-2A then become available.
[0077] Another administrative function may be to allow review of activity logs after or even during an access session that has been opened. FIG. 7 is a simplified flow diagram showing a process 700 of review of activity log by system/role/or ID Owner. In a first step 701 , activity logs are searched for session data tagged with emergency IDs. In a second step 702 , all system and PEP activity logs are collected and correlated. In a third step 703 , activity data may be joined and filtered based on defined rules. In a fourth step 704 , workflow review of activity may by ID/Role/System Owner may be initiated.
[0078] FIG. 4 illustrates hardware of a special purpose computing machine configured to perform access management according to an embodiment. In particular, computer system 400 comprises a processor 402 that is in electronic communication with a non-transitory computer-readable storage medium 403 . This computer-readable storage medium has stored thereon code 405 corresponding to a rule engine. Code 404 corresponds to an activity log (e.g. a supplemental activity log of a PEP) that may be generated.
[0079] Code may be configured to reference data stored in a database of a non-transitory computer-readable storage medium, for example as may be present locally or in a remote database server. Software servers together may form a cluster or logical network of computer systems programmed with software programs that communicate with each other and work together in order to process requests.
[0080] An example computer system 510 is illustrated in FIG. 5 . Computer system 510 includes a bus 505 or other communication mechanism for communicating information, and a processor 501 coupled with bus 505 for processing information. Computer system 510 also includes a memory 502 coupled to bus 505 for storing information and instructions to be executed by processor 501 , including information and instructions for performing the techniques described above, for example. This memory may also be used for storing variables or other intermediate information during execution of instructions to be executed by processor 501 . Possible implementations of this memory may be, but are not limited to, random access memory (RAM), read only memory (ROM), or both. A storage device 503 is also provided for storing information and instructions. Common forms of storage devices include, for example, a hard drive, a magnetic disk, an optical disk, a CD-ROM, a DVD, a flash memory, a USB memory card, or any other medium from which a computer can read. Storage device 503 may include source code, binary code, or software files for performing the techniques above, for example. Storage device and memory are both examples of computer readable mediums.
[0081] Computer system 510 may be coupled via bus 505 to a display 512 , such as a cathode ray tube (CRT) or liquid crystal display (LCD), for displaying information to a computer user. An input device 511 such as a keyboard and/or mouse is coupled to bus 505 for communicating information and command selections from the user to processor 501 . The combination of these components allows the user to communicate with the system. In some systems, bus 505 may be divided into multiple specialized buses.
[0082] Computer system 510 also includes a network interface 504 coupled with bus 505 . Network interface 504 may provide two-way data communication between computer system 510 and the local network 520 . The network interface 504 may be a digital subscriber line (DSL) or a modem to provide data communication connection over a telephone line, for example. Another example of the network interface is a local area network (LAN) card to provide a data communication connection to a compatible LAN. Wireless links are another example. In any such implementation, network interface 304 sends and receives electrical, electromagnetic, or optical signals that carry digital data streams representing various types of information.
[0083] Computer system 510 can send and receive information, including messages or other interface actions, through the network interface 504 across a local network 520 , an Intranet, or the Internet 530 . For a local network, computer system 510 may communicate with a plurality of other computer machines, such as server 515 . Accordingly, computer system 510 and server computer systems represented by server 515 may form a cloud computing network, which may be programmed with processes described herein. In the
[0084] Internet example, software components or services may reside on multiple different computer systems 510 or servers 531 - 535 across the network. The processes described above may be implemented on one or more servers, for example. A server 531 may transmit actions or messages from one component, through Internet 530 , local network 520 , and network interface 504 to a component on computer system 510 . The software components and processes described above may be implemented on any computer system and send and/or receive information across a network, for example.
[0085] In conclusion, technology trends may call for organizations to deploy multiple types of systems/applications to manage and support business activities. Conventionally, each of those technologies employed different types of emergency/urgent access management schemes.
[0086] In order to satisfy business continuity, system security, and regulatory compliance considerations, embodiments as described herein accordingly provide organizations with a consistent solution for managing emergency and urgent access for privileged user accounts and monitoring and reviewing session activities. Embodiments provide emergency and urgent access management that delivers consistent processes across systems and applications, supported by logging activities facilitating a common activity review.
[0087] Moreover, certain embodiments may address performance issues related to activity logging (e.g. processing resources consumed by logging) through dynamic configuration of the logging levels of front end (system) logging and any supplemental logging, based on system authorization information. Combining system logs with supplemental authorization logs facilitates thorough tracking of user activities during access sessions.
[0088] The above description illustrates various embodiments of the present invention along with examples of how aspects of the present invention may be implemented. The above examples and embodiments should not be deemed to be the only embodiments, and are presented to illustrate the flexibility and advantages of the present invention as defined by the following claims. Based on the above disclosure and the following claims, other arrangements, embodiments, implementations and equivalents will be evident to those skilled in the art and may be employed without departing from the spirit and scope of the invention as defined by the claims.
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Embodiments dynamically manage privileged access to a computer system according to policies enforced by rule engine. User input to the rule engine may determine an extent of system access, as well as other features such as intensity of user activity logging (including logging supplemental to a system activity log). Certain embodiments may provide access based upon user selection of a pre-configured ID at a dashboard, while other embodiments may rely upon direct user input to the rule engine to generate an ID at a policy enforcement point. Embodiments of methods and apparatuses may be particularly useful in granting and/or logging broad temporary access rights allowed based upon emergency conditions.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of my co-pending application Ser. No. 253,632, filed May 15, 1972, which was a continuation-in-part of co-pending application Ser. No. 89,929, filed Nov. 16, 1970, now abandoned, which, in turn, was a continuation-in-part of my application Ser. No. 45,558, filed June 11, 1970, now abandoned; of my co-pending application Ser. No. 462,517, filed Apr. 19, 1974, which was a continuation of application Ser. No. 89,929, aforereferenced; of my co-pending application Ser. No. 160,559, filed July 7, 1971, which was a continuation-in-part of application Ser. No. 89,929, aforereferenced; and of my co-pending application Ser. No. 480,097, filed June 17, 1974, which is a continuation of application Ser. No. 160,150, filed July 6, 1971, which was a continuation-in-part of application Ser. No. 89,929, aforereferenced.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to immunochemicalassaying. Immunochemicalassays are proving of immense value in medicine and biology for assaying liquid samples, especially, for example, body fluid samples such as blood or urine, because of the sensitivity and specificity of such assays. The present invention is concerned with assaying for phenobarbital, phenyl methyl barbituric acid and mephobarbital and related hydrantoin compounds, including diphenyl hydantoin. Accurate assay of these substances is of the utmost value in medical diagnosis and control of drug abuse.
In immunoassaying procedures, for a given target compound, a synthetic antigen is generally first prepared. Heretofore, this has usually been accomplished by coupling the target compound, through a coupling group to a carrier which confers antigenicity to the entire compound. The compound coupled to the carrier is usually known as a hapten and, when coupled, it functions as an antigenic determinant so that the antibodies produced will bind with the hapten. Thus, the antibodies produced should have a distinct and unique character, such that they will bind with only a specific compound or class of compounds. The objective in devising the synthetic hapten-carrier conjugate is to provide a compound which will generate antibodies that are specific to the target compound.
Antibodies are prepared by injecting the synthetic hapten-carrier conjugate into mammals and recovering blood serum from the mammals after they have had time to generate antibodies. Typical mammals are rabbits and goats.
The principal problem is usually that of synthesizing antigens that are capable of producing sufficiently specific antibodies. Biological fluids such as blood and urine frequently contain very closely related compounds and it is common for antibodies to be unable to distinguish the target compound from close relatives, or sometimes even from distant ones. The antibody is then considered to be a poor one and is said to have low specificity and high cross-reactivity.
The assay itself is commonly a competitive binding assay. In a useful embodiment of such an assay, the target compound, which is not necessarily extracted, is allowed to compete with known quantities of a labeled standard to bind with a known quantity of specific antibody. From measurement of the proportion of the labeling in the standard-antibody complex that results, the amount of target compound present can be calculated. Radioactive labeling is particularly convenient. Fluorescence perturbation and electron spin resonance have been used in the art. Normally it is necessary to remove any unreacted labeled standard, before making the determination on the antibody complex, although theoretically, the determination could be made on the removed unreacted portion of the standard.
2. Prior Art
Spector U.S. Pat. No. 3,766,162 discloses a radioimmunoassay for barbituric acids using antibodies generated by synthetic antigens, the subject of the patent. The antigen comprises a barbituric acid hapten coupled to a protein carrier. The barbituric acid has a 5-substituent and is coupled to the carrier by a peptide bond to that substituent. Spector reports, col. 5, lines 41-43, that the antibody will not differentiate between barbituric acids having different substituents in the 5 position.
Spector mentions phenyl as an example of aryl groups among the list of possible derivatives at the 5 position (col. 3, line 5) and states that the bartituric acid derivative may be disubstituted.
The listing of 5-position derivatives in column 3 of Spector also includes mention of other aromatic groups, namely (lines 13-14) carboxy-substituted aralkyl groups e.g. p-carboxy-benzyl, p-carboxy-α-methyl-benzyl. It will be noted that these groups have an alkyl group connecting the phenyl ring to the barbituric acid ring.
It is clear that the point of coupling is to a carboxy or amino group on a 5 substituent (col. 2 lines 68-71) and many of the possible derivatives listed in column 3 carry carboxyl groups. The Spector patent (col. 3, lines 14-19) states that these carboxyls can be converted to amines.
The general teaching of Spector is that antibodies produced from these antigens will bind with barbituric acids that are mono or di-substituted in the 5 position (col. 2 lines 33-36; col 4 lines 45-57; col. 5 lines 12-15 and 36-55; and col. 7 lines 3-10). The antibodies generally bind with barbituric acids substituted in the 5-position while being able to discriminate some variations elsewhere in the molecule, notably substitution at the 1 or 3 position and a 2-thio derivative (col. 5 lines 36-55 and Col. 7 lines 3-10). It appears that antibodies produced from any one antigen can be expected to bind with any 5-substituted 1, 3-unsubstituted barbituric acid. The particular character of the 5-substituent does not appear to be important. Thus it may be selected from the long list of derivative groups recited at the head of column 3. Further, these derivatives can be extended by reaction of a carboxyl derivative with a diamine, col. 3 lines 19-23.
Column 4, lines 54-57, states inter alia that the antibody will selectively complex with "the substituted barbituric acid". Presumably this is "The barbituric acid derivative" described in the paragraph at column 2, line 64, which according to lines 68-71 must include on the 5-substituent a carboxyl or amino group. There is however no report of the complexing of antibody with such a carboxyl or amino containing barbituric acid.
This invention differs from the Spector patent in that coupling to the carrier is through the meta or para position on the phenyl ring of the hapten compound. The resulting antigen raises an antibody which is specific to the respective hapten compound used. The Spector coupling is to a carboxyl or amino group in the 5 position and the resulting antibodies are not specific to either of the three barbituric acid target haptens, such as phenobarbital, included in this invention.
In fact, as Spector states (col. 5, lines 41-43): "the antibody will not differentiate between barbituric acids having different substituents in the 5-position."
BRIEF DESCRIPTION OF THE INVENTION
This invention provides an antigen based on a target hapten comprising the 5-alkyl, 5-phenyl barbituric acids of phenobarbital, phenyl methyl barbituric acid and mephobarbital or comprising related 5, 5' phenyl hydantoin compounds hereinafter described.
The target hapten is coupled to a carrier (which confers antigenicity) through a meta or para azo group on the phenyl ring.
An antibody raised in animals, using an antigen of this invention, shows improved specificity when used in an assay for the target hapten.
The barbituric acid targets haptens of this invention are disubstituted 5-alkyl-5' -phenyl barbituric acids selected from the class consisting of: ##SPC1##
The phenyl hydantoin target haptens of this invention have the following formula: ##SPC2##
in which X is hydrogen, methyl or ethyl and Y is hydrogen, ethyl or phenyl.
By way of advance over the Spector patent (U.S. Pat. No. 3,766,162) this invention provides an antigen in which a 5-alkyl-5'-phenyl barbituric acid, coupled to a carrier through an azo group meta or para on the phenyl ring, provides an antibody which shows substantial discrimination of barbituric acids having various substituents at the 5 position.
The Spector patent does not contemplate such discrimination or such method of coupling.
DETAILED DESCRIPTION OF THE INVENTION
An antigen according to this invention may be prepared by selecting a phenyl substituted barbituric acid or hydantoin hapten target compound corresponding to one of the formulas (1)-(4) set forth above and introducing an amino group meta or para on the phenyl ring. The amino group is then diazotized and coupled to a diazotizable carbon of an aromatic ring which is coupled to a carrier to confer antigenicity.
Conveniently, the aromatic ring will already be present on the carrier, as is the case with, for instance, natural proteins containing tyrosyl or histidyl groups, and the coupling in that case would be made directly to the carrier. However, the ring could be introduced on the carrier before coupling, or the diazonium salt of the hapten could be coupled to a suitable aromatic compound such as a hydroxyaromatic acid, e.g. salicyclic acid or p-hydroxyaniline, which may then by conventional means be coupled to the carrier.
Preparation of those amines of the phenyl barbituric acids and phenyl hydantoins is known to the art. For example, Butler in J.P.E.T. Vol. 116 (1956) pp 326-7 describes the nitration of phenobarbital followed by its reduction to the amino. Some exemplary conditions for nitration, reduction and carrier coupling are as follows. These procedures, while described in terms of phenobarbital, are applicable to all the compounds of formulas (1)-(4).
Nitration
This is generally a standard organic chemistry nitration of a phenyl ring. Some practical details will be mentioned however, as exemplary, to demonstrate the reaction.
The temperature is controlled throughout the nitration to lie between -10° and 10° C to reduce the vigor of the reaction. From 1 to 30 percent, by weight, and preferably around 20 percent of the alkylphenyl barbituric acid is dissolved in concentrated sulfuric acid and up to 20 percent molar excess of fuming nitric acid is added, dropwise, maintaining the temperature at from -10° to 0° C. The mixture is stirred for from 30 minutes to 4 hours to complete the reaction. It is then allowed to come to room temperature, which may complete the reaction if the stirring was inadequate, and poured onto an ice/water mixture to precipitate the reaction product, 5-alkyl-5' nitrophenyl barbituric acid. This is filtered off and preferably recrystallized for which acetone/ether can be used. Normally, for specificity of the antibody, a single isomer will be desired and, accordingly, fractional crystallization may be necessary to separate the meta and para isomers. When an isomeric mixture is produced, the separation can, if desired, be made after the next reduction step.
Reduction
This, too, is generally a standard organic chemistry reduction or hydrogenation of a nitrophenyl to the amine, and any known procedure can be used provided, of course, that the phenyl ring is not hydrogenated as well. Some possible practical details will however be described, as exemplary, to demonstrate the step.
From 1 to 10, and preferably about 4 percent, by weight, of the 5-alkyl-5'-nitrophenyl barbituric acid from the preceding step is dissolved in ethanol and a palladium/carbon catalyst is added. The mixture is then shaken at room temperature under from 1 to 5, and preferably about 2, atmospheres gauge of hydrogen. This is continued to completion as indicated by measurement of the quantity of hydrogen absorbed. Also, the solution clarifies from an initially yellowish color as the reaction proceeds.
The catalyst is filtered off, the solvent evaporated and the 5-alkyl 5'-aminophenyl barbituric acid recovered by recrystallization from an ether/petroleum ether solvent. The product can be fractionally crystallized if necessary.
Diazotization
This is a standard reaction and the conditions and reagents known to be effective can be employed. However, some exemplary conditions will be described. In this reaction the 5-alkyl 5'-aminophenyl barbituric acid is diazotized and coupled to the aromatic ring of the carrier.
Two aqueous solutions are prepared at 0°-5° C. One is a solution of the derivatized barbituric acid acidified with HCl to a p H of from 0.5 to 2.0, preferably from 1.0 to 1.5. The concentration is dictated by convenience and solubility, being from about 0.1 to 10 percent by weight, barbituric acid with approximately 4 percent being preferred. The other solution is a simple, aqueous solution of sodium nitrite which, for example, can be a 1 percent solution.
At a temperature of from 0° to 5° C, the sodium nitrite solution is added, dropwise, to the barbituric acid solution, to an end point with potassium iodide-starch paper. Excess nitrous acid is decomposed with sulfamic acid. Under the acid conditions, the diazonium compound forms the salt.
Carrier coupling
The carrier is dissolved at about 0.1 weight percent preferably in an aqueous medium at a p H adjusted to be from 9 to 11 with sodium hydroxide. The diazonium solution from the previous step is added, dropwise to this solution at a temperature maintained at from 0° to 5° C, maintaining also the pH at from 9 to 11 with sodium hydroxide. The mixture is stirred to completion of the reaction which takes from about 20 minutes to 1 hour.
Desirably the product is dialyzed for from 4 to 10 days with a phosphate buffer to reduce the p H to a physiologically compatible level of from 7.4 to 7.6. An injectable solution can then be obtained that can be used directly for raising antibodies. Alternatively, the solution can be lyophilized to recover the solid carrier-diazo-5 alkyl -5' phenyl barbituric acids synthetic antigen conjugate.
In order to be capable of conferring antigenicity, the carrier will normally be antigenic itself, although it may be an incomplete antigen, becoming complete only when coupled to the hapten. To be antigenic, the carrier must be an immunogenic substance, that term being used to refer to a substance capable of eliciting production of antibodies in a host animal to which the immunogenic substance is administered. While, in general, it is believed that the terms "carrier" and "immunogenic substances" are clearly understood in the art, and the discussion herein is not meant to modify the ordinary significance of the terms, further definition is provided here for a clearer understanding of the development.
The animal to which the antigenic substance is administered must be one having an effective immunological system. The immunogenic substances must be "foreign" to the animal, in the sense of not being "self." That is, the immunogenic substance administered must not be one which is a natural body substance of the animal and would, therefore, be accordingly tolerated by the animal's immunological system.
Generally, the antibodies elicited upon injection of the immunogenic substance into the animal will be generated by the host animal and will be capable of reacting or binding with the antigen in an observable and selective way. Thus, the antibodies will display some degree of discrimination between the administered immunogenic substance and other immunogenic materials.
The requirements for immunogenicity are not fully understood. However, it appears that for a molecule to be antigenic, it must have a certain complexity and a certain minimal molecular weight. Formerly, it was thought that the lower molecular weight limit to confer antigenicity was about 5,000. However, antigenicity has recently been demonstrated with molecules having molecular weights as low as 2,000. Molecular weights of 3,000 and more appear to be more realistic as a lower limit for immunogenicity, and approximately 6,000 or more is preferred.
Exemplary immunogenic carrier materials are those set forth in Cremer et al., "Methods in Immunology" (1963), W. A. Benjamin Inc., New York, pages 65 to 113. That disclosure is herein incorporated by reference. The carrier material can be a natural or synthetic substance, provided that it is an antigen or a partial antigen. For example, the carrier material can be a protein, a glycoprotein, a nucleoprotein, a polypeptide, a polysaccharide, a lipopolysaccharide, or a polyaminoacid. An example of an apparently incomplete antigen is the polypeptide glucagon.
A preferred class of natural carrier materials is the proteins. Proteins can be expected to have a molecular weight in excess of 5,000, commonly in the range of from 34,000 to 5,000,000. Specific examples of such natural proteins are bovine serum albumin (BSA), keyhole limpet hemocyanin (KLH), human immunogammaglobulin (HGG), and thyroglobulin.
Exemplary of the synthetic carrier is a polyaminoacid, polylysine. Where the synthetic antigen comprises a partially antigenic carrier conjugated with a hapten, it will generally be desirable for the conjugate to have a molecular weight in excess of 6,000, although somewhat lower molecular weight may be useful.
Preferably, the natural carrier has some solubility in water or aqueous alcohol. Also preferably, the synthetic antigen is water soluble. Desirably, the carriers are non-toxic to the animals to be used for generating antibodies.
The carrier must have a, or preferably a plurality of, functional moieties by means of which it can be coupled. Of course, these groups can be introduced synthetically. Preferably, in practicing the present invention, a single carrier moiety should have a plurality of hapten moieties coupled to it, for example, from about 10 to about 70. In general, the maximum possible number of haptenic moieties per carrier molecule is preferred. Subject to steric hindrance, the maximum number will be determined by the number of reactive coupling groups on the carrier. For example, with BSA, it appears that the maximum number of haptenic moieties that can be coupled is between 60 and 70.
In preparing the antigens of the invention it is, as a practical matter, very desirable to obtain them with a high degree of purity. High antigen purity appears to be an important requisite for optimum antibody production. Accordingly, it is desirable for the process to provide for isolation of the antigen from antigenically distinct materials. The latter will normally be undesired large molecules that may confuse the immune response of animals used for producing antibodies. A feature of the process of the invention is that it is designed to minimize the formation of such undesired antigenically distinct materials.
Removal of small molecule reactants and reaction products is generally desirable, particularly if they are likely to couple to the carrier. However, some small molecule substances may be useful, for example for p H control. Thus a convenient end-product form in which to recover the antigen is in a buffered aqueous solution which is suitable for direct administration to animals.
The process of the invention can accordingly include a number of purification steps using well-known techniques such as column chromatography, dialysis and recrystallization. Further it will be generally desirable to use high purity reactants. For a natural protein carrier commercially available high purity fractions are desirable.
Antibodies can be raised by administration of an antigen of the invention to mammals such as goats or rabbits, using known immunization procedures. Usually a buffered solution of the antigen accompanied by Freund's adjuvant is injected sub-cutaneously at multiple sites. A number of such administrations at intervals of days or weeks is usually necessary. A number of animals, for example from three to twenty, is so treated with the expectation that only a small proportion will produce good antibodies. However, one goat producing high quality antibodies can provide sufficient for several hundred thousand assays. The antibody is recovered from the animals after some weeks or months.
The assay, according to the present invention, is an immunochemical method of assaying for the presence of a target according to the present invention, that target being contained in a sample. The method employs an antibody obtained by the immunologic response of a vertebrate animal to administration of an antigen according to the present invention, and the antibody is specific to the target. Further, the assay employs a standard, the standard and target competitively binding with the antibody to form an antibody-standard complex and an antibody-target complex. The antibody-standard complex has an artificially introduced radiation label so that the complex can be assayed quantitatively by measurement of the radiation emanating from it. In order for the method to be properly employed, the affinities of the antibody for the standard and for the target must be known quantitatively. In employing the method, a known quantity of the sample and a known quantity of the standard are allowed to compete for binding with a known quantity of the antibody. The radiation emanating from the antibody-standard complex so formed is determined so that the quantity of antibody-bound standard can be calculated and the quantity of target in the sample can be deduced. This deduction is carried out by attributing any difference between the quantity of bound standard determined and the quantity expected, based on the known binding characteristics of the antibody, to binding of the antibody with the target.
In an embodiment of the assaying procedure, the introduced label is radioactive and the antibody-standard is separated from any non-complexed, labeled material after allowing competition binding and before determination of the radiation emanated.
In another embodiment of the assaying method, the introduced label is fluorescent and the standard is provided with a chemical moiety giving it a fluorescence spectrum overlapping the natural fluorescence spectrum of the antibody. The complex can then be assayed by measurement of the perturbation of the antibody fluorescence due to binding with the standard.
The standard is a substance known to bind with the antibody and can be, for example, the target, the antigen used to raise the antibody, or the hapten used to make the antigen. Similarly, it can be a similar antigen having the same hapten bound to a different carrier, but at the same position on the hapten. Conveniently, where the radiation constitutes radioactive emission, such as beta or gamma rays, the standard can carry the radioactive label in the form of a radioactive isotope, e.g., tritium, I 125 , or C 14 , although, as an alternative, the antibody can be labeled.
When separation of the complex from the unreacted standard is necessary, as is normally the case with radioactive labeling, this can be effected by phase separation, insolubilizing of one of the components to be separated, etc. Thus, with a labeled antibody, the use of an antigenic standard having a plurality of antibody binding sites causes the antibody-standard complex to precipitate while, if the target is a small molecule, the antibody-target complex will remain in solution. Alternatively, the antibody can be insolubilized, as described elsewhere in the specification, and the standard labeled, so that unreacted standard stays in solution and can easily be separated from the complex.
One example of such a separation is the addition of saturated ammonium sulfate to the complexed mixture. The mixture, with the added ammonium sulfate, is then centrifuged which results in deposition of most of the protein, including the antibody-standard complex. The antibody-standard complex can then be removed as a solid and measurement carried out on this solid. Alternatively, the uncomplexed liquid standard is subjected to measurement or radiation emanation.
A further possibility is to absorb the standard with dextran-charcoal, after allowing for competition binding, and to then make the scintillation count for radiation on the liquid phase containing the antibody-standard complex following separation of the solid phase which contains the unreacted standard. In this case, the standard is labeled and is a small molecule, especially a radioactive isotope labeled target molecule.
While the count for radiation is normally made upon the antibody-standard complex, as this is either more convenient or is believed to reduce experimental error, it will be clear that where there is a separation of unbound, labeled material from the antibody-standard complex, the determination of the radiation emanating from the antibody-standard complex can equally well be made by measuring the radiation emanating from the unreacted, labeled material. From this measurement, the difference from the known amount of labeled material added can be calculated.
The term "radiation" is used in an ordinary dictionary sense and refers to energetic emissions originating from individual atoms or molecules which are generally attributed to internal changes within the atom or molecule. These emissions are in contrast to physical phenomena, such as, for example, precipitations which are the result of the inter-molecular or inter-atomic effects, and may require a large-scale cooperation of a great number of atoms or molecules to be meaningfully expressed. Radiation is significant for immunoassays as it provides a means of remotely monitoring the behavior of very small quantities of matter.
Thus, in addition to energetic emissions, radiation includes such phenomena as fluorescence and electron spin resonance. Fluorescence usually requires excitation by exposure to ultraviolet light, but the product is radiation. Thus, energy, usually in the form of light, is emitted as a result of intra-molecular change.
Where fluorescence is the form of radiation measured, it is feasible for the assay to be conducted without any separation of materials. Thus, antibodies, which are naturally fluorescent, have an absorption spectrum and an emission spectrum. If the standard chosen is a molecule having, as a label, a chemical group which fluoresces in spectra overlapping the antibody, then, when the standard complexes with the antibody, the natural fluorescence of the antibody is perturbed by that of the standard, and this perturbation can be measured. When the emission spectrum of the standard overlaps the absorption spectrum of the antibody, fluorescence enhancement will be observed from the complex at the antibody emission wavelength, and when the absorption spectrum of the standard overlaps the emission spectrum of the antibody, fluorescence quenching will be observed from the complex at the antibody emission wavelength. Comparable effects can be displayed using polarization perturbation.
Electron spin resonance labeled assays can also be conducted without the need for separation. A para-magnetic labeling group, such as a nitroxide ring, is attached, for example, to the standard. When subjected to a microwave frequency magnetic field, an electron spin resonance spectrometer can detect distinct resonance peaks characteristic of the nitroxide ring label. When the standard combines with antibody, these peaks are substantially extinguished, providing a direct indication of the degree of binding.
The following examples illustrate the invention.
EXAMPLE 1
a. Synthesis of 5- (m-nitrophenyl) 5-ethylbarbituric acid (m-nitrophenobarbital)
10 gm. of phenobarbital is added to 40 ml. of ice-cold, concentrated sulfuric acid. A nitrating mixture of 2.2 mls. of fuming nitric acid in 10 ml. concentrated sulfuric acid is added drop-wise to the stirred reaction mixture using a mechanical stirrer while maintaining the temperature between -10° to 3° C. Stirring is continued for an hour after the nitrating mixture is added. The reaction mixture is poured into 600 ml. of an ice-water mixture and filtered when cold. The white precipitate is washed repeatedly with water until neutral to litmus and then dried under vacuum.
Several recrystallizations of the crude material from 95% ethanol gave 5- (m-nitrophenyl) -5-ethyl barbituric acid with a melting point of 283°-284° C.
b. Preparation of 5-(m-aminophenyl)-5-ethyl barbituric acid (m-aminophenobarbital)
2 gm. of m-nitrophenobarbital from (a) is suspended in 25 ml. ethanol and hydrogenated at 30 psig. and room temperature using 100 mg. Pd/C (10%) as catalyst. The hydrogenated solution is filtered to remove catalyst and the solvent is removed on a rotary evaporator. Several crystallizations from an ethanol-ether solution yield pure 5-(m-aminophenyl)-5-ethyl barbituric acid with a melting point of 208°-209° C.
c. Coupling of m-aminophenobarbital to keyhole limpet hemocyanin (KLH)
50 mg of m-aminophenobarbital from (b) is dissolved in 1 ml. of 1N HCL and the solution cooled to 0°-5° C. To it is added a cold (0°-5° C) solution of sodium nitrite (15 mg) in 0.5 ml water to an end point with starch iodide paper. Excess nitrous acid is decomposed with a few crystals of sulfamic acid. The cold diazonium salt solution is added drop-wise to a cold (0°-5° C) solution of 600 mg. KLH in 10 ml. water adjusted to pH 10.5 with 2N sodium hydroxide. During the addition the pH is maintained between 9 and 11 with 2N sodium hydroxide and the temperature is maintained at 0°-5° C. After the addition is complete the solution is stirred at 0°-5° C for 1 hour at pH 10.5. It is transferred to a dialysis tubing and dialyzed against 6L of 0.5 % sodium carbonate for 6 days with daily changes of the sodium carbonate solution.
It is next dialyzed against 6L of pH 7.4-7.6 sodium phosphate buffer for 4 days with daily changes of the buffer solution.
The optical density at 280 nm. is about 1.1 on a 0.1% solution.
EXAMPLE 2
The procedure of paragraph (a) of Example 1 is repeated except for the recrystallization step. The m - and p - nitrobarbital isomers from that procedure were hydrogenated according to the procedure of paragraph (b) of Example 1. P-aminophenobarbital was recovered by repeated recrystallization. It was then coupled to KLH according to the procedure of paragraph (c) of Example 1 to give results equivalent to those obtained in that Example.
EXAMPLE 3
Examples 1 and 2 are successively repeated using equivalent amounts of bovine serum albumin, human immuno gammaglobulin and thyroglobulin in place of the KLH. Equivalent results are obtained.
EXAMPLE 4
The procedures of Example 1, 2 and 3 are successively repeated using phenyl methyl barbituric acid in place of phenobarbital. In each case equivalent results were obtained.
EXAMPLE 5
The procedures of Examples 1, 2 and 3 are successively repeated using mephobarbital in place of phenobarbital. In each case equivalent results were obtained.
Raising of Antibodies
Approximately 2 mg. doses of antigen in 0.1% aqueous solution with Freund's adjuvant are injected at multiple, subcutaneous sites in rabbits. The injections are repeated at intervals according to known immunization procedure. The rabbits are bled at intervals and the active serum is collected and used without purification.
Radioimmune Assay
The radioimmune assay is performed by incubating various dilutions of antisera obtained from animal bleedings, with tritiated phenobarbital in the presence of buffer at 4° C. After 2 hours a neutral, saturated ammonium sulfate solution is added. The resultant precipitates are sedimented by centrifugation at 3,000 for 15 minutes at 4° C and the supernates are decanted off. Aliquots of 0.5 ml. water and 10 ml. Aquasol are counted for labeled phenobarbital. The addition of increasing amounts of unlabeled phenobarbital to a fixed amount of labeled phenobarbital and antiserum results in a competitive inhibition of the labeled phenobarbital bound to antibody.
This enables a standard curve for the antibody to be established showing the variation of inhibition of binding with concentration.
The specificity of the antibody is then determined by allowing for competitive binding of known concerntrations of the antibody with known concentration of the labeled standard and successive potential cross-reactants. The cross-reactivity is defined according to the method of Abrahams as the relative quantity of target to cross-reactant that produces 50% inhibition multiplied by 100 for percentage.
When the product of Example 1 is used to raise antibodies, and these are used in a radioassay, as previously described, the cross reactivity (at 50% inhibition) of other barbituric acids is as follows:
______________________________________Compound Percent Cross-Reactivity______________________________________Pentobarbital 2.2Secobarbital 1.8Amobarbital 0.6Thiopental 0.2______________________________________
EXAMPLE 6
The procedures of Examples 1, 2 and 3 are successively repeated using 5, 5' diphenyl hydantoin. In each case equivalent results were obtained.
Following the procedures of Examples 1 and 2 dinitro diphenyl hydantoin compounds are obtained. In converting the two resulting amine groups to azo groups and coupling to a carrier one of the azo groups couples to the carrier and the other results in a hydroxyl group under the coupling conditions. Small amounts of interlinked high, molecular weight material, in which each azo group is linked to a carrier, may be obtained. Such material may be removed by known chromatographic methods. An antibody raised to the antigen of this Example may be used to assay for diphenyl hydantoin, or any phenolic metabolite of that compound.
EXAMPLE 7
The procedures of Examples 1, 2 and 3 are successively repeated using 5 ethyl, 5' phenyl hydantoin. In each case equivalent results were obtained.
EXAMPLE 8
The procedures of Examples 1, 2 and 3 are successively repeated using 3 methyl, 5 phenyl hydantoin. In each case equivalent results were obtained.
If desired, the antibodies of this invention can be insolubilized, or otherwise supported, on a solid matrix. Examples of materials to which the antibody can be attached are glass, synthetic polymers, synthetic resins, and cellulose. The material to which the antibody is attached or otherwise insolubilized can have an extensive, continuous form, such as a sheet, or it can be in the form of discrete particles of desired size. The antibody can be secured to the material in a number of ways.
Among the methods for attaching or otherwise insolubilizing the antibody to a solid matrix are covalent bonding, van der Waal's forces, hydrogen bonding, etc. Thus, the methods for attaching the antibody to the solid matrix are relatively weak intermolecular forces, covalent bonds, or the adsorptive forces attributable to a porous surface. An example of van der Waal's forces occurs with the adhesion of an antibody to a predominantly hydrophobic plastic surface, such as a polyolefin. Apparently, there is hydrophobic bonding to the hydrophobic amino acid residues of the antibody.
Some of the methods for bonding of the antibody to a solid matrix are discussed in Weliky and Weetall, Immunochemistry, Vol. 2, pages 293-322 (1965).
Another method for conveniently covalently bonding the antibody to a solid is by diazotizing available amino groups on the antibody into available, activated, aromatic rings on the solid material.
It may be desirable to modify the material, particularly for the purpose of securing the antibody to it. Thus, for covalent bonding, carbodiimide condensation, with the formation of an amide bond between the antibody and the material, can be used. For this purpose, the material should have available primary, non-aromatic amine groups or carboxyl groups to couple with, respectively, available carboxyl or amino groups on the antibody. An amino glass suitable for this purpose is known. Suitable synthetic resins or polymers may be available, in addition, or existing resins can be modified. Similarly, many derivatized celluloses are known, and cellulose can, in general, be provided with appropriate groups.
In attaching the antibody to the substrate material, it is normally desirable to ensure that the active binding site of the antibody remains available and accessible. This can be facilitated by blocking the site before coupling to the support material, and unblocking thereafter. Blocking can be conveniently effected by complexing the antibody with the hapten for which it is specific and deblocking can be effected with an eluting agent, for example, acetic acid or urea.
For sorption on a porous surface, another method for insolubilizing the antibody on a solid matrix, it is desirable for the pore size of the material, e.g., porous particles, to be selected for optimum accommodation of the antibody.
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Antigens comprising 5,5'-alkylphenyl barbituric acid haptens and related 5,5'-phenylhydantoin haptens coupled to a carrier through an azo group connected meta or para on the phenyl ring are prepared by diazotization of the corresponding amine. Specific antibodies are raised in animals and used in radioimmuno assays for the corresponding hapten.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/601,358 filed Aug. 13, 2004, entitled “Termite, pest and fungi prevention system/wood protection.” This prior application is hereby incorporated by reference in its entirety for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates to the prevention of pests such as termites and fungi or other general pests inside and outside of homes and buildings.
BACKGROUND OF THE INVENTION
[0003] In the United States control and damage repair costs due to Subterranean Termites ( Reticulitermes ssp.) exceed $ 5 billion per year world wide (Su & Scheffrahn) and $2.5 billion in the U. S. and over $300 million in California a decade ago (Brier, Dost, & Wilcox 1988). Chemical barriers have been the dominant means of protecting the multi billion dollar national investment in the wood service for more than 50 years. Since the early 1940's when hydrocarbons were shown to have biological activity against insects, chemical barriers have been the mainstay of the pest control industry in combating termite and pest infestations. The risk homeowners face in having termite and pest infestation is substantial; 30% of all structural pest inspections reports (over 1.5 million conducted per year) reveal signs of active termites (Brier, Dost, & Wilcox 1988). Researchers predict almost 100% of untreated homes in regions of the country will eventually be infested with termites and or pests, according to a September 1999 workshop on termites sponsored by the (National Park Service in Louisiana) a state hard hit by the termite.
[0004] Other background insects include but not limited to are Ants which some are known to exist in cracks in concrete in large mounds several feet in height and from 12 to 18 inches in diameter if left undisturbed for a long period of time ants a social insect that live in well organized colonies. Nearly all of the ants in the colony are the wingless sterile females, called workers typically seen on and around the ant hill (Iowa St. Univ. Dept. of Entomology) like termites in the spring and fall ant colonies may produce winged males and females called swarmers. They disperse from well established nest to begin new colonies. Treatment for these areas onto the surface or drench the area with liquid pesticide is generally a common method of application. But this method is difficult for the cockroach, which has 47 species of the American Cockroach ( Perplaneta Americana ) alone, none of which are endemic to the U.S.(Bell and Adiyodi 1981) the American cockroach came to the United States from Africa as early as 1625 and resides indoors as well as outdoors. It is found mainly in basements, sewers, steam tunnels and drainage systems (Rust et. al 1991). This cockroach is readily found in commercial and large buildings such as restaurants, grocery stores, bakeries and where food is prepared and stored. Also in this background it would also refer to wood destroying fungus known in most circles as Dry Rot, decay fungi can cause severe structural damage to any wood member, even wood species such as redwood and cedar. All that is needed is a source of water in contact with the wood, decay will occur in untreated wood in direct contact with the ground, cement or concrete, or exposed to a source of moisture such as rain seepage, plumbing leaks or condensation. Wood kept dry will never decay! “Brown Rot” fungi feed on the wood's cellulose a component of the wood's cell wall, leaving a brown residue of lignin the substance which holds the cells together. Advanced infestations of brown rot are evidenced by wood more brown in color than normal, tending to crack across the grain eventually it will turn to powder when crushed. White Rot attacks wood, it breaks down both lignin and cellulose, white rot normally does not crack across the grain, gradually it will lose its strength and become spongy to the touch. Moisture content is the critical factor determining wood's susceptibility to decay. It must exceed 28% and liquid water must be present in all cell cavities before fungi can gain a toehold. This is one reason why framing lumber is dried to 19% moisture content or less.
[0005] Accordingly there is a need for novel compositions against termites, pests, and fungi and other wood destroying organisms, there is a need for a method of treating the structure and its surroundings to eliminate these types of pests. The present invention provides novel compositions and devices for control of various insect pests. The current invention also provides additional advantages which will be apparent upon reading of the description, claims, herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 displays the molecular structure of d-Phenothrin 3-phenoxybenzyl(1R)-cis, trans-chrysanthemate, an exemplary pesticide of the compositions of the invention.
SUMMARY OF THE INVENTION
[0007] The subject invention is based on the inventor's discovery that Phenothrin, Disodium Octaborate Tetrahydrate and N-(Hydroyethyl)amide, coconut, has a dramatic effect on termites, pests and fungi and the inventor has also found it to be lethal to these target pests. Other embodiments herein comprise chlorpyrifos and/or permethrin as the pesticide in the compositions, devices and methods.
[0008] Therefore, one aspect of the invention pertains to a novel composition comprising of Phenothrin (or optionally chlorpyrifos and/or permethrin), Disodium Octaborate Tetrahydrate and N-(Hydroxyethyl)amine, coconut in formulation for prevention and treatment of termites, pests and fungi infestations.
[0009] A further aspect of the subject invention relates to novel methods of preventing infestations of termites, pests and fungi with compositions that comprises Phenothrin (or optionally chlorpyrifos and/or permethrin), Disodium Octaborate Tetrahydrate and N-(Hydroxyethyl)amine, coconut on or near a structure desired to be protected. Those skilled in the art will realize that structures include, but not limited to posts, beams, boards, panels, sheets and wood or wood based material, as well as houses and buildings made of wood and wood based materials which can all be treated with the compositions and methods of the invention.
[0010] According to another aspect, the subject invention pertains to treating for termites, pests and fungi infestations. These and other features of the invention will become more fully apparent when the following detailed description is read in conjunction with the accompanying description and claims.
DETAILED DESCRIPTION
[0011] Before describing the present invention in detail, it is to be understood that this invention is not limited to particular embodiments, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not necessarily intended to be limiting. As used in this specification and the appended claims, terms in the singular and the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a composition,” also includes a plurality of compositions, and the like.
[0012] The present invention comprises a compilation of chemicals used as an alternative to common termiticides, pesticides and fungicides. This compilation allows resistance to termites, wood boring beetles, carpenter ants and bees, fungi and other wood destroying organisms and general pests by treating the soil at the exterior and interior portions of the foundations and walls along with treating wood members and around plants. In addition it would be desirable to provide a barrier of protection under, around and on wood components of the structure both pre-construction and post-construction and to incorporate this with under the slab/foundation of the structure this would preserve the properties of the composition and minimize the environmental impact. This Invention is designed to have a longer residual life and doesn't require special equipment and is simple in its application. These ingredients consist of a Termite and Pest killer such as Phenothrin, Chlorpyrifos, Permethrin as an Active ingredient and yet while using a Borate as a dehydrate a Soy Bean Oil, Canola Oil and or Coconut Oil as a attractant these would be considered Inert ingredients. For example: when putting these ingredients together ¾ parts “termite/pest/fungi killer” 3/16 part borate and 1/16 soy/canola/coconut oil, when combining these entities together creates this invention. When these ingredients are in concentrated form and then mixed with water it is in the ideal form for treating the “target pest.” For example: use of a 0.5 to 1.0% emulsion for Termites. Mix 1-4 gallons of the mixture in 98 gallons of water for post-construction treatment by injection or horizontal spraying not exceeding 25-50 p.s.i. at the nozzle, this method of application is especially designed for “rodding and trenching” and also maybe used in a biodegradable form. When in its concentrate form in its professional usage it allows about 4 gallons of emulsion per 10 linear feet per foot of depth. In treating problem pests such as ants, spiders, and sow bugs. For example should be 20 p.s.i. or less when treating these type of insects and should be treated at the infested areas. Note: when treating such pests in areas like these the 0.25 to 0.5% emulsion should apply. To treat or protect against fungus or fungi for Example: can be treated with these entities with 0.25 to 0.5% emulsion spraying the untreated wood members with 20 p.s.i. or less at the nozzle, if the wood should have an existing infection all decay should be removed and the member would be treated to kill the existing spores and to protect the wood itself, all these above methods could and should be applied by professionals. This method of installation is common in most areas of the country. When in its biodegradable form it must be applied to the soil grade adjacent to the foundation wall and should be trenched about 6 to 8 inches in depth and about 6 to 8 inches in width then water is added a few gallons per foot of the Termite, Pest and Fungi/Tubular Prevention Composition or until foam emulsion is established, the soil is covered over the trenched area and the “Composition” allowing it to drain down into the soil and crystallize around the area treated creating a chemical barrier.
[0013] This method and or process may apply to treating around trees, planter boxes, planter boxes, porches and decks. This method of treatment does not require a special license but will require gloves and possible protective eyewear.
[0014] In various embodiments, the current invention comprises a termite/pest/fungi prevention system comprising: phenothrin, chlorpyrifos, and/or permethrin; a borate (e.g., sodium borate, disodium octaborate tetrahydrate); and an oil such as soybean, coconut or canola. Synonyms for coconut oil include, e.g., Amides, coco, N-(Hydroxyethyl); N-(Hydroxyethyl)amide, coconut. Such systems can comprise compositions of, e.g., 75% phenothrin, chlorpyrifos, and/or permethrin; 20% disodium octaborate tetrahydrate; and, 5% oil (e.g., soybean, coconut and/or canola). Other embodiments comprise compositions comprising 25% phenothrin, chlotpyrifos, and/or permethrin; 15% disodium octaborate tetrahydrate; and, 60% oil (e.g., soybean, coconut and/or canola). In other aspects the invention comprises methods of preventing termites, using such composition by obtaining a piece of wood to be treated, and treating the wood with such compositions. Such wood can be used in construction projects similar to untreated wood. Such wood can be treated with the compositions of the invention by spraying the wood (and/or other areas) with a high-pressure sprayer. The compositions of the invention can optionally be diluted prior to their use. For example, the compositions can be diluted to 0.5-1.0%, or by diluting 100-200 times the volume of the composition in water, etc. In other aspects, the invention comprises methods of protecting a building (exterior and/or interior and/or foundation) from pests by, identifying the building to be protected, preparing a composition of the invention, and treating the soil surrounding the foundation of the building with the composition. Other embodiments include, e.g., treating a piece of wood with compositions of the invention and using such treated wood in direct contact with soil, with soil infested with insects/fungi, etc,. in order to kill insects/fungi. Again, the compositions can be diluted prior to use in protection of buildings and the diluted compositions can be applied to the building and its surroundings via a high-pressure sprayer.
EXAMPLE 1
[0015] The goal is to establish a continuous chemical barrier between the termite colony (usually in the soil) and wood in a building. Sometimes there may be a second termite colony above the soil (in the roof or other areas with a constant moisture supply) that requires additional treatment. Insecticide barriers may be established during or after building construction. In an existing building, termite treatments may involve any of the following procedures: a) mechanical alterations and/or b) use of an insecticide to treat the soil, foundation and wood. In most cases, it is beyond the ability of an untrained person to attempt the termite treatment, unless is a spot treatment or a person has work experience in this area.
EXAMPLE 2
[0016] Generally termite treatment should be performed by professional pest control operators. Termite treatment requires special tool such as hammer drills, sub-slab injectors, rodding devices, engines equipped with pumps, protective equipment. These insecticide methods control termites, pests if applied properly.
EXAMPLE 3
[0017] When the compound is in a tubular form of concentrate the component is “Bio degradable” like peat moss rolled in cellophane. This component can be applied by any homeowner as a “do-it-yourself installation and is placed in areas around the structure and foundation were trenching is performed and then the component is placed in the trench water is applied until emulsification then covered over with the trenched soil. This application is useful in the remediation of pests and termites.
[0018] References cited: 1514377 November 1924 Dow et al., pp. 514/730; Rust M K, Reierson D A, Hansgen K H. 1991 210-213; Bell W J, Adiyodi KG 1981 Chapman and Hall, London V. Lewis, M. Haverty, D. S. Carver and C. Fouche—Insecticide Barriers for Control of Reticulitermes ssp. (Isoptera: Rhinotermitidae) Div. of insect Biology, Dept. of Environmental Sciences, U.C. Berkeley,
[0019] While the foregoing invention has been described in some detail for purposes of clarity and understanding, it will be clear to one skilled in the art from a reading of this disclosure that various changes in form and detail can be made without departing from the true scope of the invention. For example, all the techniques and apparatus described above may be used in various combinations. All publications, patents, patent applications, or other documents cited in this application are incorporated by reference in their entirety for all purposes to the same extent as if each individual publication, patent, patent application, or other document were individually indicated to be incorporated by reference for all purposes
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The invention provides compositions, devices, and methods for the control of Termites, General Pests and Fungi, such compositions and devices comprising one or more of Phenothrin, a Borate, and a Plant Oil or a derivative thereof.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to handheld electronic devices and, more particularly, to a handheld electronic device that enables a user to establish a prioritized list of preferred networks to be used in roaming situations. The invention also relates to an improved method of establishing a prioritized list of preferred networks to be used by a handheld electronic device in roaming situations.
2. Description of the Related Art
Numerous types of handheld electronic devices are known. Examples of such handheld electronic devices include, for instance, personal data assistants (PDAs), handheld computers, two-way pagers, cellular telephones, and the like. Such handheld electronic devices are generally intended to be portable and thus are relatively small.
Many handheld electronic devices include and provide access to a wide range of integrated applications, including, without limitation, email, telephone, short message service (SMS), multimedia messaging service (MMS), browser, calendar and address book applications, such that a user can easily manage information and communications from a single, integrated device. These applications are typically selectively accessible and executable through a user interface that allows a user to easily navigate among and within these applications.
Many handheld electronic devices include wireless telephone and data (e.g., email, SMS, Internet) functionality. As is known in the art, wireless services, such as telephone and data services, are provided by way of an air interface involving radio frequency (RF) communications between wireless enabled equipment, such as a handheld electronic device described above, and one or more networks of land based radio transmitters or base stations. Each such network is commonly referred to as a public land mobile network (PLMN). PLMNs interconnect with other PLMNs and the public switched telephone network (PSTN) for telephone communications or with Internet service providers for data and Internet access.
In order to use wireless communications functionality, a user must subscribe with a wireless service provider or operator. The subscription permits the user to utilize the PLMN operated by the service provider or operator (referred to as the “home PLMN”). As is known in the art, roaming is a service offered by PLMN operators which allows a subscriber to use his or her wireless enabled equipment while in the service area of another operator (and outside of the user's home PLMN). Roaming requires an agreement between operators of technologically compatible systems to permit customers of either operator to access the other's PLMN. Service providers or operators typically charge a higher per-minute fee for calls placed outside their home calling or coverage area (the area serviced by their PLMN).
As is also known in the art, devices, such as handheld electronic devices, that include wireless functionality, such as telephone and data functionality, are provided with a subscriber identity module card (SIM card). A SIM card is a small printed circuit board that contains subscriber details, including data that identifies the user to the service provider, security information, and memory for a personal directory of numbers. In addition, the SIM card stores a pre-set, prioritized list of particular PLMNs to be used by the device in roaming situations. The particular PLMNs included in the list are normally based on the marketing preferences of a particular operator. However, as will be appreciated, different PLMNs have differing charges associated with them and offer different levels of reliability and service quality. Thus, a user may desire to use PLMNs other than those pre-stored in the SIM card and/or use PLMNs in a different order of priority than that specified in the SIM card based on issues of cost, reliability, and service quality, among others. Thus, there is a need for an improved handheld electronic device that enables a user to establish a prioritized list of preferred PLMNs to be used in roaming situations.
SUMMARY OF THE INVENTION
An improved handheld electronic device and an associated method enable a user to selectively establish a prioritized list of preferred PLMNs to be used in roaming situations. As a result, a user is able to select particular PLMNs based on issues of PLMN cost, reliability, and service quality, among others.
These and other aspects of the invention are provided by a wirelessly enabled handheld electronic device including an input apparatus, a communications subsystem, a display, a processor, and a memory storing one or more applications executable by the processor. The one or more applications are adapted to display a listing of one or more known networks for which network information is stored in the memory, scan for one or more available networks, which are networks available for use in conducting wireless communications in the area in which the handheld electronic device is currently located, and display a listing of the available networks. The applications are also adapted to enable the entry of information relating to one or more manually entered networks. Furthermore, the applications are adapted to (1) enable the addition of one or more preferred networks to a preferred network list wherein the preferred networks are one or more of: (i) certain of the known networks selected from the listing of known networks, (ii) certain of the available networks selected from the listing of available networks, and (iii) the manually entered networks; (2) enable the assignment of a priority value to each of the preferred networks; and (3) utilize one or more of the preferred networks for performing wireless communications when the handheld electronic device is in a roaming situation, wherein the preferred networks are utilized in a priority order that is based on the priority value assigned to each of the preferred networks.
The communications subsystem may include a SIM card, wherein the applications are further adapted to store the preferred network list in the SIM card. The preferred network list also preferably includes network information for each of said preferred networks, such as the MNC and MCC for each of the preferred networks. The handheld electronic device may also include a thumbwheel that may be used to scroll up and down for data selection purposes.
Preferably, the preferred network list is displayed in a display order corresponding to the priority order. In one case, the priority value of a first one of the preferred networks is a highest priority, and the priority value of a second one of the preferred networks is a lowest priority, and the priority order is sequential beginning with the first one of the preferred networks and ending with the second one of the preferred networks. The applications may be further adapted to enable the movement of a selected one of the preferred networks on the display to create an altered display order, wherein the priority value assigned to one or more of the preferred networks is changed such that the priority order corresponds to the altered display order. In addition, the one or more applications may be further adapted to enable the deletion of a selected one of the preferred networks on the display to create an altered display order, wherein the priority value assigned to one or more of the preferred networks is changed such that the priority order corresponds to the altered display order.
According to another aspect of the invention, a method of establishing a prioritized list of networks to be used by a handheld electronic device in roaming situations is provided. The method includes displaying a listing of one or more known networks upon request of a user of the handheld electronic device, with each of the known networks having network information stored by the handheld electronic device, scanning for one or more available networks upon request of the user, with each of the available networks being available for use in conducting wireless communications in an area in which the handheld electronic device is currently located, and displaying a listing of the available networks. The method further includes receiving information relating to one or more manually entered networks when input into the handheld electronic device by the user. Finally, the method includes adding one or more preferred networks to a preferred network list, the preferred networks being one or more of: (i) certain of the known networks selected from the listing of known networks, (ii) certain of the available networks selected from the listing of available networks, and (iii) the manually entered networks, and assigning a priority value to each of the preferred networks, wherein one or more of the preferred networks are utilized for performing wireless communications when the handheld electronic device is in a roaming situation in a priority order that is based on the priority value assigned to each of the preferred networks.
BRIEF DESCRIPTION OF THE DRAWINGS
A full understanding of the invention can be gained from the following Description of the Preferred Embodiment when read in conjunction with the accompanying drawings in which:
FIG. 1 is a front view of an improved handheld electronic device in accordance with the invention;
FIG. 2 is a block diagram of the handheld electronic device of FIG. 1 ; and
FIGS. 3 through 20 are exemplary views of a portion of the display of the handheld electronic device of FIGS. 1 and 2 that illustrate a routine or routines for enabling a user to selectively establish a prioritized list of preferred PLMNs to be used in roaming situations according to the invention.
Similar numerals refer to similar parts throughout the specification.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An improved handheld electronic device 4 in accordance with the invention is depicted generally in FIGS. 1 and 2 . The handheld electronic device 4 includes a housing 8 , a display 12 , an input apparatus 16 , and a processor 20 ( FIG. 2 ) which may be, without limitation, a microprocessor (μP). The processor 20 is responsive to inputs received from the input apparatus 16 and provides outputs to the display 12 . While for clarity of disclosure reference has been made herein to the exemplary display 12 for displaying various types of information, it will be appreciated that such information may be stored, printed on hard copy, be computer modified, or be combined with other data, and all such processing shall be deemed to fall within the terms “display” or “displaying” as employed herein. Examples of handheld electronic devices are included in U.S. Pat. Nos. 6,452,588 and 6,489,950, which are incorporated by reference herein. The handheld electronic device 4 is of a type that includes a wireless telephone capability which, as will be described in greater detail below, enables a user to selectively establish a prioritized list of preferred PLMNs to be used in roaming situations in accordance with the invention. As used herein, the terms “phone” and “telephone” shall refer to any type of voice communication initiated and conducted over a wired and/or wireless network.
As can be understood from FIG. 1 , the input apparatus 16 includes a keyboard 24 having a plurality of keys 26 , and a rotatable thumbwheel 28 . As used herein, the expression “key” and variations thereof shall refer broadly to any of a variety of input members such as buttons, switches, and the like without limitation. The keys 26 and the rotatable thumbwheel 28 are input members of the input apparatus 16 , and each of the input members has a function assigned thereto. As used herein, the expression “function” and variations thereof can refer to any type of process, task, procedure, routine, subroutine, function call, or other type of software or firmware operation that can be performed by the processor 20 of the handheld electronic device 4 .
As is shown in FIG. 2 , the processor 20 is in electronic communication with memory 44 . Memory 44 can be any of a variety of types of internal and/or external storage media such as, without limitation, RAM, ROM, EPROM(s), EEPROM(s), and the like, that provide a storage register for data storage such as in the fashion of an internal storage area of a computer, and can be volatile memory or nonvolatile memory. The memory 44 further includes a number of applications executable by processor 20 for the processing of data. The applications can be in any of a variety of forms such as, without limitation, software, firmware, and the like, and the term “application” herein shall include one or more routines, subroutines, function calls or the like, alone or in combination.
As is also shown in FIG. 2 , processor 20 is in electronic communication with communications subsystem 45 . Communications functions for handheld electronic device 4 , including data and voice communications (wireless telephone), are performed through communications subsystem 45 . Communications subsystem 45 includes a transmitter and a receiver (possibly combined in a single transceiver component), a SIM card, and one or more antennas. Other known components, such as a digital signal processor and a local oscillator, may also be part of communications subsystem 45 . The specific design and implementation of communications subsystem 45 is dependent upon the communications network in which handheld electronic device 4 is intended to operate. For example, handheld electronic device 4 may include a communications subsystem 45 designed to operate with the Mobiltex™, DataTAC™ or General Packet Radio Service (GPRS) mobile data communication networks and also designed to operate with any of a variety of voice communications networks, such as AMPS, TDMA, CDMA, PCS, GSM, and other suitable networks. Other types of data and voice networks, both separate and integrated, may also be utilized with handheld electronic device 4 . Together, processor 20 , memory 44 , and communications subsystem 45 may, along with other components (having various types of functionality), be referred to as a processing unit.
In FIG. 1 , the display 12 is depicted as displaying a home screen 43 that includes a number of applications depicted as discrete icons 46 , including, without limitation, an icon representing a phone application 48 , an address book application 50 , a messaging application 52 which includes email, SMS and MMS applications, and a calendar application 54 . In FIG. 1 , the home screen 43 is currently active and would constitute a portion of an application. Other applications, such as phone application 48 , address book application 50 , messaging application 52 , and calendar application 54 can be initiated from the home screen 43 by providing an input through the input apparatus 16 , such as by rotating the thumbwheel 28 and providing a selection input by translating the thumbwheel 28 in the direction indicated by the arrow 29 in FIG. 1 .
FIGS. 3 through 17 are exemplary depictions of display 12 of handheld electronic device 4 that illustrate a routine or routines performed by processor 20 for enabling a user to selectively establish a prioritized list of preferred PLMNs to be used in roaming situations according to the invention. By utilizing the invention, a user of handheld electronic device 4 is able to override the list of particular PLMNs to be used by the handheld electronic device 4 in roaming situations that is pre-stored in the SIM card forming a part of communications subsystem 45 by establishing and storing a user selected and prioritized list of PLMNs to be used by the handheld electronic device 4 in roaming situations. In the particular embodiment shown in FIGS. 3 through 17 , this list is called the “My Preferred Network List.”
FIG. 3 is an exemplary depiction of display 12 showing an “Options-Network” screen 50 generated by an operating application of handheld electronic device 4 which provides a user with information and options relating to the PLMNs used or to be used by handheld electronic device 4 . As seen in FIG. 3 , menu 52 may be accessed from “Options-Network” screen 50 in a known manner using input apparatus 16 . Menu 52 includes an item 54 entitled “My Preferred Network List.” When a user desires to create a prioritized list of PLMNs to be used by handheld electronic device 4 in roaming situations according to the invention, the user first selects item 54 . When a user does so, a “Preferred Network List” screen 56 as shown in FIG. 4 is displayed on display 12 . “Preferred Network List” screen 56 displays a prioritized listing 58 of PLMNs selected by the user as described herein to be used by handheld electronic device 4 in roaming situations. As seen in FIG. 4 , the listing 58 is initially empty. To add a PLMN to the listing 58 , the user accesses menu 60 in a known manner and selects item 62 entitled “Add Network.” Next, as seen in FIG. 6 , “Add Network” screen 64 is displayed to the user on display 12 . At this point, the user has three options to choose from for adding a PLMN to the listing 58 . Each option is described below.
In the first option, a user can manually add a PLMN to the listing 58 by entering identifying information for the PLMN into the data fields provided on “Add Network” screen 64 using input apparatus 16 . In particular, to add a particular PLMN to the listing 58 , the user must enter the mobile network code (MNC) for the PLMN at field 66 , the mobile country code (MCC) for the PLMN at field 68 , and the priority the user wishes to assign to that PLMN at field 70 . The respective priorities assigned to the PLMNs listed on listing 58 determines the order in which the PLMNs are to be used by handheld electronic device 4 , if available, in roaming situations.
In the second option, the user can add a PLMN to the listing 58 by selecting the PLMN from a group of “known networks” stored in memory 44 of handheld electronic device 4 (the MNC and MCC is stored for each such “known network”). To do so, the user accesses menu 72 in a known manner and selects item 74 entitled “Select From Known Networks.” Next, as seen in FIG. 8 , “Find” screen 76 is displayed on display 12 . “Find” screen 76 includes a listing 78 of all of the “known networks” stored by memory 44 of handheld electronic device 4 . A user may then identify for selection a particular PLMN from listing 78 by scrolling down listing 78 in a known manner using input apparatus 16 or by typing a portion of or all of the name of the PLMN using input apparatus 16 as shown in FIG. 9 . Once a particular PLMN has been identified, a user may then select the PLMN for inclusion in the listing 58 by accessing menu 80 in a known manner and selecting item 82 entitled “Select Network” as shown in FIG. 10 . When this is done, “Add Network” screen 64 is displayed on display 12 as shown in FIG. 11 , and information for the PLMN is automatically provided in fields 66 (MNC) and 68 (MCC), as well as field 84 , which is the name of the PLMN. The user must then enter information into field 70 using input apparatus 16 to establish the priority to be assigned to the PLMN. Once all of the information has been entered, the selected PLMN may be saved to the listing 58 by accessing menu 72 in a known manner and selecting item 86 entitled “Save” (which item was added to menu 72 because listing 58 is no longer empty; compare FIG. 7 ) as shown in FIG. 12 . As seen in FIG. 13 , when saved, the selected PLMN appears in listing 58 . When all the desired PLMNs have been added to and prioritized in the listing 58 , listing 58 may be saved to the SIM card forming part of communications subsystem 45 by accessing menu 60 in a known manner and selecting item 88 entitled “Save” (which item was added to menu 60 because listing 58 is no longer empty; compare FIG. 5 ) as seen in FIG. 14 . Note that, for illustrative purposes, FIG. 14 assumes that additional PLMNs have been added to the listing 58 , and thus the listing 58 shown in FIG. 14 includes additional PLMNs not shown in FIG. 13 . Once the listing 58 is saved to the SIM card, it, and not the pre-stored list described above, is used to determine which and in what order PLMNs are to be used by handheld electronic device 4 , if available, in roaming situations. In other words, listing 58 overrides the pre-stored list of PLMNs provided with the SIM card.
In the third option, the user can add a PLMN to the listing 58 by selecting the PLMN from a group of “available networks,” which handheld electronic device 4 is able to locate from its current location using communications subsystem 45 and a known network scanning procedure. To do so, the user accesses menu 72 in a known manner and selects item 90 entitled “Select From Available Networks” as shown in FIG. 15 . Next, handheld electronic device 4 performs a scan to locate the current “available networks.” As seen in FIG. 16 , while this is being done, a dialog box 92 is displayed on display 12 to inform the user that the scan is taking place. Once the scan is completed, “Find” screen 76 as seen in FIG. 17 is displayed on display 12 and includes a listing 94 of all of the “available networks” located during the scanning procedure. The user may then select a particular PLMN for inclusion in the listing 58 and save the listing 58 to the SIM card in the manner described in connection with FIGS. 8 through 14 above. In one embodiment, “available networks” will consist of only “known networks” stored by memory 44 . Alternatively, any network located during the scan may be a “available network.” Again, once the listing 58 is saved to the SIM card, it, and not the pre-stored list provided in the SIM card described above, is used to determine which and in what order PLMNs are to be used by handheld electronic device 4 , if available, in roaming situations.
According to an aspect of the invention, the user may easily reorder, and thus change the priority of, the PLMNs listed in listing 58 by selectively moving their location in listing 58 . Specifically, according to one embodiment, if a user wants to move a PLMN appearing on listing 58 (for example, the “ABA Network”), the user can, as shown in FIG. 18 , identify the PLMN to be moved on “Preferred Network List” screen 56 using the input apparatus in a known manner, access menu 60 therefrom, and select item 96 entitled “Move.” When this is done, the identified PLMN is highlighted as shown in FIG. 19 . The identified and highlighted PLMN may then be moved to another location on the listing 58 using input apparatus 16 , preferably, although not necessarily, by rotating thumbwheel 28 (alternatively, various keys, such as “up” and “down” arrow keys, may be used). Once the identified PLMN is in the desired location on listing 58 , its location may be confirmed using input apparatus 16 , preferably, although not necessarily, by pressing thumbwheel 28 , at which time the moved PLMN will no longer be highlighted. As seen in FIG. 20 , once the PLMN is moved, the PLMNs in listing 58 are automatically reordered and renumbered, meaning their assigned priority is changed, if necessary. If desired, the listing 58 as currently appearing in “Preferred Network List” screen 56 may then be saved to the SIM card (with the new assigned priorities) in the manner described in connection with FIGS. 8 through 14 . In addition to moving PLMNs listed in listing 58 , particular PLMNs may be deleted from listing 58 and/or stored information (the information in fields 66 , 68 , 70 and 84 ) for particular PLMNs may be displayed on display 12 by identifying the particular PLMN as described above and then selecting the appropriate item (“Delete” or “View”) in menu 60 shown in FIG. 18 . When a PLMN is deleted from listing 58 , the remaining PLMNs in listing 58 are automatically reordered and renumbered, meaning their assigned priority is changed, if necessary.
Thus, the invention provides a handheld electronic device that enables a user to selectively establish a prioritized list of preferred PLMNs to be used in roaming situations. In this manner, a user is able to select and prioritize particular PLMNs based on issues of PLMN cost, reliability, and service quality, among others, thereby saving the user money and/or enhancing performance of the handheld electronic device.
While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the claims appended and any and all equivalents thereof.
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A handheld electronic device adapted to display a listing of known networks, scan for available networks, display a listing of the available networks and enable the entry of information relating to manually entered networks. In addition, the device is adapted to (1) enable the addition of preferred networks to a preferred network list wherein the preferred networks are one or more of: (i) certain of the known networks selected from the listing of known networks, (ii) certain of the available networks selected from the listing of available networks, and (iii) the manually entered networks; (2) enable the assignment of a priority value to each of the preferred networks; and (3) utilize the preferred networks for performing wireless communications when the device is in a roaming situation, wherein the preferred networks are utilized in a priority order that is based on the priority value assigned to each of the preferred networks.
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This is a divisional of application Ser. No. 07/904,559 filed Jun. 26, 1992 now U.S. Pat. No. 5,282,490 which is a continuation-in-part application of Ser. No. 07/451,806, filed Dec. 18, 1989, now abandoned.
As is known, a need exists at various industrial production facilities involving high pressure low flow conditions for mechanically metering, monitoring and injecting specific amounts of materials required for a variety of end purposes, to-wit, additives, dyes, reagent type chemicals, resins, corrosion inhibitors, other forms of chemicals, stabilizers, and emulsion breakers to mention but a few.
In other words, a far reaching need extends, broadly, for high pressure low flow mechanical chemical feed/control systems. More specifically, and by way of further example, a need also exists for the removal of the pulsations inherent with the use of positive displacement pumps through an arrangement omitting such.
In any event, the industrial magnitude of invention usages is almost unending, where countless modifications to satisfy and/or custom refine an ongoing problem is accomplishable. Such applications may include, still by way of example, multi-location chemical injection via a single pump header arrangement; systems requiring high pressure and extremely low yet verifiable flow or injection rates; applications requiring future expansion at lower installation cost; and, applications where electrical and pneumatic supply sources are limited or undesirable.
BACKGROUND OF THE INVENTION
Briefly, and basically, the self-contained controller of the invention maintains constant low flow rates of fluids regardless of downstream pressure or pressure changes, incorporating a metering valve as an integral part of the controller and, preferably, includes a direct read dial flow indicator. The controller discharges liquids at a fixed high pressure greater than the downstream pressure and allows continuous non-pulsive flow even from piston or diaphragm type pumps.
Existing differential pressure regulation devices, such as the Moore Model Series 63DL, manufactured by Moore Products Co. of Spring House, Pa., and similar devices by other manufacturers, are designed for relatively low pressure and high flow rate applications (generally in the range of 30-210 gallons per hour). When these units are used for extremely low flow rates (0.005-10.0 gallons per hour), problems are encountered. Extremely high velocities are produced within the pressure regulation device, causing associated erosion of seat material and extreme chemical or fluid shear. Such problems have been found to lead to inaccurate metering, an inability to operate at extremely low flow rates, and shortened useful life of the unit due to deterioration of the valve seat.
DISCLOSURE OF THE INVENTION
Features of the present invention are to provide a differential pressure regulating device that operates under extreme low flow high pressure conditions; to provide such a device which will function accurately over extended periods of time; and, to provide a chemical injection system for process lines that is capable of accurately metering injection chemicals into the pipeline under high pressure low flow conditions.
The aforesaid results are achieved by providing a differential pressure/flow regulator having a specially designed flow channel. An annular passage within the differential pressure regulator is sized to create a pressure drop within the regulator at high pressure low flow conditions, thereby substantially reducing the pressure drop and resultant high fluid velocities that otherwise would occur at the seat of the unit. High velocity wear points in the flow path are thus eliminated.
The invention also preferably includes a seat-ball that is relatively small with respect to the main piston of the unit, providing increased accuracy, as described in more detail herebelow.
The metering controller of the invention is capable of injecting a continuous flow of chemical, for example, in contrast to intermittent flow, through the use of positive displacement metering pumps. The preceding is a significant advantage in many applications where low chemical contact time is a concern or where a uniform blend of two or more chemical components is desired.
BRIEF DESCRIPTION OF THE FIGURES
In any event, a better understanding of the invention will become more apparent from the following description, taken in conjunction with the accompanying drawings, wherein
FIG. 1 is a schematic representation of a typical installation employing a flow metering injection controller in accordance with the teachings of the present invention;
FIG. 2 is a view in front elevation of the controller presented herein, partly broken away and in vertical section to detail certain of the components prior to piston movement;
FIG. 2a is a view comparable to FIG. 2, but further detailing the invention upon piston movement;
FIG. 2b is a view in side elevation of one of the components making up the controller of FIGS. 2-2a;
FIG. 2c is a view in side elevation detailing another component of FIGS. 2-2a;
FIG. 3 is a view in end elevation, looking from right to left in FIG. 2, affording further details of the invention;
FIG. 4 is another view in vertical section showing the piston after movement;
FIG. 5 is schematic representation of a typical controller installation detailing the electrical circuitry;
FIG. 6 is a schematic representation of an installation showing the mechanical circuitry operable with FIG. 5; and,
FIG. 7 is a view in front elevation, partly broken away, detailing a modified controller in accordance with the teachings of the invention.
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated devices, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The figures presented herein illustrate an application of the controller of the invention in two typical installations, i.e. one representative of controller usage in a multi-location metering mechanical system, and the other, a modified controller, in a closed loop system serving, for example, ratio, as pH, purposes.
More specifically, the controller 10,40' of the invention, either as respectively presented in FIGS. 2, 2a, 3 and 4 or in modified form in FIG. 7, is an integral part of the system of FIG. 1, and, as well, the system of FIGS. 5 and 6.
FIGS. 2-2a illustrates a differential pressure regulator 10 of the invention in the form of a cylindrical body including a central bore of varying diameters which extends longitudinally through the body to house the various components of the regulator.
The fluid to be regulated, such as scale-inhibiting chemicals in liquid form, enters the regulator under pressure P In through a fluid inlet 35 at the inlet end 37 of the regulator and exits the regulator at a pressure P Out at a fluid outlet 39 that extends transversely from the bore in the central portion of the regulator body.
Fluid at the reference pressure P Ref is directed into the regulator at the reference end 10b of the regulator. As the fluid travels between the fluid inlet and the fluid outlet, it is regulated such that the outlet pressure P Out is a constant differential greater than the reference pressure P Ref .
The value of P Out is controlled by applying preset, opposed, longitudinal forces to control members within the regulator, as described below. Devices of this type are sometimes referred to as dome-loaded pressure regulators.
An identification and explanation of the mechanical components and fluid forces within the regulator is necessary to a proper understanding of operation. Fluid to be regulated enters the regulator through the fluid inlet at the inlet end 37 of the bore.
The fluid then enters an inlet passage 35a and travels through a passageway 19 formed in a seat member 18. A poppet 42 is housed at an end of a passageway 29' in another seat member 44 and biased towards seating by a seat spring 49 housed within the seat member 44. Fluid travels past the ball and seat into the annular passageway 29' formed by a cylindrical bore in the seat member 44 and the cylindrical portion 75 of the poppet 42 therein.
Fluid enters an outlet passage 48 from the annular passageway 29' and exits the regulator through the fluid outlet at the regulated pressure P Out .
At the reference end of the regulator, hydraulic input is received into a reference passage 50 at the reference pressure P Ref . Reference fluid from the reference passage communicates with an adjoining chamber 52 and flows toward a piston 15 that is slidably mounted within the bore. The piston 15 is biased towards the inlet end of the bore by the reference fluid and a main spring 17 which engages the reference end of the piston 15.
An adjustment member engages the reference end of the main spring 17 to compress the spring into a preload condition during normal operation. The inlet end of the piston 15 engages the end of the poppet which is slidably housed within the seat member 44 to form the annular passage.
In the preferred embodiment illustrated in FIGS. 2-2a, each end of the bore is threaded. The reference end of the bore is sealed by a threaded end cap 10b. At the inlet end of the bore, a locking member is mounted in the threaded portion to engage the seat member 44 and seat spring 49 and preload the seat spring 49 during normal operation. An inlet end cap 10c is mounted at the inlet end of the bore to seal the bore.
The end caps and locking members each include assembly bores for receiving a compatibly shaped tool (not shown), as a spanner wrench, for threading the pieces into place during manufacture. The assembly bores that are accessible from the exterior of the regulator are preferably filled with correspondingly sized pins after assembly of the unit to prevent tampering with the unit in the field.
The operation of the differential pressure regulator of the type disclosed herein can be understood by examining the fluid and mechanical forces that act on the piston 15 housed within the regulator. Forces acting to push the piston 15 toward the inlet end of the regulator (to the left in FIGS. 2 and 2a) will be considered positive. The piston receives forces from the main spring (F S1 ), the reference fluid (F PRef )), the outlet fluid (F P (Out)), and the poppet (F D ). Balancing the forces acting on the piston yields the following equation:
F.sub.P(Ref) +F.sub.S1 -F.sub.D -F.sub.P(Out) =0 (Equation 1)
where
F P (Ref) =force of reference fluid on piston
=(P.sub.Ref)Ap (Equation 2)
where Ap=cross-sectional area of piston
F S1 =force of main spring on piston
=K1(X1+DX1) (Equation 3)
where K1=spring constant main spring
X1=main spring travel during operation
DX1=main spring preload
F P (Out) =force of outlet fluid on piston
=P.sub.Out Ap (Equation 4)
where Ap=cross-sectional area of piston
F D =force of poppet on piston
=net force on ball which drives poppet
=P.sub.Out A.sub.B =P.sub.In A.sub.B +F.sub.S2 (Equation 5)
where A B =cross-sectional area of ball
F S2 =force of ball spring on ball
=K2(X2+DX2) (Equation 6)
where K2=spring constant of ball spring
X2=ball spring travel
DX2=ball spring preload
In accordance with the teachings herein, an accurate differential pressure (P Out -P Ref ) is obtained by utilizing a ball having a diameter which is relatively small as compared to the diameter of the piston.
Substituting values for Equation 1 above will yield the following equation: ##EQU1##
It can be seen from Equation 7 that the differential pressure maintained by the regulator will be a function of values that can be preset in the regulator (i.e., F S1 , F S2 , A p ) except the term: ##EQU2##
It has been discovered that in high pressure low flow conditions, extreme accuracy can be obtained by minimizing the cross-sectional area of the ball A B and maximizing the cross-sectional area of the piston A p to force this term to zero. Thus, in accordance with the invention, the ratio A B /A p is maintained at a value equal to 0.012 or less, and preferably 0.009 or less, to maintain an accurate differential pressure under high pressure low flow conditions.
The preferred embodiment of the invention also includes a specially designed annular passage. In a pressure regulating unit of the instant type, total pressure drop (DP total) through the pressure regulating unit can be described as follows:
DP total=P.sub.In -P.sub.Out
=DP inlet+DP seat+DP outlet
where
DP inlet=pressure drop through inlet orifice or channel
DP seat=pressure drop across pressure/flow regulating seat
DP outlet=pressure drop across outlet orifice or channel
At very low flow rates, DP inlet and DP outlet each approach zero, such that the total pressure drop within the unit must be taken at the seat. Thus,
DP total=DP seat.
The pressure drop across the seat can be estimated using the equation for a square-edged orifice which describes a "best case" flow scenario at the seat. The flow equation is as follows: ##EQU3## where C=flow coefficient (0.55 for low-flow small orifices)
A=cross-sectional area through which flow occurs (ft 2 )
DP=pressure drop across the seat (psig)
r=density of fluid (lbs/ft 3 )
Q=flow rate (ft 3 /sec)
The velocity through the seat can be described using the relation:
V=Q/A (Equation 9)
where
V=velocity in ft/sec
Q=flow rate in ft 3 /sec
A=area in ft 2
Substituting Equation 9 into Equation 8 yields: ##EQU4## where K=constant of proportionality.
At relatively high flow rates, pressure drop is distributed throughout the regulator unit and velocity is not a major problem. However, at very low flow rates, DP total=DP seat and the entire internal pressure drop is taken at the seat. Equation 10 indicates a very high velocity occurring at the seat, with resultant eroding of the seat material.
The preceding problem is addressed by adding an annular passage having a very small annular cross-section to the fluid flow path within the regulator, such that a pressure drop will occur in the fluid as it passes through the annular passage. With a pressure drop occurring in the annular passage, the pressure drop at the seat is greatly reduced, causing a corresponding reduction in velocity and associated wear problems.
Moreover, the spacing between the poppet and seat member in the annular passage is sized so that flow in the annular passage can be compared as flow between infinite parallel plates. Such a comparison assumes the following: (1) steady flow; (2) fully developed flow; and, (3) neglecting gravity and other bodily forces.
The following relationship can be shown to be applicable: ##EQU5## where Q=flow rate in ft 3 /sec
U=viscosity in lb sec/ft 2
L=length of the annular passage in feet
π=3.14159
D=drive pin diameter in ft
A=radial clearance in ft
Using the above equation, an annular passage is preferably specially designed for a given application by inserting the appropriate values into the equation for the viscosity of the fluid to be regulated, the desired flow rate, and the pressure drop to be taken by the annular passage.
The annular passage will preferably take a large portion of the total pressure drop, leaving a portion of the pressure drop to be taken at the seat to enable throttling to occur at the seat. If all the pressure drop is taken in the annular passage, the ball/seat system at the seat would be unable to open and close. Thus, in preferred embodiments designed for the system of FIG. 1, 80 percent of the internal pressure drop was designed to be taken at the annulus.
A detailed view of the seat member 44 is shown in FIGS. 2a and 2c. In the preferred embodiment, the seat member 44 is fabricated from stainless steel and includes a 0.141 inch chamfer surface forming the seat 45. The seat adjoins a 0.063 inch diameter, 0.625 inch long cylindrical bore 29' that receives a 0.059 inch diameter poppet 42 in the annular passage. The poppet in the preferred embodiment illustrated herein is 0.50 inch long and fabricated from stainless steel and includes a 0.125 inch diameter ball on the end.
Flow is typically adjusted through a twenty-turn metering valve 11 and the resulting flow is read on the direct read dial flow indicating device 21 (downstream of the metering valve 11).
As evident from FIG. 1, controllers 10 are typically installed in a multi-location delivery system which includes liquid/fluid storage tank 25, pump 27, inlet filter 29, ball valve 31, back pressure and pressure reducing regulators 32, and pressure gauges 33, all leading to an appropriate header line. For multi-injection, high pressure low flow conditions, it is preferred to use a forward pressure regulator capable of accurately regulating fluid pressure under such conditions.
Referring now to the controller 40' disclosed in FIG. 7, such is, as stated, an integral part of the system of FIGS. 5 and 6. In this connection, the controller 40' deals with a closed loop defined as an automated electronic/mechanical control system which works with accurate digital based information supplied from both ends and controlled from the center, where one end may represent a process flow stream or condition in the form of an electronic signal proportional to same and the other end an electrical signal proportional to flow provided by controller 40'. The center, in a typical preferred embodiment, is a processor, such as a programmed logic controller (PLC) and/or a personal computer (PC) based system, into which input signals are introduced.
Representative types of closed loop applications include high pressure low flow control responsive to a condition, such as pH, conductivity, speed, or time, or in the control of a stream blending a substance into an actual or known volumetric flow, as in plastics (e.g., the blending of liquid additives in proportional amounts to the delivery of bulk feed resins) or in the gasoline industry (e.g. the blending of gasoline additives in proportional amounts into untreated gasoline streams).
In a usage directed to pH control, for example, a pH sensor and a transmitter on a liquid containing line or vessel serves to measure and forward pH data into a microprocessor based programmed logic controller (PLC) at the center of the loop. The processor looks at the actual pH signal in comparison to the desired pH condition "set point" and sends an electrical signal to controller 40' to affect a desired change, if required.
Any reference to pH application above serves merely as a representative use situation selectively involving a controller 10 of the general type illustrated in FIGS. 2, 3 and 4, but modified to the showing of FIG. 7 (controller 40'), as through a metering valve actuator 41' (used instead of metering valve 11) and an electro-mechanical flow meter 42' (used instead of the flow indicating device 21).
In a closed loop situation, a conversion is achieved, i.e. a positive displacement (PD) flow transducer (mechanical) responsive to electronic read-outs in the form of transmitters (electronic). An electronic signal is achieved which is proportional to fluid flow or a condition.
Referring to FIGS. 5 and 6, the controller 40', serving a closed loop system function, includes metering valve actuator 41', as an electromechanical control valve. The latter may be, for example, 115 V AC and reversibly motorized; in the form of a packless/pack arrangement; and, include electrical feedback in the form of limit switches and/or a potentiometer. In any event, such serves the ability to remotely monitor and adjust the valve coefficient and to permit desired flow. The preceding structure, not detailed in the figure, is used with a pressure control device, as controller 40'.
Flow meter 42', in this embodiment, is presented as a positive displacement unit coupled to an electronic transmitter which, for example, utilizes a photo-optic sensor pickup to transmit an electrical signal which is proportional to the volumetric flow (or flow condition) to the flow meter 42'.
Flow meter 42' serves to provide an accurate verifiable flow signal which may be transmitted remotely to a processor, whereby the flow data thereof is representative of flow achieved by the adjustment of metering valve actuator 41'. Restated otherwise, flow meter 42' performs an actual verification of flow achieved by metering valve actuator 41'. Thus, with constant P, as provided by controller 40', and a constant repeatable C v as provided by metering valve actuator 41', flow meter 42' will also be constant and serves only as a verification of flow achieved by controller 40 and metering valve actuator 41'.
In kindred uses, metering valve actuator 41' can be removed and replaced by metering valve 11, whereby a remote signal representative of flow is all that is required, or, in the alternative, flow meter 42' may be removed and replaced by flow indicating device 21 while still utilizing metering valve actuator 41' in conjunction therewith to provide local indication of flow with remote control.
As to FIGS. 5 and 6, and in a preferred embodiment, FIG. 6 shows a mechanical arrangement including controller 40', serving however in a manner, to provide individual pressure and flow control in a centralized multi-point or multi-location system which, in such instance, may include a (non-rotating) stem control valve 45' and a positive displacement flow meter 46'.
FIG. 5, in such preferred embodiment, shows an electrical/electronic arrangement which may include an electric motorized actuator (with or without feedback) in the form of limit switches or a potention-meter, represented by reference numeral 47'; an electronic optical sensor, with pickup transmitter in the form of frequency or analog output from a signal 24 DC control power output; a microprocessor based processor with an I/O configuration providing inputs and outputs in the form of, for example, 115 V AC, 24 V DC, and 4-20 milliamp (Ma) analog and frequency signals; a common 24 V DC power module; a terminal block arrangement of 115/230 voltage control; and, a microprocessor based rate and/or totalizer, with frequency and analog I/O and with menu-driven user configurable program, represented by reference numeral 56'.
FIG. 5 is the electrical/electronic control for a multi-head system (using controller 40' of FIG. 6) which provides automation (closed loop control), i.e. automated control and monitoring. Microprossessor based processor 50' utilizes a developed software program to provide instantaneous monitor/adjustment control, as required. Thus, FIGS. 5 and 6 provide an easily expandable or reconfigurable automatic system as experience defines requirements.
FIGS. 1, 5 and 6 are similar to the extent of presenting high pressure low flow control, where verification to considerable accuracies, without control (mechanical), flow and pressure compensation (either the automatic or another version of FIG. 5), would not otherwise be possible. Flow meter 46', control valve 45' and controller 40', in FIG. 6, provide constant stabilization and equalization of process pressure and control of flow of same, where any variation or unbalance of pressure would result in all items (in FIGS. 1, 5 and 6) to be continuously in unwanted "hunting."
Thus, two systems, common in part, are presented and/or illustrated herein, the first identifiable as a mechanical multi-point or multi-flow high pressure low fluid flow disposal system served by a single centralized pump, whereby individual rates and specific amounts of liquid can be adequately and uniformly discharged, i.e. controlled, and measured, to individual local or remote locations irrespective of downstream process pressure conditions because of constant differential pressure achieved by the controller for each location.
The second system is identifiable as an automated version of the above, including a microprocessor based processor with certain electronic and electrical controls which provide on-line real time closed loop process monitoring and control.
The common denominator between the two systems is the multi-point disposition of liquids served by a centralized controller (10,40') utilizing the differential pressure theory to accurately and repeatedly control a given flow stream. The latter may be in the form of flow rate, total, speed or time conditions, or other quality functions. An electronic sensor provides an electrical signal representative of the aforementioned flow rate, total, speed or time conditions, or other quality functions, from the controlled process and into the micro processor based processor at the center.
In further contrasting controller 10 (FIG. 2) from controller 40' (FIG. 7), the latter serves to provide a specific gravity and viscosity compensated automated controller system, whereas controller 10 is chemically dependent. In other words, the latter is selective to a fixed chemical (because of a fixed area orifice coupled with a fixed differential pressure, i.e. such cannot vary without recalibration).
The loop arrangement of the invention is readily workable with three forms of industrial applications with which the invention may be employed, to-wit, a batching system, a blending system and a treatment system.
The batching system is involved with volume, speed and time and does not require the usage of a process signal, i.e. one which determines a condition of the controlled system.
On the other hand, the blending system and the treatment system each require the process signal, determining the condition, to be fed into a micro processor based processor (which has an established desired "set point"). The flow signal, actually representing what is flowing and confirming the results, is also introduced into the processor. The processor, in turn, feeds an actuator valve which modulates upwardly and downwardly, changing the C v , which increases or decreases the liquid flow. The C v is maintained until a disruption occurs in the control process requiring further adjustments.
In any event, the controller(s) presented herein is susceptible to various changes within the spirit of the invention, including the many applications and/or usages thereof (where the latter have only been representatively discussed). Controller changes may include proportioning, component placement, material selection, and, the like. Thus, the preceding description should be considered illustrative and not as limiting the scope of the following claims:
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A differential pressure regulator and accompanying system enabling accurate metering of fluid under high-pressure, low-flow conditions. An annular passage within the fluid flow path of the regulator creates an additional pressure drop within the regulator to reduce fluid velocity within the regulator and associated wear problems. A ball and seat mechanism is specially sized with respect to a piston and provides improved accuracy.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Patent Provisional Application 61/802,059, filed on Mar. 15, 2013, U.S. Patent Provisional Application No. 61/811,023 filed on Apr. 11, 2013 and U.S. Patent Provisional Application No. 61/827,994 filed May 28, 2013, the disclosures of which are incorporated herein by reference in their entirety for any purpose whatsoever.
BACKGROUND
1. Field
The present application relates to medical devices and methods for the detection of the Streptococcus bacteria.
2. Description of Related Art
According to the CDC, there are several million cases of Group A-hemolytic streptococcus bacterial infection (Strep A) reported each year. The strep bacteria is transmitted through the air and is highly contagious. Children who contract strep throat can develop PANDAS (Pediatric Autoimmune Neuropsychiatric Disorders), a disorder associated with streptococcal infections. One of the symptoms of PANDAS is OCD (Obsessive Compulsive Disorder). For years medical experts thought the link between a strep throat and OCD was only coincidental, but now many believe PANDAS affects the part of the brain that controls movement and behavior. CDC guidelines for medical doctors state that a strep test should be performed if a patient presents with two of the four symptoms, namely: white matter on tonsils; fever; painful swollen glands; and a lack of coughing. Group A Streptococcus is one of the most significant human pathogens causing acute pharyngitis, tonsillitis impetigo, and scarlet fever. It is very important to differentiate streptococcal infection from other etiologic agents so that appropriate therapy may be initiated. Rapid diagnosis and timely treatment of Group A Streptococcal pharyngitis infections will reduce the severity of symptoms and further complications such as rheumatic fever and glomerulonephritis.
The accurate diagnosis of Strep A in children is largely dependent on the cooperation of the child and the medical practitioner's ability to collect a good specimen. The current device for collecting a sample is a sterile swab comprised of polyester and rayon. The tip rests at the end of a wooden stick which measures six inches in length. The method of specimen collection involves the use of two sterile swabs held together and simultaneously inserted into a child's mouth. In children over the age of 6, the child's head is tipped slightly backward so that the practitioner can visualize the tonsils. The tonsils are then swabbed with the sterile swabs. This sensation for many children is uncomfortable and engages the gag reflex. For children undergoing the conventional swab method, it often feels as if the swabs are being jammed or forced down their throat. In children ages 2-5, the practitioner must hold the child's jaw firmly with one hand while trying to swab the throat with the other. Parents are often asked to assist in mildly restraining their children so that the swabs may be inserted far enough into the mouth in order to reach the back of the throat to collect the specimen. This method is unpleasant for the child and awkward to administer for the practitioner. However, this is the only test on the market for the diagnosis of Strep A bacteria. One swab is used for the rapid test, performed on site in the practitioner's office or on-site laboratory, and the other swab is sent to an off-site lab to be cultured. With a rapid strep test, results are ready in 10 minutes instead of 1 to 2 days with a throat culture. The rapid test utilizes a chromatographic immunoassay for the qualitative detection of Group A Streptococcal antigen. Test strips or devices are treated with specific Strep A antibodies which react with the Strep A antigen if the bacteria is present. If the rapid strep test results are positive, antibiotics may be started immediately. The rapid strep test can give false-negative results even when strep bacteria are present. For these reasons, a throat culture is more accurate than the rapid strep test. Regardless, the accuracy of these tests is totally dependent on the collection of a good sample from the mucosa located in the back of the throat where the Strep A bacteria cultivates. The present application advances the current method and eliminates the problem of unpleasantness for a child and awkwardness for the medical practitioner while ensuring a sufficient sample is obtained.
SUMMARY
Advantages of the present disclosure will be set forth in and become apparent from the description that follows. Additional advantages of the disclosure will be realized and attained by the methods and systems particularly pointed out in the written description and claims hereof, as well as from the appended drawings.
The present disclosure relates to devices and related methods for rapidly detecting streptococcus bacteria. One embodiment of a device includes a first elongate handle having a proximal end and a distal end, the distal end of the first handle being connected to a first edible substance, a second elongate handle having a proximal end and a distal end, the distal end of the second handle being connected to a second edible substance. The first elongate handle is connected to the second elongate handle by a banding material. The first edible substance and the second edible substance are configured to be inserted into the mouth of an individual for receiving a saliva sample.
In some embodiments, the first and second edible substances can include a plurality of edible components selected from the group consisting of corn syrup, sugar, water, gelatin, modified corn syrup, and mineral oil. the first and second edible substances can include flavored material. The first and second elongate handles can include at least one of plastic and wood, among other materials. The banding material can include glue, tape, paper, or any other suitable material.
The disclosure also provides an illustrative device for rapidly detecting streptococcus bacteria. The device includes an outer elongate tubular handle having a proximal end and a distal end, the distal end of the outer elongate tubular handle being disposed within an edible substance. The device further includes a plurality of swabs for receiving a saliva sample slidably disposed within an elongate passage of the outer elongate tubular handle.
If desired, the device can further include an elongate proximal handle disposed within the elongate passage of the outer elongate tubular handle. The elongate proximal handle can be disposed in operable communication with the plurality of swabs to advance the plurality of swabs into a throat of a patient after the edible material is disposed in the mouth of the patient.
The disclosure further provides a device for rapidly detecting streptococcus bacteria, including an outer elongate tubular handle having a proximal end and a distal end, and a plurality of swabs slidably disposed within the outer elongate flavored tubular handle, each swab being mounted on a respective elongate member.
The device can further include an elongate proximal handle disposed within the elongate passage of the outer elongate tubular handle, the elongate proximal handle being disposed in operable communication with the plurality of swabs to advance the plurality of swabs into a throat of a patient after the edible material is disposed in the mouth of the patient. If desired, the outer elongate tubular handle includes edible flavored material.
The disclosure further provides a method for rapidly detecting streptococcus bacteria, comprising inserting a first elongate handle connected to a first edible substance and a second elongate handle connected to a second edible substance into the mouth of an individual for a predetermined amount of time until saliva is received on the first and second edible substances, removing a banding material that connects the first elongate handle from the second elongate handle, and testing the first and second edible substances for strep A bacteria. Similar methods may be practiced with any embodiment disclosed herein.
The disclosure further provides a further device for the rapid detection of strep A including a plurality of elongate handles attached by a banding material, each elongate handle including a row of bristles located at the distal end of the elongate handles including edible material, the bristles being configured to receive a saliva sample from a patient. If desired, the bristles can include a strep A antigen.
The disclosure still further provides a device for the rapid detection of streptococcus bacteria, including a first elongate handle connected to a first edible substance having a plurality of bristles suitable for receiving a saliva sample from a patient, and a second elongate handle connected to a second edible substance having a plurality of bristles suitable for receiving a saliva sample from a patient. The first and second elongate handles can include, for example, at least one of plastic and wood. The banding material can include, for example, glue or tape.
The disclosure yet further provides a device for the rapid detection of streptococcus bacteria, including a first component for disposing in the mouth of a patient, the first component including a an inner hollow channel, the inner hollow channel ending in a test tube that is connected to the base of the mouthpiece, the test tube being configured to receive a saliva sample when the patient coughs into the first component. In another embodiment, a device for the rapid detection of streptococcus bacteria, includes a piece for fitting into the mouth of an individual. The mouthpiece includes an inner hollow channel located at the base of the mouthpiece distal into the mouth of the individual. The inner hollow channel culminates into a test tube which is connected to the base of the mouthpiece. The test tube is used for the receiving of a saliva sample by the individual coughing into the mouthpiece.
It is to be understood that the foregoing general description and the following detailed description are exemplary and are intended to provide further explanation of the disclosed embodiments. The accompanying drawings, which are incorporated in and constitute part of this specification, are included to illustrate and provide a further understanding of the disclosed methods and systems. Together with the description, the drawings serve to explain principles of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a schematic illustration of a device for the detection of Strep A.
FIG. 1B is a side view of the device for the detection of Strep A shown in FIG. 1A .
FIG. 2 is a schematic illustration of an alternative embodiment of a device for the detection of Strep A.
FIG. 3 is a schematic illustration an alternative embodiment of a device for the detection of Strep A.
FIG. 4A is a schematic illustration of an alternative embodiment of a device for the detection of Strep A.
FIG. 4B is a side view of the alternate embodiment of a device for the detection of Strep A shown in FIG. 4A .
FIG. 5A is a schematic illustration of an alternative embodiment of a device for the detection of Strep A.
FIG. 5B is a side view of the alternate embodiment of a device for the detection of Strep A shown in FIG. 5A .
FIG. 6 is a schematic illustration of an alternative embodiment of a device for the detection of Strep A.
DETAILED DESCRIPTION
The present application relates to diagnostic tests, particularly for the pediatric population for the detection of Strep A bacteria, a test that is more user friendly compared to the current polyester swab method. The preferred embodiment of the application replaces the conventional sterile swab with, for example, a gelatin-based circular/rounded substance (a “lollipop-like” or candy-like object) on a stick for a child-friendly diagnostic test for Strep A. As a lollipop, for example, children of all ages are familiar with the shape and therefore less fearful of the gag reflex they have come to expect from conventional sterile swabs. Since lollipops are “treats” for children, the circular/rounded shape triggers a pleasant and fun feeling for the child. Sucking on lollipops is instinctive for children and is done independently while still under the supervision of the practitioner. Applicant intends that the name of the device will be branded and marketed as StrepPop™.
In FIG. 1 , an illustrative device includes a circular, organic, soft, gelatinous substance 13 preferably measuring, for example, 13/16″ wide and 2/16″ in depth. The substance 13 of the circular member may include corn syrup, sugar, water, gelatin, modified corn syrup, mineral oil, and the like. The substance of the circular member 13 may be clear in color and non-flavored. The circular substance 13 is attached to the distal end of a wooden stick handle 10 which measures 6″ long. The stick, as illustrated, is rounded and has a diameter of 2/16 th of an inch. The stick 10 is inserted into the circular substance, for example, at a midway point 14 , approximately 7 1/16 th ″ deep in order to secure the circular member onto the stick, such as by the adhesive properties of the substance of the circular member. An identical circular member, on an identical stick, is banded with another circular member on the stick device. The two devices are banded together, for example, 2½″ from the bottom of each device (second device not shown) The banding material 12 is a paper or other wrap which is glued and is ½″ thick. An intact band signifies that the device is sterile. The paper band remains intact until after the specimen has been collected. The band is cut or broken by the practitioner after removal from the patient's mouth and one device is used for the rapid test, and the other device is sent away to be cultured. The device's circular, lollipop-like component may further include any material that is best identified for sample and specimen collection, including but not limited to, rayon polyester, cotton or any safe or nontoxic material suitable for this purpose. In another embodiment, the banding material may be made of any material which can secure the handle and be easily breakable. In another embodiment, the handle may be flat or may be of a plastic material. It will be appreciated by those of skill in the art that reference to dimensions herein of the disclosed embodiments are meant only as examples, and that the precise dimensions disclosed are not critical.
In another embodiment, the device may be in the classic lollipop shape or in more playful shapes such as different animals, fictional characters, cartoon characters or popular culture references known to children, or any other suitable shape. The device can also be available in varying sizes depending on the age of the child. In addition, the clear organic, soft, gelatinous substance of the device may be available in attractive, bright or neon colors. The device may be one solid color or arranged in multiple colors, stripes and polka dots. In another embodiment, the device may be available in different flavors, including but not limited to strawberry, cherry or grape, citrus, lemon, lime, orange, and the like.
In FIG. 2 , another illustrative embodiment of the application is illustrated. In this embodiment, the circular member 26 includes an organic, soft, gelatinous substance measuring 13/16″ wide and 7/16″ in depth. The substance of the circular member 26 includes corn syrup, sugar, water, gelatin, modified corn starch, and mineral oil. The substance is clear in color and non-flavored. The tube which holds the circular member is made of wood 20 . The tube is 5¾″ long and 7/16″ in outer diameter. The tube 20 is rounded, hollow and may be made of any safe and nontoxic material such as unfinished solid wood, hemp or BPA-Free PVC-free plastic #2, #4, #5. The tube 20 is inserted all the way to the top edge of the circular member in order to secure the circular substance to the stick. The circular member contains two openings 22 and 23 close to the outer rim of the circular member, each opening measuring 4/16 th ″ in diameter. Each opening 22 and 23 is placed 2/16 th ″ off the center line. The center line is located 6 and one half sixteenths measured from the edge of the circular member. The tube 20 can accommodate an interior stick 24 which is comprised of plastic and is 4/16 th ″ in diameter. The interior stick 24 is 4 inches long and rests 4″ down from the top of the tube at the base of the rayon swabs. While the device is in the mouth of a child, the interior stick 24 is pushed forward, and the two polyester swabs 25 and 27 eject through the two holes on the top of the device 22 and 23 . Subsequently, the two swabs 25 and 27 touch the tonsils at the back of the throat, and a specimen is collected. The swabs 25 and 27 are removed from the top of the pop and one swab is used for the rapid test, and the other is sent off site for the throat culture. The device is then discarded.
It will be appreciated that the embodiment of FIG. 2 can be varied in many ways. For example, it will be appreciated that the dimensions may be varied, as desired, and that the shape of the cross section of the tubular member may be circular, rectangular, elliptical, oval, triangular in shape or have any other suitable shape. It will further be appreciated that while the disclosed embodiment depicts two swabs being delivered, any desired number of swabs (e.g., three) can be delivered.
In FIG. 3 , an alternative embodiment of the device omits the “lollipop” feature. The disclosed device 30 accordingly contains a hollow tube 32 which, in the illustrated embodiment, measures 7/16 th ″ in diameter and is 5¾″ in length. The hollow tube 32 is made of plastic, but can be made from any suitable material. The hollow tube 32 contains two (e.g.,) rayon swabs 31 and 33 which are located at the distal end of the hollow tube 32 . Each rayon swab 31 and 33 is 2/16 th ″ in diameter. A solid cardboard cylinder 34 acts as a plunger. The solid cardboard cylinder 34 measures 4/16″ in diameter and is 4″ long. The cardboard cylinder 34 would push forward the rayon swabs. The outside of the hollow tube 32 would measure how far the swabs are pushed forward. A measurement line 35 on the hollow tube 32 would indicate that the cardboard has pushed the rayon swabs ( 31 and 33 ) 13/16″ outward from the top of the vessel. This would be sufficient depth to touch the mucosa in the child's throat. The second position would eject the swabs 31 and 33 another two inches, such that the swabs may be safely removed by the practitioner. One swab would be used for the rapid test, and one swab would be sent for a throat culture. The hollow tube could be manufactured in a variety of flavors making the hollow tube more palatable for the child. Since the swabs are safely housed inside the hollow tube until pushed forward by the cardboard cylinder, the flavoring of the hollow tube would not come in contact with the specimen.
In FIG. 4 , a further illustrative embodiment of a device includes a double-sided brush mechanism for use on the surface of a child's teeth. The device is comprised of a small colorful handle 40 which measures 4″ long and made of plastic. The handle 40 of the brush is flat and 4/16 th ″ wide. At the distal end of the handle are three rows of rayon bristles 42 . From the first row of bristles to the third row of bristles, the bristles measure 4/16 th ″ wide by 4/16″ long by 8/16″ in height. The bristles 42 form a triangle comprised of three rows of bristles. Each triangle set of bristles is configured as three bristles in one row, two bristles in the second and one bristle in the third row. Each set of bristles 42 is comprised of a cluster of rayon bristles packed together tightly. The bristles may be made of any material, such as polyester, cotton or microfiber. There are two of these brush mechanisms banded back-to-back (not shown). The brush mechanism could also be produced to include but not limited to, fun shapes, colors, and animal shapes. The band is broken only after the specimen has been collected. One brush's specimen is used for the rapid test, and the other brush's specimen is used for the overnight culture. While not shaped like a device, a proper specimen is able to be collected from the child by brushing the rayon swabs over the top and bottom teeth simultaneously. A child could do this alone or with support from the practitioner. Like sucking on a lollipop, brushing one's teeth is a familiar and pleasant task for a child. In another embodiment, colored bristles would be impregnated with Strep A antibodies. The child then brushes his teeth, mouth and/or tongue which causes the production of saliva. The saliva is collected on the bristles. The bristles would change to a different color if the Strep A antigen is detected in the saliva. In another embodiment, a similarly shaped test tube is impregnated with the Strep A antibodies When the brush device is inserted into the tube, the brush changes color when the Strep A antigen is present. In another embodiment, the test tube may contain a test trip which contains the Strep A antigen, such that when the bristles comes in contact with test strip, the test strip changes color to signify that the Strep A bacteria is present in the saliva sample.
The embodiments described in FIGS. 1, 2, and 3 are given to a patient to suck on for 60 seconds to ensure that it is well-coated with a potential streptococcus bacteria. The patient is instructed by the practitioner not to touch the device to the sides of the cheek. Instead, the patient would be instructed to touch the device to the tongue and top of the mouth area. After the 60-second period, the practitioner takes the device back to the testing area and removes the band that secures the two devices together. One device is placed in the rapid test vessel, which mirrors the shape of the device. At this point, either Reagent A, sodium nitrate, Reagent B, phosphoric acid, or acetic acid are placed in the device-shaped vessel to determine the presence of the Strep A antigen. The test strip is then inserted which shows a control line and a positive or negative result. The other device is sent to the laboratory to be cultured. All embodiments further the art in this field by creating a new diagnostic tool which is child-friendly and which assists in the accurate diagnosis of the Strep A bacteria.
In FIG. 5 , an alternative embodiment of the device 50 is comprised of a circular, organic, soft, gelatinous substance 54 which measures 13/16″ wide and 4/16″ in depth. The ingredients of the circular member substance 54 include corn syrup, sugar, water, gelatin, modified corn syrup, and mineral oil. The circular substance is soft and gelatinous in texture. The circular substance is clear in color and non-flavored. Spanning across the top of the arc of the circular member are rayon bristles 56 which protrude 2/16 th ″ from the circular member. The length of the span across the top of the arc of the circular member is 8/16 th ″. The rayon bristles run the length of the circular member and are imbedded into the circular member, such that the bristles are secure. The bristles may be made of any material, such as polyester, cotton or microfiber. The device circular lollipop component may be comprised of any material that is best identified for sample and specimen collection, including but not limited to, rayon or polyester, or any safe or nontoxic material suitable for this purpose. The rayon bristles 56 are 1/16 th ″ in diameter. The wooden stick measures 5¾″ long. The wooden stick 58 is inserted into the circular substance midway to approximately 7½/16 th , such that the wooden stick 58 is secured to the circular member and forms a lollipop formation or device. The wooden stick 58 is comprised of solid wood and is 2/16 th ″ in diameter. An identical device with identical rayon bristles is paired with another service as described, and both are banded to each other (not shown). The identical devices are banded together at 2½″ from the bottom of each. The banding material 52 is a paper wrap which is glued and is ½″ thick. The unbroken band signifies that the service is sterile. The banding material 52 remains intact until after the specimen has been collected. The band 52 is cut or broken by the practitioner and one device is then used for a rapid test and the second identical device is sent offsite to be cultured. In another embodiment, the bristles may be impregnated with Strep A antibodies. In this embodiment, a similarly shaped test tube is impregnated with the Strep A antibodies When the bristles is inserted into the test tube, the bristles change color when the Strep A antigen is present. In another embodiment, the test tube may contain a test trip which contains the Strep A antigen, such that when the bristles come in contact with test trip the test strip changes color to signify that the Strep A bacteria is present in the saliva sample. In another embodiment, the circular substance may contain the Strep A antigen, such that when the saliva sample comes in contact with the bristles and travels to the circular substance, the circular substance changes color if the Strep A bacteria is present in the saliva. In another embodiment, the bristle may be 4/16 inches in diameter.
In FIG. 6 , a multi-component device is shown. The device includes a soft rubber or hard plastic mouthpiece 60 . Practitioners may choose which material is the most cost-effective vehicle to be used. The mouthpiece 60 measures 1″ wide by 6/16″ deep by 2½″ long. The mouthpiece 60 has a hollow inner channel 62 which measures 5/16 th in diameter and 2½″ long. The base of the inner channel has one opening 64 . The second component is a plastic test tube 66 which measures 7/16 th ″ in diameter and is 2″ in length. The test tube 66 is removed from a sterile package by a practitioner and inserted into the hollow channel on the bottom of the mouthpiece. The child coughs into the mouthpiece 60 , and the streptococci bacteria sample travels through the inner channel 62 into the test tube 64 where the sample is collected. The test tube 64 is removed from the inner channel of the mouthpiece and placed into a stand. Normal reagents are added directly to the test tube and the rapid test is performed. If the result of the rapid test is negative, a second test tube (not shown) may be attached to the channel of the mouthpiece, and the test is repeated. The second test tube is swabbed with a rayon swab, to collect the bacteria produced by the cough, and is sent off site to be cultured. In another embodiment, the test tube is impregnated with the Strep A antibodies, such that when the bristles are inserted into the test tube, the bristles change color when the Strep A antigen is present. In another embodiment, the test tube may contain a test trip which contains the Strep A antigen, such that the test trip turns colors if the Strep A bacteria is present in in the saliva of the individual.
In another embodiment, a colored fiber membrane is attached to the bottom of the mouthpiece, which would be impregnated with Strep A antibodies. The child then coughs into the mouthpiece, and saliva produced by the cough is collected on the fiber membrane. The fiber membrane would change to a different color if the Strep A antigen is detected in the saliva.
The following sources are hereby incorporated by reference:
Bisno Al Group A Streptococcal Infections and acute rheumatic fever. New England Journal of Medicine 325:783-793 (1991) Kuttner AGand KrumweideE. Observations on the effect of streptococcal upper respiratory infections on rheumatic children: a three-year study. Clin. Invest.:273-287 (1941) Shea, Y. Specimen Collection and Transport in Clinical Microbiology Handbook. Isenberg H. D. Am Society of Microbiology 1.1 1-11.30 (1992) Polymedco Inc. Poly Stat Strep A Strip Test leaflet CDC Website specifically information on Strep A bacteria (2011) UCSF Medical Center Clinical Laboratories Point of Care testing (White Paper) Approved by Tim Hammil, MD Quidel Corporation's CEO Presents at The JP Morgan Healthcare Conference (Transcript) Jan. 11, 2012
The methods and systems of the disclosed embodiments, as described above and shown in the drawings, provide for equipment and related techniques with superior attributes including, among other things, improved ease of use. It will be apparent to those skilled in the art that various modifications and variations may be made in the devices and methods of the disclosed embodiments without departing from the spirit or scope of the disclosure. Thus, it is intended that the disclosure include modifications and variations that are within the scope of the appended claims and their equivalents.
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The present disclosure relates to devices and methods for rapidly detecting streptococcus bacteria. An illustrative device includes a first elongate handle connected to a first edible portion and a second elongate handle connected to a second edible portion. The first and second elongate handles are connected by a banding material. The first and second edible portions are inserted into the mouth of an individual for receiving a saliva sample.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a concealed fastening building finishing element system that enables concealed fastening of finishing elements such as trim components, fascia boards, frieze boards, belly band boards, and the like to an underlying structure and to the fixings used in these systems.
[0002] The invention is particularly useful with trim elements around window and door frame openings and at building corners and will be described hereinafter with reference to these applications. It will be appreciated, however, that the invention is not limited to these particular fields of use and can be used in connection with other building finishing elements where concealed fastening is desired, including but not limited to, band board features, fascia boards, soffits and the like.
[0003] Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of the common general knowledge in the field.
[0004] In one popular form of building structure, trim installations are applied around window or door frame openings and at internal or external corners of a building. The trim serves both an aesthetic purpose in adding a decorative feature to building envelopes and also adds an additional weatherproofing purpose in allowing for more complete weatherproofing of building envelope corners and openings.
[0005] Without trim at the external corners of the building, for example, cladding such as planks or panels are each necessarily cut, nailed in place, and sealed against weather effects individually. Traditionally, a favored method was to mitre cut the plank edges to form a joint line which requires a high skill level. However, any building movements tended to cause the mitre joints to open up which as well as being unsightly, exposed the edges and the underlying structure to the weather. Additionally, because primary framing members are traditionally located at the external corners of buildings, it is important for the long term durability of a building that corner treatments are both easy to install and provide improved weather resistance for protection of the structural elements of the building.
[0006] Again, without finishing trim at window and door openings, the surrounding cladding panels or planks are necessarily individually cut, fixed in place and weatherproofed to a sophisticated level.
[0007] Trim may also allow for simplified installation of cladding such as planks and panels. At corners, for example, the trim is fixed in place first and then the cladding planks are simply square cut and fixed so that the cut edges of the planks butt up against the sides edges of the trim. A sealing compound is also used between the side edges of the trim and the cut edges of the planks to provide additional weatherproofing, without the need to individually treat each plank.
[0008] Trim is typically installed by driving fasteners, such as nails or screws through each the surface of trim member and into the underlying structure. The head of the nail or screw is thus visible on the face of the trim. On a pre-finished trim piece, if a smooth surface appearance on the face of the trim is required, the nails must be installed flush with the surface of the trim and the nail heads touched up with paint. If the nails are overdriven below the surface of the trim, the resulting holes must be filled with a water-proof filling compound and/or touched up with paint. It will be appreciated that these additional steps are time consuming and add additional cost to the installation.
[0009] U.S. Pat. No. 7,028,436 describes a corner trim piece which includes a cementitious layer moulded on a rigid right-angle backing. The rigid backing reinforces the cementitious layer and overhangs along one longitudinal side of the trim to provide a nailing flange for fixing the sheathing product to an exterior surface of a building. Holes may also be provided through the cementitious layer to allow nailing through the integrated sheathing product. While the reinforcing provided by the backing member provides resistance to cracking of the cementitious layer, it is also likely to increase the overall weight and cost of the trim piece. Additionally, manufacture of the integrated product is likely to be more complex than the manufacture of a simple discrete trim piece suitable for nail or screw fixing, as described above. Furthermore, this sheathing product is likely to have limited installation flexibility, in particular relating to ease of positioning the product in situ due to the nailing flange extending along the entire length of the trim piece. Furthermore, the described trim piece is necessarily provided as a pre-fabricated product and can only be used on corners limiting the flexibility on window and door trim installation.
[0010] Similar issues arise with the installation of other standard building finishing elements such as fascia boards, band boards, soffits and the like, in that face fixing through the element complicates the finishing process by requiring touch up painting or the use of prefinished or capped fasteners or the like. This is particularly relevant when prefinished finishing elements are to be used.
BRIEF SUMMARY OF THE INVENTION
[0011] In accordance with one aspect of the present invention, there is provided a load-bearing concealed building finishing element fixing tab, the tab including a first portion and a second portion, the first portion being adapted for connection to a structure-facing surface of a building finishing element such that said second portion of said tab extends outwardly from said building finishing element, and said second portion being adapted for connection to a support structure thereby to secure a portion of said building finishing element to said support structure whereby the connection between said first portion of said tab and said structure-facing surface of said building finishing element is substantially concealed from an outwardly directed exterior-facing surface of said building finishing element, the tab being configured, and defined as being load-bearing, in its ability to support said portion of the building finishing element and retain it in a fixed position.
[0012] According to another aspect of the invention, there is provided a concealed building finishing element system including a building finishing element having a structure-facing surface and an exterior-facing surface; and at least one load-bearing concealed building finishing element fixing tab, the tab including a first portion and a second portion, the first portion being adapted for connection to a structure-facing surface of a building finishing element such that said second portion of said tab extends outwardly from said building finishing element, and said second portion being adapted for connection to a support structure thereby to secure a portion of said building finishing element to said support structure whereby the connection between said first portion of said tab and said structure-facing surface of said building finishing element is substantially concealed from an outwardly directed exterior-facing surface of said building finishing element, the tab being configured so as to support said portion of the building finishing element and retain it in a fixed position.
[0013] According to another aspect of the invention, there is provided a method of securing a building finishing element to a support structure, said method including the steps of selecting one or more load bearing concealed building finishing element fixing tabs, each tab including a first portion and a second portion, connecting said first portion of the tab to a structure-facing surface of the building finishing element such that the second portion extends outwardly from the building finishing element, and connecting the second portion of the tab to a support structure to thereby secure the building finishing element to the support structure whereby the connection between the first portion of the tab and said structure facing surface of the building finishing element is concealed from an outwardly directed exterior facing surface of said building finishing element, the tab or tabs being configured to support the building finishing element and retain it in a fixed position.
[0014] According to another aspect of the invention, there is provided a load-bearing concealed corner trim fixing tab, said tab being substantially L-shaped and including a pair of perpendicularly extending arms, each arm including a first portion and a second portion, wherein each said first portion is adapted for connection to one of a pair of perpendicular structure-facing surfaces provided on a corner trim and such that each said second portion extends outwardly from its respective structure facing surface, said second portions each being adapted for connection to a corner structure, thereby to secure a portion of said corner trim to said corner structure such that the connection between each said first portion and said structure-facing surface of the trim is substantially concealed from an outwardly directed exterior-facing surface of said trim, the tab being configured so as to support said trim and retain it in a fixed position. This substantially L-shaped tab can be used for inside or outside corners of a structure.
[0015] In a preferred form the trim comprises a pair of trim members which are affixed together in a substantially L shaped configuration by connection of the perpendicular first portions of the tab to each of the structure facing surfaces of the trim elements.
[0016] According to another aspect of the invention, there is provided a concealed corner trim system including a pair of trim members, each trim member having a structure-facing surface and an exterior-facing surface; and at least one load-bearing concealed corner trim fixing tab, said tab being substantially L-shaped and including a pair of perpendicularly extending arms, each arm including a first portion and a second portion, wherein each said first portion is adapted for connection to a structure-facing surface of a respective one of a pair of trim members such that said trim members are affixed together in a substantially L-shaped configuration and such that each said second portion extends outwardly from its respective trim member, said second portions each being adapted for connection to a corner structure, thereby to secure a portion of each of said trim members to said corner structure such that the connection between each said first portion and said structure-facing surface of said respective trim member is substantially concealed from an outwardly directed exterior-facing surface of said respective trim member, the tab being configured so as to support said portions of the trim members and retain them in a fixed position.
[0017] According to another aspect of the invention, there is provided a method of securing a pair of trim members to a corner structure, said method including the steps of selecting one or more substantially L-shaped load bearing concealed corner trim fixing tabs, each tab including a pair of extending arms, each arm including a first portion and a second portion, connecting said first portions of the tab on each arm to a structure facing surface of a corresponding one of a pair of trim members such that the trim members are affixed together in a substantially L-shaped configuration and such that each second portion extends outwardly from its respective trim member, and connecting said second portions of the tab to a corner structure whereby connection between the first portion of the tab and said structure facing surface of the trim members is substantially concealed from an outwardly facing surface of the trim members, the tab or tabs being configured to support the trim members and retain them in a fixed position.
[0018] Preferably, the substantially L-shaped load bearing tabs may be utilized to connect a pair of trim members to either an external corner or an optional internal corner.
[0019] The above referenced system and method set out in the above aspects of the invention can be modified for use with a unitary corner trim element as described with reference to the substantially L-shaped fixing tab aspect of the invention. The tab in all aspects may be configured to support and positionally retain the building finishing elements via selection of various features including, for example, material properties, size and shape. Generally, the tabs will require a combination of load bearing strength, bending resistance under cantilevered loads and a resistance to buckling or extension under compressive or tensile loads.
[0020] In one embodiment the tab material is selected so as to have sufficient holding strength and rigidity while also being penetrable in situ with a suitable impact fastener such as a nail, staple or screw fastener. In such cases, the tab may be made of any suitable material including metals, plastics, timber or composites such as glass reinforced plastic, etc. Requisite strength and rigidity properties would depend on the properties of the trim component and the number of tabs proposed per trim component.
[0021] In accordance with one preferred embodiment of the invention, the first and/or second portions of the tab include one or more pre-formed fastener receiving perforations or areas directed to receive the fasteners, thereby enabling use of a harder, and, possibly structurally more rigid material, which in turn may facilitate use of thinner sectioned tabs which will allow the trim to sit closer for a more flush mounting to the supporting structure.
[0022] Alternately, each portion of the load-bearing tabs may include more than one perforation. Additionally, the load-bearing tabs may be multi-perforate. In such embodiments, the first and second portions may each be respectively connected to the corresponding trim member and the underlying structure via one or more of the available perforations. In other embodiments both portions may be solid and without perforations. Yet further embodiments may include a combination of any two or more of solid, single perforation, multiple positioned perforations or general and/or continuous perforations. The first and second portions each include at least one optional perforation for fastening and may be multi-perforate. The number of fasteners used to attach the tab to the trim member and the tab to the underlying building structure will typically depend on the size and weight of the trim member and in some circumstances regard may also be had to the resulting load requirements on the tab.
[0023] Advantageously, the perforations in the load-bearing tabs may allow the use of both impact fasteners and screw fasteners with thicker and/or harder high strength material tabs than would otherwise be possible. Again, the required overall strength of the tabs is typically determined by the strength required across one or more tabs to support a trim member having a given length and specific orientation, usually horizontal or vertical. The required strength of the tab may also be determined to some degree by the effect of winds loading on the trim member where this is a relevant consideration.
[0024] Additionally, the use of perforations advantageously assists with positioning the tabs relative to the trim members and the underlying structure and/or may provide a guide to appropriate fastener spacing and positioning relative to the tab boundaries. The perforations can be sized and located as necessary depending on the size and weight of the trim member, the number of fasteners required for the forces acting on the load-bearing tab, ease of installation, and for aesthetic reasons.
[0025] The perforations are preferably configured to correspond to the received fastener. The perforations may be of any suitable shape and size, including a clearance hole, aperture, cross, circle, square, etc. The perforations may include a screw thread.
[0026] Preferably, the fasteners are impact fasteners. The number of fasteners used to attach the tab to the trim member and the tab to the underlying building structure will typically depend on the size and weight of the trim member and the resulting load requirements on the load-bearing tab. In one embodiment staples are used to attach the tab to the trim member, however, alternate fastening means may be used. It is also preferred that nails are used to attach the tab to the structure. However, it will be appreciated that any suitable means of fastening may be used that are in compliance with local building codes. This may include, for example, screws, rivets, bolts, staples, adhesives etc.
[0027] In preferred embodiments of the invention the tabs include some form of indicia to provide fastener positioning guides and/or other information that may be useful to the installer. The indicia can be formed in any suitable manner including, for example, by embossing, engraving, etching or printing, and may be in multiple locations on the tabs. In one embodiment of the present invention, a positioning guide is located along a length of the tab. In another embodiment of the present invention, a positioning guide is located along a width of the tab. In another embodiment of the present invention, multiple positioning guides are located on the tab, such multiple positioning guides may be in the same or different directions from one another, depending on the desired positioning for the specific installation. For example, in one embodiment of the present invention, the tab contains a positioning guide running the length of the tab, and a shorter positioning guide perpendicular to the lengthwise positioning guide and running from the lengthwise positioning guide to the edge of the tab.
[0028] The invention advantageously allows the use of standard fastening guns and standard commercially available fasteners. This advantageously results in minimum cost of implementation and minimum additional skills required for installers. These advantages are further enhanced when the tabs include indicia in the form of fastening guides.
[0029] Preferably, the load-bearing tabs are discrete tabs. Advantageously, tabs are able to be connected to any position on the structure facing surface of the trim member. This provides flexibility of positioning the tabs to suit various installation requirements and work around various obstructions, etc. The width of each tab is preferably smaller than the edge dimensions of the building finishing element to which it is connected. In this regard, the width is preferably selected such that when a tab is secured to the end of a first building finishing element which is to abut with an adjacent second building finishing element, such as happens with trim at the corners of openings and the like, there is room for the second trim member to sit over the second portion of the tab securing the adjacent end of the first trim member, without the first portion of the tab on the second trim member overlapping with the second portion of the first trim member.
[0030] Preferably, the first portion and second portion of the tab are substantially collinear with respect to each other. The second portion preferably extends outwardly from the building finishing element in a direction parallel to the structure-facing surface.
[0031] When installed, the load-bearing tabs are required to resist compression loads, tension loads and cantilevered bending loads. In a preferred form, the load-bearing tabs are formed from steel or aluminum strips, however, it will be appreciated that a wide variety of materials and configurations could be used to achieve the desired result of supporting the building finishing element and fixing them to the underlying building structure.
[0032] In preferred forms, the building finishing elements are trim members which are preferably formed of fibre reinforced cement but can be made of other materials including but not limited to wood, vinyl, plastics, and the like and composites thereof.
[0033] Preferably the support structure and corner structure are formed using a weatherproof material. This material may be in the form of sheets or weather barriers. In one preferred form, the support structure and corner structure are formed from an OSB substrate. Alternatively, the support structure and corner structure may be formed from plywood sheets.
[0034] Preferably, each building finishing element is secured to the support structure by a plurality of the load-bearing tabs. It will be appreciated that the number, size and configuration of the tabs will depend upon the size and weight of the trim member. Other factors may, in some situations, include external forces acting on the building finishing element when installed, for example, wind loading.
[0035] Preferably, the structure facing surface of each building finishing element is substantially planar. In some embodiments, the rear-surface of each building finishing element includes a recess for locating the load-bearing tab such that, when connected to the trim member, the first portion of the tab lies generally flush with the structure-facing surface of the trim member. The structure facing surface of the trim member may also have one or more grooves along its length and/or width.
[0036] In some preferred applications, cladding is installed adjacent the edge of each installed trim member. Further preferably, the installed cladding covers the exposed second portion of each load bearing tab. A sealing compound is preferably applied between the edges of the trim and the adjacent ends of the cladding pieces.
[0037] While the preferred forms of the tabs, system and construction method relate to the installation of building finishing elements in the form of trim, other embodiments can be configured for use with other building finishing elements such as fascia boards, band boards, soffits and any other finishing elements where concealed fixing is desired using the basic principles described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:
[0039] FIG. 1 is a front view of a window trim installation of trim members incorporating fixing tabs in accordance with one embodiment of the present invention;
[0040] FIG. 2 is a rear view of one of the trim members from FIG. 1 , showing a use of load bearing tabs connected thereto;
[0041] FIG. 3 is a front view of the window from FIG. 1 , showing one side trim member installed;
[0042] FIG. 4 is a view similar to FIG. 3 , showing the side trim member as transparent to show the connection between the tabs and the structure facing side of the side trim member;
[0043] FIG. 5 is another front view of the window of FIG. 1 , showing the other side trim member installed;
[0044] FIG. 6 is a front view of the window of FIG. 1 , showing the bottom trim member installed;
[0045] FIG. 7 is a view similar to FIG. 6 , showing the bottom trim member as transparent to show the connection between the tabs and the structure facing side of the bottom trim member;
[0046] FIG. 8 is a perspective view of a corner trim member;
[0047] FIG. 9 is a perspective view showing one trim member connected to an L-shaped tab;
[0048] FIG. 10 is a top view showing the L-shaped configuration of the connected trim members;
[0049] FIG. 11 is an underside plan view of an alternative system incorporating a trim member with a clip retaining groove in its structure facing surface and a second embodiment concealed fixing tab; and
[0050] FIG. 12 is a an end view of the trim member and tab assembly shown in FIG. 11 .
DETAILED DESCRIPTION OF THE INVENTION
[0051] In the description which follows like parts are marked throughout the specification and drawings with the same reference numerals, respectively. The drawings figures may not necessary be to scale and certain elements may be shown in generalized or somewhat schematic form in the interest of clarity and conciseness.
[0052] Referring to FIGS. 1 and 2 of the drawings, a system according to one embodiment of the invention is illustrated in the form of window trim installation which includes a plurality of building finishing elements in the form of trim members 1 , each affixed around a window 2 to the underlying exterior structure of the building 3 by three rigid load bearing tabs 4 .
[0053] Each load bearing tab 4 includes a first portion 5 and a second portion 6 , each portion, optionally, having a number of perforations 7 . The tab 4 may be, for example, nailed, stapled, or screwed to a structure-facing surface 8 of each trim member 1 through one or more of the optional perforations 7 in the first portion 5 of the tab 4 , such that the second portion 6 extends outwardly from the trim member, as best shown in FIG. 2 . The second portion 6 of each tab 4 preferably extends directly outwardly in a direction parallel to the structure-facing surface 8 to advantageously provide parallel installation of the trim members relative to the underlying structure 3 . The tab 4 may be attached to the trim members 1 either on the building site during installation or pre-fitted elsewhere and delivered to the site. Tab 4 may be secured to the trim member 1 by laying the trim members 1 in the configuration in which they are to be applied to the structure 3 and utilizing tabs 4 of suitable width. In one embodiment, the width of tab 4 is selected such that when a tab 4 is secured to the end of a first trim member 1 which is to abut with an adjacent second trim member 1 , such as happens with the trim members at the corners of the illustrated window opening, there is room for the second trim member to sit over the second portion of the tab securing the adjacent end of the first trim member, without the first portion of the tab 5 on the second trim member overlapping with the second portion of the first trim member. This is best illustrated with reference to FIG. 7 which shows the first portions 5 of the tabs on the bottom trim member 11 as providing clearance with the second portions of the lowermost tabs on each of the side trim members. For trim member 1 having a width of 4″, the length and width dimensions of tab 4 is preferably about 3.5″×2″, respectively, and the overall thickness of tab 4 is generally 18 gauge. It is understood that tabs 4 may vary in length and width, depending, for example, on the size of the trim member. It is also understood that the thickness of tabs 4 may vary. In one embodiment of the invention tab 4 has a thickness in the range of from about 16 to 20 gauge. It will be further understood that the tabs 4 may be of varying shapes and sizes (and thicknesses) depending on various factors, for example, the type, size, and weight of the trim member utilized.
[0054] In some embodiments, the structure-facing surface 8 of each trim member 1 includes a recess (not shown) in which the load-bearing tab may be placed such that, when connected to the trim member, the first portion of the tab lies generally flush with the structure- facing surface of the trim member.
[0055] Turning to FIGS. 3 and 4 , there is illustrated an installation of building finishing elements around a window in accordance with one embodiment of the invention. As shown in FIGS. 3 and 4 , a building finishing element 1 is placed in the desired position at one side of the window and the protruding second portion 6 of each tab 4 is secured (e.g., by nailing) to the underlying exterior structure 3 of the building. This secures the building finishing element to the underlying support structure 3 . Referring to FIGS. 5 to 7 and FIG. 1 , additional trim members are installed by the same method to completely surround the window opening 2 . In the embodiment shown, the side trim members 9 which are to be fixed within the ends of the top and bottom trim members are installed first, followed by the top 10 and bottom 11 trim members. It will be appreciated that the order required will vary according to the particular configuration of the trim members in the installation.
[0056] As best shown in FIGS. 1 , 3 , 5 and 6 , the connection between the first portion 5 of each tab 4 and the structure facing surface 8 of the trim member 1 is not visible from an outwardly-directed exterior facing surface 12 of the trim member.
[0057] The tabs 4 and trim members 1 may also be used to provide a door trim installation (not shown), in which case there is typically no bottom trim member 11 present. The location of the tabs with respect to each trim member may necessarily be altered to suit such an installation. For example, in a door trim installation, the side trim members 9 may each have one tab connected to the upper end of the trim member and one or more tabs connected along the length of the trim member so that the trim member can be installed with the lower end substantially flush to the ground, if desired.
[0058] Referring now to FIGS. 8-10 , a corner trim arrangement 13 is shown having a pair of trim members 14 , 15 connected to a substantially L-shaped tab 16 . The structure facing surface 17 of one of the trim members 14 is connected to a first portion 18 of a respective arm 19 of the tab via one or more of the optional perforations 20 in the respective first portion 18 , as shown in FIGS. 8 and 9 . The other trim member 15 is positioned at right angles to the first trim member 14 and its structure facing surface 17 is connected to the first portion 18 of the other arm 21 of the load bearing tab 16 , such that the trim members 14 , 15 form an L-shape when viewed in cross-section. In the embodiment shown, two L-shaped tabs 16 are used to connect the trim members 14 , 15 together. However, it will be appreciated that any number of tabs 16 may be used, depending upon the size and weight of the trim members and, in some circumstances, the forces acting upon them when installed may also need to be taken into consideration. The trim members are back fixed together with the external faces (not shown) of the trim members being free from any fixing marks.
[0059] Optionally, the first portion 18 of each arm 19 , 21 includes at least one perforation 20 to facilitate fastening of the tab 16 to each trim member 14 , 15 . In the embodiment shown, each first portion 18 includes four perforations 20 however it will be appreciated that the first portions may each include any number of perforations. The two first portions of the L-shaped tab 16 may each include a different number of perforations, if desired. In some embodiments, each first portion 18 will be multi-perforate to allow for multiple connections points as well as providing a number of options in respect of the location of each of the connection points relative to the L-shaped tab. In other preferred embodiments no perforations will be required and the fasteners can automatically pierce through the tab portions during the fastening process.
[0060] It will be appreciated that the trim members 14 , 15 may each be installed on the other side of the L-shaped tab 16 to form an internal corner (not shown).
[0061] Each arm 19 , 21 of the load bearing tab 16 is longer than the width 22 of the connected trim member 14 , 15 , forming a second portion 23 which extends outwardly from the respective trim member.
[0062] The corner trim arrangement 13 is positioned with the L-shaped tabs 16 placed adjacent a corner structure (not shown), such as a wall or a frame, and the overhanging second portions 23 of the tabs 16 are connected to the underlying structure via the optional perforation or perforations 20 in each second portion 23 . It will be understood that the corner structure may be either an external corner as for the corner trim arrangement 13 shown in FIG. 8 , or an internal corner for a corner trim arrangement (not shown) where the structure facing surfaces of the trim members 14 , 15 are each connected to the other side (not shown) of the L-shaped load-bearing tab 16 .
[0063] While the corner trim illustrated is comprised of two planar trim members, it will be appreciated that the L shaped tab can readily be used with preformed three dimensional corner members such as those that may be pre-connected to each other prior to installation, or unitary corner pieces such as those that may be formed by a casting, folding or extrusion process.
[0064] Following installation of the trim members 1 , 14 , 15 around a window 2 or door opening or to a corner structure, cladding (not shown) is installed adjacent the edge of each trim member 1 , 14 , 15 . The installed cladding ideally abuts the edge of the adjacent trim member and covers the exposed second portion 6 , 23 of each load bearing tab. A weatherproof sealing compound (not shown) can also be applied to any gaps between the cladding and the trim members to provide additional protection against weather effects.
[0065] As shown in FIG. 10 , for trim members 14 , 15 having a width of 4″, the length and width dimensions of tab 16 is preferably about 5.5″ long for the first arm 19 , 5.5″ long for the second arm 19 and 1.5″ in width for both first and second arms, and the overall thickness of tab 16 is generally 18 gauge. It is understood that tab 16 may vary in length and width, depending, for example, on the size of the trim members 14 , 15 . In another embodiment, the length of the first arm 19 of the substantially L-shaped tab 16 is approximately 5.9″ and the length of the second arm 21 of the substantially L-shaped tab 16 is approximately 6.7″. It is also understood that the thickness of tab 16 may vary. It will be further understood that the tab 16 may be of varying shapes and sizes (and thicknesses) depending on various factors, for example, the type, size, and weight of the trim member utilized.
[0066] In one embodiment, the length of the planar tab 4 is approximately 3.0 inches. In another embodiment the width of the tab 4 , 16 is about 2″ and the preferred thickness of the tabs is about 0.63″. In a further embodiment of the invention tab 4 has a thickness in the range of from about 16 to 20 gauge.
[0067] The optional perforations 7 , 20 are preferably circular in shape and in one embodiment have a diameter of 0.094″. Where the tabs are multi-perforate, the perforations preferably have a centre to centre distance of 0.144″ with a perforate area of approximately 40% of the total tab area. Further preferably, the perforations are arranged in rows with every second row offset to provide a close packing perforation density. It will be appreciated, however, that a circular geometry is not essential and that the perforations may be slot, diamond, square, or any other suitable shape.
[0068] While the preferred form of the invention utilizes varying tabs which are not perforated being penetrable in situ with a range of suitable fasteners including nails, staples, and/or screws as required, other embodiments utilize various other perforated sheet materials which have sufficient holding strength and rigidity. Tabs of the present invention may be made of any suitable material including metals, plastics, timber or composites such as glass reinforced plastic, etc. Requisite strength and rigidity properties of the tab would depend on the properties of the trim component and the number of tabs proposed per trim component. As indicated previously, the tab may be configured to support and positionally retain the trim member via selection of various features including, for example, any one or more of: material properties, size and shape. Generally, the tabs will require a combination of load bearing strength, bending resistance under cantilevered loads and a resistance to buckling or extension under compressive or tensile loads respectively.
[0069] In preferred forms the tabs may include some form of indicia to provide fastener positioning guides and/or other information that may be useful to the installer. The indicia can be formed in any suitable manner including, for example, by embossing, engraving, etching or printing.
[0070] Preferably the support structure and corner structure are formed with a weatherproof material such as, for example, weather resistant and/or water resistant house wrap over an OSB substrate.
[0071] While three tabs are connected to each window trim member and two tabs to each corner trim member in the accompanying drawings, it will be appreciated that any number of tabs may be used. For example, in the case of short and/or lightweight window trim pieces, a tab affixed at each end of the trim member is likely to be suitable, while for longer and/or heavier trim pieces, it may be necessary to connect one or more tabs along the length of the trim member.
[0072] It will be appreciated that concealed tabs in accordance with the present invention are able to be connected to any position on the trim members. This advantageously provides flexibility of positioning the tabs in situ to suit various installation requirements.
[0073] In preferred embodiments, the width 24 of each tab is smaller than the edge dimensions of the trim member or trim member to which it is connected. For example, the width of each tab 4 , 16 is significantly smaller than the length of the trim member 1 , 14 , 15 . For installations where a substantially planar tab 4 is used, it is also preferred that the width of the tab 4 is smaller than the width of the trim member 1 to allow for flexibility of connection of tabs to the ends 25 of the trim member. As best shown in FIG. 7 , the smaller width of tab 4 allows the second portions of the tab 4 connected to side members 9 to be concealed by the adjacent bottom trim member 10 and top trim member 11 without the tabs overlapping.
[0074] In one embodiment, staples are used to connect the load bearing tab 4 , 16 to the trim members. These staples are necessarily short enough so that they do not protrude all the way through the trim but have sufficient holding power to maintain the connection between the trim member and the tab under normal load conditions. This is preferably advantageous when the trim member is made of fiber cement. The fasteners used to fix the second portions of the tab 4 , 16 to the support structure and corner structure are typically normal nail gun framing constructions nails
[0075] In another embodiment, hardened “T” nails (Brad nails) are used to connect the load bearing tab 4 , 16 to the trim members. These nails are necessarily short enough so that they do not protrude all the way through the trim but have sufficient holding power to maintain the connection between the trim member and the tab under normal load conditions. This is preferably advantageous when the trim member is made of fiber cement. The nails used to fix the second portions of the tab 4 , 16 to the support structure and corner structure are typically normal nail gun framing constructions nails.
[0076] While nails have been referred to throughout the specification as one method of connecting the tabs to both the trim members and the underlying building structure, it will be appreciated that any suitable means of fastening may be used. This may include, for example, screws, rivets, bolts, staples, adhesives, etc.
[0077] Referring next to FIGS. 11 and 12 , another embodiment of a system for concealed fastening of building finishing elements is illustrated. As shown in FIGS. 11 and 12 , the system incorporates a trim member 26 with a clip retaining groove 27 in its structure facing surface 28 and a concealed fixing tab 29 . The tab 29 includes on its first portion 30 a retaining formation such as the generally v or tick sectioned clip element shown generally at 31 . The clip element is configured in this particular embodiment to have a sprung flange 32 which in use in entering the groove 27 , compresses toward the adjacent planar part 33 of the first portion 30 , and then springs away to engage against the inner surface 34 of the groove to thereby retain the tab. It will be appreciated that the groove may be a simple channel shape of generally u or v shaped cross section or include some element of undercut such as in an “l” or “t”-slot to help retain the clip portion of the tab. Where the building finishing element is longitudinal such as with the illustrated trim component, the groove is preferably provided along the full length of the building element. In some forms more than one groove may be provided.
[0078] While the form of the retaining formation can vary, so can the rest of the tab. For example the second portion may be perforate or solid or any combination thereof. The earlier comments apply in terms of preferred methods of securing the second portion of the tab using one or more siding nails although once again other alternative fasteners may be suitable.
[0079] Preferably, the load bearing tabs in all embodiments are formed of aluminum or steel. However, it will be appreciated that the tabs may be formed of any material suitable for supporting the trim members and fixing them to the underlying structure.
[0080] The optional perforations in the tabs advantageously allow fastener fixing with thicker tabs than would otherwise be possible. The thickness of the tabs is typically determined by the strength required to support a trim member having a given length and specific orientation, usually horizontal or vertical. The thickness of the tab may also be influenced to some degree by the effect of wind loading on the trim member.
[0081] The system advantageously allows the use of standard fastening guns and standard commercially available fasteners. This advantageously results in minimum cost of implementation and minimum additional skills required for installers.
[0082] Although preferred embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.
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In one form of building structure, trim installations are applied around window or door frame openings and at internal or external corners of a building. The trim serves both an aesthetic purpose in adding a decorative feature to building envelopes and also adds an additional weatherproofing purpose in allowing for more complete weatherproofing of building envelope corners and openings. The present invention relates to a concealed fastening building finishing element system that enables concealed fastening of finishing elements such as trim components, fascia boards, frieze boards, belly band boards, and the like to an underlying structure and to the fixings used in these systems. The invention is particularly useful with trim elements around window and door frame openings and at building corners.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention may be generally classified in the field of oscillator circuitry, and more particularly, circuitry of this type specially adapted for use in simultaneous multi-frequency ultrasonic generators of the kind employed to resonate transducers associated with cleaning tanks in which articles are immersed in a liquid subjected to ultrasonic wave energy transmitted by the transducer or transducers.
2. Description of the Prior Art
It is already known to utilize the concept of resonating a transducer in a plurality of differing fundamental modes and their harmonics for transmitting, simultaneously, a multiplicity of frequencies in the ultrasonic range, through a liquid of a cleaning tank to which the transducer is attached. U.S. Pat. No. 3,371,233 issued to Edward G. Cook discloses this concept.
It has been found, however, that while this concept produces excellent results, and has found strong commercial acceptance, the oscillating circuitry embodied therein results in less output power than is truly desirable, in relation to the energy input to the oscillator. And, it is also considered that improved transistors, having higher reverse base-emitter breakdown voltage ratings, could be advantageously employed in the oscillation circuits, but for the fact that the present circuit configurations have a base drive network that is unsuitable for this purpose. Accordingly, while the existing circuitry as disclosed in the above mentioned patent is commercially acceptable, improvements therein are desirable for the purpose of making effective use of newly available transistor technology.
SUMMARY OF THE INVENTION
Summarized briefly, the present invention utilizes an oscillator circuit for simultaneous multi-frequency ultrasonic generators, in which transistors having high transverse base-emitter breakdown voltage ratings are employed, in association with an improved base drive network in which an alternative discharge path is substituted for coupling capacitors already incorporated in the circuit, to compensate for a lower averge discharge current through the base-emitter circuits of the transistors resulting from their higher reverse base-emitter breakdown voltage.
BRIEF DESCRIPTION OF THE DRAWING
While the invention is particularly pointed out and distinctly claimed in the concluding portions herein, a preferred embodiment is set forth in the following detailed description which may be best understood when read in connection with the accompanying drawings, in which:
FIG. 1 is a schematic view of a prior art circuit already in use in simultaneous multi-frequency ultrasonic generators; and
FIG. 2 is a similar view showing the improvements in said circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In order to obtain a full appreciation of the nature and importance of the present improvement, it is considered desirable to first describe in detail a known prior art circuit used for the purpose of resonating a transducer in a plurality of differing fundamental modes (and their harmonics) simultaneously. FIG. 1 is an illustration of such a circuit.
In FIG. 1, there is shown a prior art circuit in which lines 10, 12 extend from a source of line voltage, in this case a single phase supply in which main power supply lines 10, 12 are extended from a 115 V.A.C. supply source. Lines 10, 12, extend to opposed terminals 14, 16 of a full wave bridge rectifier 18, having rectifiers D1, D2, D3, D4. Extending from the output terminals 20, 22 of the bridge rectifier are power supply leads 24, 26 through which the rectified voltage is applied to an oscillator circuit 28. This circuit, when used in a simultaneous multi-frequency ultrasonic generator, must be capable of oscillating from a voltage of near zero volts to a value equal to the peak of the rectified line voltage. A capacitor C1 is connected across the supply leads 24, 26, for the purpose of providing a low impedance power supply bypass at all oscillation frequencies. It may be observed that the capacitor is not of sufficient size to serve as a filter at twice power line frequency.
The oscillator circuit 28, the component values, and the transducer characteristics, are typically selected, in the prior art circuitry shown in FIG. 1, to produce multiple frequencies at the generator output. This inhibits the formation of standing waves in the cleaning tank and provides more uniform cleaning in relation to the depth of the tank.
The operation of the FIG. 1 prior art circuit may be readily understood, in that when voltage is applied thereto, resistors R3, R4, R9, and R10 bias transistors Q1, Q2, Q3, Q4 "on". A voltage thus appears across capacitors C4, C5 and windings L2, L5. As current starts to flow through the primary windings L2, L5 of the respective oscillator coils embodied in the illustrated circuit, a current is induced in the feedback windings of said coils, shown at L1 and L6 respectively. The feedback windings are wound upon the same oscillator coils as the respective primary windings L2, L5. The current thus imposed upon the feedback windings causes the transistors to turn "on" still further, until the circuit saturates.
Capacitors C4, C5 and primary windings L2, L5 form a tuned circuit which produces oscillations by causing the feedback windings L1 and L6 to alternately turn the transistors "on" and "off".
Incorporated in the circuit are feedback capacitors C2, C3, C6, C7. These are charged when the transistors are turned on, and are discharged when the transistors are turned off. The discharge current flowing from the transistors flows through the emitter resistors R1, R6, R7, R12, through the reverse biased base emitter junctions of transistors Q1, Q2, Q3, Q4, and through the base resistors R2, R5, R8, and R11, generating heat in all of these components. Heat is also generated in the transistors themselves, when the collector voltage and the collector current overlap.
The above constitutes a prior art circuit which has been found to work efficiently, when older transistor technology was used. Newer transistors are known, however, that have higher reverse base-emitter breakdown voltage ratings, resulting in marked efficiency of the oscillating circuit in the above described environment.
However, it has been found that in order to use transistors having these improved characteristics, a new base drive network must be developed, since the discharge path embodied in the prior art oscillating circuit described above, offers insufficient compensation for the lower average discharge current passing through the transistor base-emitter circuits as a result of their higher reverse base-emitter breakdown voltages.
In the improved circuit devised to offer this specific compensation, and shown in FIG. 2, the feedback capacitors C2, C3, C6, and C7 have a charge stored in them when the transistors are driven "on". In the next half cycle, these capacitors must be discharged, else they will bias the transistor bases negatively and thus prevent stable oscillation. The discharge currents flow through the base resistors R2, R5, R8, and R11, the transistors Q1, Q2, Q3, and Q4, and the emitter resistors R1, R6, R7, and R12 respectively. By increasing the base-emitter reverse breakdown voltage, less capacitor discharge current flows in the transistors, and less power is lost in the resistive elements as heat. Measurements of transistors Q1, Q2, Q3 and Q4 usable advantageously in the FIG. 2 circuitry, have revealed that their actual base-emitter breakdown voltages are in the range of 10 to 15 volts. These transistors are Type MJ-12010, a product of Motorola Semi-Conductor Products, Inc., Phoenix, Ariz. Accordingly, in the improved circuit, resistors R13, R14, R15, and R16 have been added in parallel with capacitors C2, C3, C6, and C7 respectively, to provide an alternate discharge path for the feedback capacitors. This replaces the discharge path in the original circuit which included the reverse breakdown of the transistors' base-emitter junctions. The higher reverse base-emitter breakdown voltage rating of the new transistors in and of itself reduces the discharge current which can flow in that path. It may be noted, in this regard, that resistor R3 is still connected in the circuit in the same manner, basically, as it was in the prior art circuit, being connected by lead 30 between the R2-C2 junction 31 and the power supply lead 26.
As noted, higher reverse base-emitter breakdown voltage ratings resulting from new and improved transistor technology effects a reduction of the discharge current flow in the path through the feedback capacitors. However, unless the feedback capacitors are substantially discharged during alternate half cycles of the driving wave form, unstable oscillator operation will occur. This is true especially during the low voltage "turn on" portion of each cycle of the power supply voltage. In the improved arrangement, most of the discharge current is diverted from the transistors. There is, thus, an effective reduction in power loss, and hence in temperature rise, in the transistors and in their base and emitter resistors. A consequent improvement in transistor reliability and oscillator power efficiency results.
The number of turns on the feedback windings L1 and L6 of the oscillator coils is proportioned in accordance with the base drive resistor-capacitor configuration shown in FIG. 2, and values are selected for these components to achieve the desired wave form for the base drive of the transistors. This change has increased output power while reducing power loss in the transistors. This particular improvement results by reason of a decrease in the overlap of the collectors' voltage and in the current wave form.
It may also be observed that in the FIG. 2 circuit configuration, it is possible to use only a single starting resistor R3. The resistors R4, R9, R10 are not needed. This is true because only one transistor is required to start the oscillations since all are interconnected by means of the parallel collector circuits and the primary windings of the oscillation transformers. The other three transistors (in this case Q2, Q3, and Q4) start oscillating when the feedback voltage from windings L1, L6 becomes great enough to exert a forward bias on their base-emitter junctions.
In the FIG. 2 circuit, as in the prior art circuit, the several transistors Q1, Q2, Q3, and Q4 are connected in parallel, with their collectors connected to conductor 34, and their emitters connected through resistors R1, R6, R7, R12 to power supply lead 24. Thus, the application of the rectified line voltage through leads 24, 26 to the circuit results in appearance of voltage across capacitor C4 and primary winding L2, which are connected between lead 34 and the rectified power supply lead 26. This occurs concurrently with the biasing of the transistors to their "on" condition by resistor R3, which actually turns on transistor Q1, but produces the same response in the other transistors in view of their connection in parallel with transistor Q1 by reason of the common collector line 34. During this half cycle, windings L3, L4, through leads 36, 38 connected thereto, cause the transducer 40 to resonate in the manner disclosed in U.S. Pat. No. 3,371,233 mentioned above, the disclosure of which is incorporated herein by reference. Winding L7 is connected between the leads 36, 38.
Since resistors R4, R9, and R10 are not needed in the improved circuit shown in FIG. 2, the connecting lead 32 shown in FIG. 1, extending parallel to the lead 30, is omitted in FIG. 2.
The improved circuit, it may be noted, has greater output power than the original circuit, and transistor losses are measurably reduced.
While particular embodiments of this invention have been shown in the drawings and described above, it will be apparent that many changes may be made in the form, arrangement and positioning of the various elements of the combination. In consideration thereof it should be understood that preferred embodiments of this invention disclosed herein are intended to be illustrative only and not intended to limit the scope of the invention.
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An improved oscillator circuit, adapted especially for use in generating multi-frequency wave patterns occurring within the ultrasonic range, incorporates a transistor base drive network in which an alternate discharge path is used for coupling capacitors already known in circuits of this type. Power losses occurring in the transistors are lessened by employing transistors having reverse base-emitter breakdown voltage ratings that are higher than those conventionally employed. Use of the substituted transistors becomes possible by substituting the mentioned alternate discharge path, to compensate for the lower average discharge current that is known to pass through the base-emitter circuits of the transistors by reason of their higher reverse base-emitter breakdown voltages. The improved circuit in this way reduces power loss and its consequent temperature rise in the transistors and in their base and emitter resistors to increase output power to the accompanying reduction of transistor losses.
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BACKGROUND OF THE INVENTION
The present invention relates to a substrate transferring apparatus for transferring a large-sized substrate such as an LCD substrate, and to a substrate processing apparatus using the substrate transferring apparatus.
In the manufacture of liquid crystal displays (LCD), a circuit pattern is formed by the so-called lithography technique. That is, the LCD substrate, made of glass, is coated with photo resist liquid to form a resist film, the resist film is exposed to a pattern correspond to the circuit pattern, and the LCD substrate is developed to form the circuit pattern thereon.
Conventionally, a series of coating/developing processes is carried out by a system in which the respective processing apparatus are incorporated. Such a system comprises processing units for performing the respective processes such as a cleaning process, a coating process, a developing process and a heating process, and a cassette station on which a cassette for containing a plurality of substrates is mountable. A substrate transferring apparatus is provided between the cassette station and a transferring mechanism of each processing unit to receive and transfer the substrate.
Such a substrate transferring apparatus is structured to be movable on a carrying path formed along the plurality of cassettes arranged in parallel in the cassette station. The substrate transferring apparatus comprises a support member, which is called tweezers, for supporting the substrate, a base member for supporting the support member to be movable back and forth, a lifting member, provided to be movable upward and downward, for supporting the base member to be rotatable in a horizontal plane, and a hold-and-guide member, formed on both sides of the lifting member, for supporting and guiding the lifting member when the lifting member moves up and down. The hold-and-guide member is structured such that its upper end is always positioned at a lower portion of the base member not to prevent the rotation of the base member.
By the way, the need for enlarging the size of the LCD substrate has recently been increased more and more. Specifically, there has been needed the size of the substrate, which is greatly enlarged, for example, 830×650 mm from the conventional size of 650×550 mm. If the size of the substrate is greatly increased, an amount of deflection of the substrate is increased in the cassette. Therefore, the distance between substrates in the cassette must be increased. From the viewpoint of improvement of throughput, the number of substrates to be contained in one cassette must be maintained. Therefore, the height of the cassette is increased, the motion strokes of the lifting member of the substrate transfer mechanism is increased. In this case, the upper end of the hold-and-guide member is positioned at the lower portion of the base member. For this reason, the upper end position is adjusted to a position where the rotation of the base member is prevented in receiving/transferring the substrate from/to the lower stage of the cassette. As a result, there emerges a need for reducing the lower end position of the guide and support member to be lower than a floor surface. This forces a user to do additional work, unfavorably. Also, if the hold-and-guide member is structured to be projectable upward than the base member in order that the base member is rotatable, the transferring apparatus itself will be extremely enlarged.
BRIEF SUMMARY OF THE INVENTION
An object of the present invention is to provide a substrate transferring apparatus, which can deal with an increase in motion strokes of a lifting member without providing additional work and enlarging the size of the apparatus when transferring a large-sized substrate, and to provide a substrate processing apparatus using the substrate transferring apparatus.
According to a first aspect of the present invention, there is provided a substrate transferring apparatus comprising:
a substrate support member for supporting a substrate;
a base member for holding the substrate support member to be movable horizontally;
a lifting member, having one end and another end, for holding the base member at the one end to be rotatable in a horizontal plane, the lifting member being movable upward and downward; and
a hold-and-guide member for holding the lifting member at the another end and for guiding the lifting member when the lifting member is moved upward and downward.
According to a second aspect of the present invention, there is provided a substrate transferring apparatus comprising:
a substrate support member for supporting a substrate;
a base member for holding the substrate support member to be movable horizontally;
a first driving mechanism, provided in the base member, for linearly driving the support member;
a lifting member, having one end and another end downward, for supporting the base member to be rotatable in a horizontal plane, the lifting member being movable upward and downward;
a second driving mechanism, provided in the lifting member, for rotably driving the base member;
a hold-and-guide member for holding the lifting member at the another end and for guiding the lifting member when the lifting member is moved upward and downward; and
a third driving mechanism for driving upward and downward the lifting member.
According to a third aspect of the present invention, there is provided a substrate processing apparatus for providing a predetermined process to a substrate to be processed, comprising:
a processing section for providing the predetermined process to the substrate to be processed; and
a substrate transferring apparatus for receiving and transferring the substrate between a substrate carrying in/out section or the other apparatus and the processing section;
the substrate transferring apparatus comprising:
a substrate support member for supporting the substrate;
a base member for holding the substrate support member to be movable horizontally;
a lifting member, having one end and another end, for holding the base member at the one end to be rotatable in a horizontal plane, the lifting member being movable upward and downward; and
a hold-and-guide member for holding the lifting member at the another end and for guiding the lifting member when the lifting member is moved upward and downward.
According to a fourth aspect of the present invention, there is provided a substrate processing apparatus for providing a predetermined process to a substrate to be processed, comprising:
a processing section for providing the predetermined process to the substrate to be processed; and
a substrate transferring apparatus for receiving and transferring the substrate between a substrate carrying in/out section or the other apparatus and the processing section;
the substrate transferring apparatus comprising:
a substrate support member for supporting the substrate;
a base member for holding the substrate support member to be movable horizontally;
a first driving mechanism, provided in the base member, for linearly driving the support member;
a lifting member, having one end and another end downward, for supporting the base member to be rotatable in a horizontal plane, the lifting member being movable upward and downward;
a second driving mechanism, provided in the lifting member, for ratably driving the base member;
a hold-and-guide member for holding the lifting member at the another end and for guiding the lifting member when the lifting member is moved upward and downward; and
a third driving mechanism for driving upward and downward the lifting member.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
FIG. 1 is a perspective view showing a resist coating/developing system to which the substrate transferring apparatus of the present invention is applied;
FIG. 2 is a plane view showing an arranging state of a transferring apparatus of a receiving/transferring section in the coating/developing system of FIG. 1;
FIG. 3 is a perspective view showing an arranging state of a transferring apparatus of a receiving/transferring section in the coating/developing system of FIG. 1;
FIG. 4 is a horizontal cross sectional view showing an arranging state of a transferring apparatus of a receiving/transferring section in the coating/developing system of FIG. 1; and
FIG. 5 is a vertical cross sectional view showing an arranging state of a transferring apparatus of a receiving/transferring section in the coating/developing system of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
The embodiments according to the present invention will now be specifically described with reference to the accompanying drawings.
FIG. 1 is a plan view showing an LCD substrate coating/developing process system.
The coating/developing process system comprises a cassette station 1 in which a cassette C holding a plurality of substrates G therein is loaded, a processing section 2 including a plurality of processing units which apply a series of processes including coating/developing of resist to the substrates G, and an interface portion 3 for transferring the substrate G between the coating/developing process system and an exposure unit (not shown). The cassette station 1 and the interface portion 3 are respectively provided to one end and the other end of the processing section 2.
The cassette station 1 comprises a transferring section 10 for transferring an LCD substrate between the cassette C and the processing section 2. Loading/unloading the cassette C is carried out into/from the cassette station 1. The transferring section 10 comprises transferring apparatus 11 which is movable on transferring paths 10a provided along an alignment direction of the cassettes C, and the substrate G can be carried between the cassette C and the processing section 2 by virtue of the transferring apparatus 11.
The processing section 2 is divided into a front stage portion 2a, an intermediate stage portion 2b, and a rear stage portion 2c, in which transferring paths 12, 13, 14 are provided in their central areas respectively and processing units are arranged on both sides of these transferring paths respectively. Relay portions 15, 16 are provided between the front stage portion 2a, the intermediate stage portion 2b, and the rear stage portion 2c respectively.
The front stage portion 2a comprises a main transferring apparatus 17 which is movable along the transferring path 12. Two cleaning units (SCR) 21a, 21b are provided to one end side of the transferring path 12, while a ultraviolet irradiating/cooling unit (UV/COL) 25 and a heating process unit (HP) 26 and a cooling unit (COL) 27, both being stacked as two upper and lower stages respectively, are provided to the other end side of the transferring path 12.
The intermediate stage portion 2b comprises a main transferring apparatus 18 which is movable along the transferring path 13. A resist coating process unit (CT) 22 and a peripheral resist removing unit (ER) 23 which can remove the resist coated on the peripheral portion of the substrate G are provided integrally to one end side of the transferring path 13, whereas heating process units (HP) 28 which are stacked as two stages vertically, a heating/cooling process unit (HP/COL) 29, in which the heating process unit and the cooling process unit are stacked vertically, and an adhesion/cooling process unit (AD/COL) 30, in which an adhesion process unit and a cooling unit are stacked vertically, are provided to the other end side of the transferring path 13.
The rear stage portion 2c comprises a main transferring apparatus 19 which is movable along the transferring path 14. Three developing process units 24a, 24b, 24c are provided to one end side of the transferring path 14, while heating process units 26, which are stacked as two stages vertically, and two heating/cooling process units (HP/COL) 32, 33, in which a heating process unit and a cooling process unit are vertically stacked respectively, are provided to the other end side of the transferring path 14.
It is apparent from FIG. 1, the processing section 2 is so constructed that spinner system units such as a cleaning process unit 21a, a resist process unit 22a, a developing process unit 24a, etc. are arranged on one side of the transferring path, while only thermal system process units such as the heating process unit, the cooling process unit, etc. are arranged on the other side of the transferring path.
Chemical liquid supply units 34 and spaces 35 for loading and unloading of the main transferring apparatus are arranged at the spinner system units side of relay portions 15, 16.
The interface portion 3 comprises an extension 36 for holding the substrate temporarily when the substrate is transferred/received to/from the processing section 2, two buffer stages 37 which are provided on both sides of the extension 36 and in which buffer cassettes are arranged, and a transferring mechanism 38 for transferring the substrate G between the extension 36/two buffer stages 37 and an exposure unit (not shown). The transferring mechanism 38 includes a transferring arm 39 which is movable on transferring paths 38a provided along the alignment direction of the extension 36 and the buffer stages 37. The substrate G can be carried between the processing section 2 and the exposure unit by the transferring arm 39.
Like the above, space saving and improvement in the efficiency of the process can be achieved by incorporating respective process units together.
In the coating/developing process system as constructed above, the substrate G in the cassette C is carried into the processing section 2. Then, in the processing section 2, first the substrate G is subjected to surface modifying/cleaning process in the ultraviolet irradiating/cooling unit (UV/COL) 25 and then to scriber cleaning process in the cleaning units (SCR) 21a, 21b after the substrate has been cooled, then is dried by heating operation in the heating process unit (HP) 26, and then is cooled in the cooling unit (COL) 27.
After this, the substrate G is carried to the intermediate stage portion 2b and then to hydrophobicity process (HMDS process) in the upper stage adhesion process unit (AD) of the unit 30 in order to enhance a fixing property of the resist. Then, the substrate G is cooled in the cooling unit (COL) and then coated with the resist in the resist coating unit (CT) 22. Then, extra resist on the peripheral portion of the substrate G is removed in the peripheral resist removing unit (ER) 23. Then, the subject G is subjected to prebake process in the heating process unit (HP) in the intermediate stage portion 2b and then is cooled in the lower stage cooling unit (COL) in the unit 29 or 30.
Thereafter, the substrate G is carried by the main transferring apparatus 19 from the relay portion 16 to the exposure unit via the interface portion 3, and then predetermined patterns are exposed on the substrate G. Then, the substrate G is carried again via the interface portion 3 and then is developed in any of the developing process units (DEV) 24a, 24b, 24c to form predetermined patterns thereon. The developed substrate G is subjected to postbake process in any of the heating process unit (HP), then is cooled in the cooling unit (COL), and then is put in the predetermined cassette on the cassette station 1 by virtue of the main transferring apparatus 19, 18, 17 and the transferring apparatus 11.
Next, the following will specifically explain the transferring apparatus 11 in the receiving/transferring section 10 of cassette station 1 with reference to FIGS. 2 to 5. FIG. 2 is a plane view showing an arranging state of the transferring apparatus 11 of the transferring section 10, FIG. 3 is a perspective view of the transferring section 10, FIG. 4 is a horizontal cross sectional view thereof, and FIG. 5 is a vertical cross sectional view thereof.
As shown in FIG. 2, the transferring apparatus 11 is movable along the carrying path 12. The transferring apparatus 11, as shown in FIG. 3, comprises a substrate support member 41, a base member 42, a lifting member 43, and a hold-and-guide member 44. The substrate support member 41 supports the substrate G to receive and transfer the substrate G. The base member 42 supports the substrate support member 41 to be movable back and forth in a horizontal plane. The lifting member 43, which is provided to be movable up and down, supports the base member 42 to be rotatable in a horizontal plane. The hold-and-guide member 44 supports the lifting member 43 in its single support state, and guides the lifting member 43 at the time of moving up and down the lifting member 43.
As shown in FIG. 2, the hold-and-guide member 44 can be moved on the carrying path 10a by a driving apparatus (not shown) in a state in which a leg portion 45 is guided by a rail 46 provided on the carrying path 12. Then, the hold-and-guide member 44 is moved to the position of a predetermined cassette C, so that the substrate G is loaded and unloaded on/from the cassette C. Also, the hold-and-guide member 44 is moved to a position of the main transferring mechanism 17, so that the substrate G is received and transferred between the main transferring mechanism 17 and the processing section 2.
In the drive control of the up and down motion of the lifting member 43, that of the rotation of the base member 42, and that of the back and forth motion of the substrate support member 41, there is used the so-called S-shape driving control method to transfer a large-sized substrate with high throughput and high transfer stability. The S-shape driving control method is that the driving velocity is changed to describe an S-shape at the operation starting and stopping time instead of linear driving. Also, from a viewpoint of the improvement of throughput, there is used the so-called pass-operation in which a next operation started before one operation is completed. Moreover, from a viewpoint of transfer stability, multishaft synchronization and auto-acceleration are used. The multishaft synchronization is that the other shafts move in agreement with the terminal of the rate-determining shaft when a plurality of shafts moves. The auto-acceleration is that acceleration and deceleration value is controlled when the range of motion is small.
As shown in FIG. 5, the hold-and-guide member 44 is box-shaped to have a hollow interior. In the interior of the hold-and-guide member 44, a pair of guide rods 50a and 50b for guiding the lifting member 43 is perpendicularly provided on both end portions widthwise. Receiving plates 51a and 51b are fixed to the rear sides of the guide rods 50a and 50b, respectively. A ball screw 53 for moving up and down the lifting member 43 is perpendicularly provided at the center of the interior of the support guide member 44. The ball screw 53 is rotated through a belt (not shown) by a motor 57 provided on the bottom of the hold-and-guide member 44.
As shown in FIG. 3 and FIG. 4, a pair of connecting sections 43a and 43b, which project inwardly, is formed widthwise on both end sides of the base portion of the lifting member 43. A slit 47 (FIG. 4) is perpendicularly formed on the front surface of the hold-and-guide member 44 along the motion paths of the connecting sections 43a and 43b not to prevent the motion thereof when the lifting member 43 moves up and down. In the hold-and-guide member 44, the connecting sections 43a and 43b are connected to a plate member 48, which is provided to be parallel with the front and rear surfaces of the hold-and-guide member 44. Sliders 49a and 49b are attached to the backsides of both end portions of the plate member 48 widthwise. The guide rods 50a and 50b are inserted to these sliders 49a and 49b, respectively.
A ball 58 is inserted to the inserting portion in each of the sliders 49a and 49b. The ball 58 is the socalled over-ball whose size is larger than the space where the ball is inserted. The ball 58 presses to apply a pre-pressure to improve support force between the guide rods 50a and 50b and the sliders 49a and 49b.
A projection member 52, which projects backward, is provided at the center of the plate member 48. The projection member 52 is screwed with the ball screw 53. In other words, the motor 57 is driven to rotate the ball screw 53. Thereby, the guide rods 50a and 50b guide the lifting member 43 so as to be moved up and down.
As shown in FIGS. 3 and 5, a shield belt 54 is provided on the each of the connecting sections 43a and 43b of the lifting member 43 in up and down directions. The shield belt 45 has a function of shielding the slit 47. The shield belt 54 is wound around support rollers 55a and 55b and rollers 56a and 56b in a loop shape to be movable with the lifting member 43. The rollers 55a and 55b are provided on the front surface side of the upper end portion of the hold-and-guide member 44 and that of the lower end portion thereof. The rollers 56a and 56b are provided on the backward portions of the rollers 55a and 55b.
As shown in FIG. 5, the lifting member 43 is structured to become thinner as advancing to its top end side. Then, a motor 61 for rotating the base member 42 is provided at the lower central portion in a state in which its shaft is projected upwardly. A cylindrical coupling portion 66 is coupled to the top end portion of the lifting member 43 through a bearing 67. The base member 42 is fixed onto the coupling portion 66. A pulley 62 is attached to the shaft of the motor 61, and a belt 63 is wound around the pulley 62 and the lower end portion of the coupling portion 66. When the motor 61 is driven, the belt 63 and the base member 42 rotate in the horizontal plane through the coupling portion 66.
A base plate 70 is horizontally extended to the base member 42, and a motor 71 is provided on the lower surface of the end portion of the base plate 70. A pulley (not shown) is attached to the rotational shaft of the motor 71. On the other hand, at the upper portion of the base plate 70, pulleys 72 and 73 are provided at both end portions thereof, and a belt 76 is wound around the pulleys 72 and 73. The pulley 73 has two belt winding portions coaxially, and a belt 77 is wound around one winding portion. The belt 77 is also wound around the pulley of the motor 71. The substrate support member 41 and the belt 76 are coupled to each other by a coupling member (not shown). Therefore, when the motor 71 is driven, the substrate support member 41 moves back and forth on the base member 42 through the belts 77 and 76. In this case, a slider (not shown), that is provided in the substrate support member 41, runs on a rail 42a (FIG. 3) provided on the base member 42.
As shown in FIG. 5, in the base member 42, there is horizontally provided an exhaust path 74 toward the coupling portion 66 from the portion close to the motor arranging portion provided on the lower side of the base plate 70. The exhaust path 74 is communicated with the interior of the lifting member 43 through an inner space of the coupling portion 66. An exhaust fan 75 is provided at an entrance portion of the exhaust path 74, thereby allowing forcible exhaust.
On the other hand, in the lifting member 43, there is provided an exhaust path 64. The exhaust path 64 passes via the driving portion of the motor 61 and the connecting portion 43a from the connecting portion 66, and reaches the interior of the hold-and-guide member 44 through the plate member 48. In the vicinity of the motor 61 of the exhaust path 64, there is provided an exhaust fan 65, thereby allowing forcible exhaust.
On the bottom of the hold-and-guide member 44, there is provided an exhaust fan 59, thereby allowing the exhaust to the outside of the apparatus from the lower portion. In other words, forcible exhaust to the outside of the apparatus is performed via the exhaust path 74, the coupling portion 66, the exhaust path 64, and the interior of the hold-and-guide member 44.
In carrying the substrate G to the processing section 2 by the above-structured transferring apparatus 11, the hold-and-guide member 44 is moved along the carrying path 10a to rotate the base member 42, thereby placing the substrate support member 41 at a position corresponding to a predetermined cassette C. Then, the lifting member 43 is moved up and down to adjust the height of the substrate support member 41, so that the substrate support member 41 is moved forward to take up one substrate G. Next, the base member 42 is rotated to position the substrate support member 41 to be opposite to the processing section side. Then, the hold-and-guide member 44 is moved along the carrying path 10a, so that the substrate support member 41 is placed at a position corresponding to the carrying path 12. At this time, the main transferring apparatus 17 is moved to the end portion of the cassette station 1 of the carrying path 12. Then, the height of the substrate support member 41 is adjusted by the lifting member 43, and the substrate support member 41 is moved forward to transfer the substrate G to the main transferring apparatus 17.
In containing the substrate G, to which a series of processes have been provided, into the cassette by the transferring apparatus 11, the substrate support member 41 is directed to the processing section 2 to be set on standby at the position corresponding to the carrying path 12. When the substrate G is carried into the end portion of the cassette station side of the carrying path 12 by the main transferring mechanism 17, the substrate support member 41 is moved forward so as to receive the substrate G. Then, the base member 42 is rotated, and the hold-and-guide member 44 are moved along the carrying path 10a, and the substrate support member 41 on which the substrate G is mounted is made to correspond to the position of the predetermined cassette C. In this state, the lifting member 43 is moved up to adjust the height of the substrate support member 41. As a result, the substrate support member 41 is moved forward so as to contain substrate G in the cassette C.
In this case, the hold-and-guide member 44 supports the lifting member 43 in its single support state. As a result, unlike the conventional case in which the lifting member is guided by both sides, the base member 42 can be rotated without enlarging the size of the apparatus even if the hold-and-guide member 44 projects to the upper portion of the base member 42. Therefore, even if the height of the cassette is increased to deal with a warp of the substrate occurred when the substrate is enlarged, it is possible to deal with an increase in the motion strokes of the lifting member without providing addition work such as a formation of a hole since there is no limitation of the height of the hold-and-guide member 44.
Also, since pre-pressure is added by the ball 58 inserted to the insertion portion of the sliders 49a and 49b, support force using the guide rods 50a and 50b can be improved, and the large-sized substrate can be supported more safely in its single state. Moreover, since the lifting member 43 has a thick base end portion and becomes thinner as advancing to its top end side, the structure becomes stable.
The exhaust path is structured to have the exhaust path 74 of the base member 42, the inner space of the coupling portion 66, and the exhaust path 64 of the lifting member 43 continuously arranged. The exhaust fans 75 and 65 are provided close to the motors 71 and 61, respectively, to guide particles generated from the driving system to the hold-and-guide member 44 through the exhaust path, thereby forcibly exhausting particles to the outside of the apparatus. As a result, particles are prevented from being scattered to have unfavorable influence on the processing substrate G. Moreover, the slit 47 formed on the front surface of the hold-and-guide member 44 is shielded by the shield belt attached to the lifting member 43. As a result, the particles generated from the driving system of the hold-and-guide member 44 can be prevented from being scattered.
The present invention is not limited to the above-mentioned embodiment, and various modifications can be made. For example, the above embodiment explained the case in which the present invention was applied to the transferring apparatus between the cassette station 1 and the processing section 2. The present invention can be used as a transferring apparatus in an interface between the processing section 2 and an exposing unit. Moreover, the above-mentioned embodiment showed the example in which the present invention was used as the resist coating and developing unit. However, the present invention may be applied to the other process without limiting the above example. Also, the above-mentioned embodiment showed the case in which the LCD substrate was used as the substrate. However, it is needless to say that the present invention may be applied to the other substrate process without limiting this case.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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A substrate transferring apparatus comprising a substrate support member for supporting a substrate, a base member for holding the substrate support member to be movable horizontally, a lifting member, having one end and another end, for holding the base member at the one end to be rotatable in a horizontal plane, the lifting member being movable upward and downward, and a hold-and-guide member for holding the lifting member at the another end and for guiding the lifting member when the lifting member is moved upward and downward.
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CROSS-REFERENCE TO RELATED APPLICATIONS
(Not Applicable)
STATEMENT RE: FEDERAL SPONSORED RESEARCH/DEVELOPMENT
(Not Applicable)
FIELD OF INVENTION
The present invention relates to an apparatus and technique useful to repair honeycomb core structures, such as used in unmanned aircraft, small submersibles and the like.
BACKGROUND OF THE APPLICATION
Many contemporary aircraft have honeycomb sandwich structures formed in the wing leading edges. In the course of use the leading edges may sustain damage, e.g. from bird strikes and accidents during maintenance.
In some cases a honeycomb core may be crushed proximate the point of impact, but the outer skin may not show any visual damage at that location. The resulting core shear failure may extend over a larger area than the original damaged area. Such unseen core damage may result in the outer skin buckling and delaminating under stress.
Repair of the damage may require skin and core repair operations, either in the field or in a repair depot. A replacement core specific to that wing must be matched to correctly restore the aircraft's integrity. However, maintaining a stock of cores specific to each aircraft is logistically challenging, especially during field operations.
In accordance with contemporary repair techniques damaged skin and the adjacent honeycomb core are completely removed to the opposing skin. A replacement core may be shaped and sanded to fit snugly into the area being repaired. Replacement material may be selected to substantially match the original case material. However, conformity of the materials does not insure conformity to the structural and mechanical properties of the honeycomb shaped core. One type of replacement material is syntactic foam, an epoxy resin material that contains glass micro-balloons. This material can be tailored to different densities and properties. However the material may be too heavy for certain applications. Moreover, the material is isotropic in nature, i.e. the strength is equal in all directions, which may be undesirable or at least differ from the honeycomb properties of the adjacent structure.
For reference, several prior art methods to repair aircraft laminates are described below. U.S. Pat. No. 6,149,749 discloses a patch used to cover the damaged area, without any replacement of the original structure, including the lightweight structure between the two outer skins. The patch has apertures that allow air to be removed from below the patch thereby improving the adhesion.
U.S. Pat. No. 4,961,799 discloses a method for repairing damaged areas by bolting or bolt bonding a repair patch on the outer surfaces of the damaged material. This method does not provide a matching replacement honeycomb structure.
U.S. Pat. No. 5,741,574 discloses a truss reinforced sandwich structure that uses fiber bundles or tows cured in very small diameters; the preferred method of the attachment being stitching the foam core within the face sheets or laminates. U.S. Pat. No. 3,328,218 discloses using rigid filaments to manufacture the core structure. In both references the filaments must be fastened to the outer plies. Moreover, the references require the foam to be under compressive pressures of 50 to 90 psi.
U.S. Pat. No. 5,612,117 discloses an anchoring means comprising an insert introduced into a hole in the skins and held in place by the core to provide an anchoring of the entire structure.
U.S. Pat. No. 5,773,121 describes a syntactic form core structure that is produced using a powdered resin instead of a liquid resin. In order to improve or modify characteristics of the resultant structure, chopped fibers or pre-built honeycomb structure is added to the powered resin, before curing.
U.S. Pat. No. 5,547,629 discloses a method using rubber mandrels to fabricate hollow structures such as a wing. After the two skins are compressed together, with the mandrels in the hollow cavities providing support, the mandrels are pulled from one end. As they stretch, they contract and can be removed from the molded part. No foam honeycomb structure is introduced during the molding process.
U.S. Pat. No. 5,868,886 discloses the use of Z-pins to provide a mechanical link between the patch/parent structures. It suggests removal of the pins, leaving holes that are filled when the patch material is introduced into the repair area. Small pin sizes are used in order to reduce associated structural degradation caused by fiber breakage due to concentrated stress.
BRIEF SUMMARY OF THE INVENTION
It is an object of this invention to provide an improved method for repairing structures having outer skins and an inner honeycomb core structure.
It is another object of this invention to provide a repair method that can be implemented in-site or at a facility to separate from the aircraft.
It is an additional object of this invention to reduce the weight of the syntactic foam by displacing a part of the volume of foam with air tunnels.
It is a further object of this invention to regulate the structural or mechanical characteristics of the replacement core by selection of the core angle(s), number of layers and choice of materials. It is a further object of this invention to reduce the inventory of core specific parts that must be matched with a particular aircraft, which creates a logistic nightmare, especially during field operations.
In order to reduce the inventory of specific foam cores, a small number of tools can be kept that will allow syntactic tunnel cores to be fabricated as needed. The tooling can be used to produce these syntactic tunnel cores both off or on the vehicle. The tooling utilizes metal rods that are removable and are held in place with at least 2 rod guide plates. The mechanisms, to hold the tooling in place for repair work both off and on the vehicle, may be the same depending on the area to be reworked.
If the repair is to be accomplished off aircraft, then the first step is typically to remove the damaged skin and inner honeycomb core. This damaged area is normally removed to the opposite skin. If both skins are damaged, one skin is typically repaired first. The tooling that holds the removable rods may be positioned above a container or tray. This tray is typically deeper and larger than the scraped out area.
The removable rods are placed into the aligning holes in the rod guide plates and positioned in the cavity created in the tray. The syntactic foam may be introduced into the cavity, surrounding the removable rods. Once the foam has cured, the removable rods may be removed and the tooling is extracted. The top and bottom surface of the replacement syntactic tunnel core is now shaped to match the final surface shapes and the original core shape. The shaping of the replacement tunnel core include matching the physical shape of the scraped outer area. The outer skin can now be repaired using contemporary skin replacement techniques.
The core tunnels made from the space taken up by the removable rods may all be the same geometric shape or vary across the replacement tunnel core. The most common shapes are circular or hexagonal cylindrical tunnels.
The shape of the tunnels may be a series of graduated sectional profiles narrowing in the direction of the tunnel depth. Preferably there are no undercuts that may damage the tunnel shapes upon the extraction of the removable rods.
The angle of the tunnels may typically be perpendicular to the direction of the load of the structure or outer surface or may be offset from the being perpendicular. Alternatively, to implement selective structural or mechanical features, the tunnels may be bored at other angle/gradients. A 5-degree offset, for example, will increase the shear characteristics.
During the process, the metal rods may be heated or cooled in accordance with predetermined temperature probes, to regulate the final structural characteristics or speed up the curing process.
The technique and tool used to implement repaired damaged honeycomb structures is as follows. The tool includes a plurality of rods axially translatable into the damaged area. Foam material is inserted about the rods and allowed to cure. The rods are later withdrawn, leaving a porous core of material. Sleeves may be provided to receive and support the rods as they translate into the damaged area. The sleeves may remain in the damaged area after the rods are withdrawn into the sleeves.
Rods may be formed to have various cross-sectional areas, such as circular, hexagonal, or other geometric shapes. Rods may be inserted into the area at different angles relative to the load flow in the damaged area. The particular angle at which the rods are inserted into the damaged area may be selected to increase the sheer strength or other properties of the honeycomb structure, or to match the properties of the particular remaining structure.
In one embodiment the rods may be heated, or the temperature otherwise regulated in order to facilitate curing of the foam material to produce desired properties.
In another embodiment the foam may be inserted in sequential applications to define a series of separate layers, wherein each layer may be formed of different material, and/or cured in accordance with different profiles, in order to achieve a desired set of core/structure properties.
BRIEF DESCRIPTIONS OF THE DRAWINGS
FIG. 1 is an illustration of the parts of an aircraft structure.
FIG. 2 contains views of two types of honeycomb structures.
FIG. 3 is an illustration of a removable pin with multiple geometric shapes.
FIG. 4 is a view of a damaged honeycomb section after removal of the damaged honeycomb section
FIG. 5A is a view of the tooling that is utilized to fabricate the syntactic tunnel core off of the aircraft.
FIG. 5B is a view of the tooling that is utilized to fabricate the syntactic tunnel core on the aircraft.
FIG. 6 is an illustration of a removable plug and insert.
FIG. 7 is a view of an off-aircraft repair plug.
FIG. 8 is an illustration of the placement of the plug into the removed damaged honeycomb area.
FIG. 9 is a top view of the replacement honeycomb plugs in the aircraft structure.
DETAILED DESCRIPTION OF THE INVENTION
The aircraft or vehicle structure 10 is shown in FIG. 1 . The structure 10 is made up of two exterior skins 11 and 13 . Sandwiched between the skins 11 and 13 is a honeycomb structure 12 . Skin 11 is illustrated in a translucent rendering so that the honeycomb structure 12 can be seen. This honeycomb structure 12 is used to not only reduce the weight of the overall structure 10 , but also to provide the required characteristics for a specific application. The tunnels or air pockets of the honeycomb structures can be of any geometric shape.
FIG. 2 shows two different honeycomb structure geometric shapes from two viewing angles 20 . The honeycomb views, 23 and 24 are from different elevations, based on a circular, cylindrical rod. The honeycomb views, 21 and 22 , are based on a hexagonal cylindrical rod.
The characteristics of the honeycomb structure can be made directional, whether mechanical, electrical or dielectric, by controlling the amount of holes, their sizes, their geometric shape, their sectional views, their direction, syntactic resin wall thickness and strength, composition of the syntactic material and/or temperature/pressure curing profiles. The shape of the tunnels, and their angles to the direction of the load of the honeycomb structure can further be varied across the face of the repaired area.
FIG. 3 illustrates a removable rod 25 , that includes multiple geometric shapes on a single rod. It shows a rod with three geometric shapes, a larger circle 26 , a smaller circle 27 just below the larger circle 26 , and a hexagonal shape 28 just below the smaller circle 27 . Draft may be added to any of the geometric shapes. The only design preference is that the removable rod be capable of being pulled out of the cured honeycomb core. Undercuts could damage the core, by scraping out part of the core.
It is also within the scope of this invention to use layers of syntactic foam, with each having different properties, to introduce structural gradients or otherwise improve matching to the surrounding honeycomb structure.
FIG. 4 shows an area of the aircraft structure 30 that was damaged, and the repair has been started. Though hitting an object, such as by a bird or a projectile, could damage both skins 31 and 32 , FIG. 4 assumes that only the top skin 31 is damaged. First, the damaged portion of the skin 31 is removed as show as a circle of material missing from skin 31 . The honeycomb internal structure 33 is thereby exposed. The damaged area is normally removed down to the undamaged skin 32 and the removed area 34 is hexagonal in the shape for clarity. It is also possible that the damaged area of the honeycomb structure 33 will not require the entire removal of the honeycomb structure down the other skin 32 surface.
Now that the damaged honeycomb area 34 has been removed, a replacement must be fabricated. This can be accomplished offsite or directly on the vehicle. The decision is based on several factors, including the location of the structure being repaired. In a repair depot, when room safety is more readily insured, the fabrication of the syntactic tunnel core will most likely be performed on the vehicle. In the field, especially in war theater, the fabrication of the syntactic tunnel core would more likely be accomplished off the vehicle.
FIG. 5A shows the fabrication tooling 40 for a syntactic tunnel core that is fabricated offsite or off the aircraft. The fabrication tool 40 basically consists of a housing including at least guide plates 42 and 43 and a number of extendable rods 41 . The rods 41 in FIG. 5A are typically of circular, cylindrical shape, and adapted for axial movement within the guide plates. As will be apparent to those in the field, the rod shapes may alternately be of other geometric shapes as shown in FIG. 2 and FIG. 3 . The outer mechanism used to position the plates above the work area may be any of a number of different mechanisms that are well known in the industry.
The removable rods 41 may be positioned into a container or tray 44 of an appropriate depth, typically at least as deep as the removed area 34 , as shown in FIG. 4 . Syntactic foam is then placed into the remaining cavity of the tray 44 and allowed to cure. If required, the removable rods 46 can be heated or cooled to reduce the cure time or to maintain a temperature to achieve selected properties in the cured foam. The rods 46 , are then removed leaving a replacement syntactic tunnel core tray-shaped structure. This syntactic tunnel core structure may be shaped to fit into the cavity 34 of FIG. 4 . The final shape of the syntactic tunnel core 55 mates with the cavity 65 is shown in FIG. 8 . The mated replacement honey tunnel core and original honeycomb core is shown in FIG. 9 .
FIG. 5B shows the fabrication tooling 44 for a syntactic tunnel core that is fabricated on aircraft. The fabrication tooling 45 is basically consisting of at least 2-rod guide plates 47 and 48 and a number of removable rods 46 . The rods 46 in FIG. 5B are a circular, cylindrical shape. The shape may be other geometric shapes as shown in FIG. 2 . The rods or rod guide plates may, depending on the honeycomb design, be made up of several sections that are mechanically fastened together. The plate sections may contain aperture patterns that are different from the other plate sections, so that the properties of the final syntactic tunnel core replacement is better matched to the original honeycomb core. Once the fabrication tooling 45 is in place, the syntactic foam material can then be poured into the remaining cavity of the removed area 34 . The syntactic foam is allowed to cure. If required, the removable rods 46 can be heated or cooled at selected thermal profiles to reduce the cure time, or to regulate the temperature to achieve described properties in the cured foam. The rods 46 are removed, leaving a replacement syntactic tunnel core structure 73 as shown in FIG. 9 .
FIG. 6 illustrates a rod set 51 . Sleeve 53 is placed on the first end of the rod 52 , which will have syntactic foam material placed around it. The sleeve 53 may remain in the tunnel core after removal of rod 52 , any may be thermally or otherwise controlled to provide additional desired core properties. The sleeve 53 may be made of Teflon or any material that will provide desired characteristics.
FIG. 7 illustrates a completed off aircraft fabricated syntactic tunnel core 56 . The shape of the edges 57 are fabricated to fit properly within the cavity in the repair area 65 as shown in FIG. 8 .
The off aircraft fabricated replacement syntactic tunnel core 56 may be placed into the cavity 65 of the original honeycomb core 63 . As shown in FIG. 8 the shape defined by the edges of core 61 mate with the shape defined by the edges of the cavity 65 . The procedure to fasten the core 61 to the undamaged skin 64 may then proceed in accordance with standard repair procedures.
FIG. 9 shows the top view of a repaired honeycomb area 70 . The repaired area may have been fabricated off aircraft or on aircraft. Within the repaired area 70 , the dark hexagonal shaped area is the replacement syntactic tunnel core 73 of the present invention. The lighter colored syntactic tunnel core 72 is the original undamaged tunnel core. The bottom skin 74 supports the bottom of the replacement tunnel core 73 . The upper surface of the replacement core 73 must be shaped to match the upper surface shape of the original core 72 . Once the surfaces are uniform between the two cores 72 and 73 , then a patch can be added to close the opening hole 75 in the damaged skin 71 . The patch is not shown.
The shear strength of the core with tunnels perpendicular to the skins is low. If desired, the rods 41 or 45 can be positioned at an angle that is not perpendicular to the load path direction. Even a 5 -degree offset will increase the load angle. The angle selected is based on the desired characteristics.
It is understood that although the above represents several embodiments of the invention, the invention may take a wider variety of embodiments intended to effect alternate designs or additional features. Such embodiments are within the scope and spirit of the present invention.
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A technique and tool are provided for repairing damaged areas of honeycomb structures. The tool includes a plurality of rods axially translatable into the damaged area. Foam material is inserted about the rods and allowed to cure. The rods are later withdrawn leaving a porous core of material. Sleeves may be provided to receive and support the rods as they translate into the damaged area. The sleeves may remain in the damaged area after the rods are withdrawn into the sleeves.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/596,936 filed on Oct. 31, 2006 which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates generally to an apparatus for supporting a toilet, and more particularly to a support for a wall mounted toilet.
BACKGROUND
[0003] Wall mounted toilets provide the advantage of improved cleaning ability, since the floor underneath can be accessed with a mop. Wall mounted toilets have a limitation in that they are typically capable of supporting between 300 to 350 pounds, which is somewhat less than a typical floor mounted toilet. The wall mounted toilet is usually supported by a carrier installed inside the wall to which the toilet is attached. Often, the carriers installed inside the wall are only rated to 300 pounds. That is, the toilets secured to the carriers are engineered to hold a person weighting no more than 300 pounds.
[0004] There are a number of people that weigh over 300 and many over 400 pounds. If such a person uses a typical wall mounted toilet, they exceed the weight limit of the wall mounted toilet. Since wall mounted toilets are common in hospitals, hotels, airports, and various other locations, there is a likelihood that a person of a weight that exceeds the weight limit of a wall mounted toilet, may use a wall mounted toilet, causing it to break off from its supporting carrier. Injury, discomfort, and embarrassment may result when this happens. Therefore, what is needed is an effective means for supporting a wall mounted toilet, to prevent these situations, thereby reducing injury, as well as legal liability for the owners of facilities with wall mounted toilets.
SUMMARY OF INVENTION
[0005] The present invention provides a support for a wall mounted toilet. An adjustable leg is attached to a bumper. The bumper supports the bowl, and the leg rests on the floor, providing additional vertical support. The present invention increases the weight limit of a wall mounted toilet to approximately 1,000 pounds, thereby safely accommodating obese people.
[0006] It is an object of the present invention to provide a toilet support that is compatible with a variety of toilets from various manufacturers.
[0007] It is another object of the present invention to provide a toilet support that is quick and easy to install.
[0008] It is yet another object of the present invention to provide an aesthetically pleasing toilet support, suitable for use in places such as hotels and restaurants.
[0009] It is still another object of the present invention to provide an aesthetically pleasing toilet support that is retractable and allows for full cleaning access to the floor.
[0010] According to the present invention, there is disclosed an apparatus for supporting a wall mounted toilet, comprising a toilet bumper in contact with the underside of the wall mounted toilet; an adjustable support leg having an upper end mounted to the toilet bumper; and a support foot mounted a lower end of the adjustable support leg and being adapted to rest against a floor.
[0011] Further according to the present invention, the toilet bumper has a three sided curved shape in plane view with a rear wall between two outside corners of the bumper and two side walls between the two outside corners and a front corner. Also the upper surface of the toilet bumper has a concave shape and the toilet bumper includes a sidewall which extends about the three sided curved shape in a perpendicular direction to a bottom surface of the toilet bumper.
[0012] Still further according to the present invention, the upper surface of the toilet bumper has a three sided cavity formed therein and extending from the rear wall and inward of the two side walls and towards the front corner. Also the three sided cavity has a bottom surface at a depth extending partially towards a lower surface of the toilet bumper.
[0013] Yet further according to the present invention, the toilet bumper has an insert disposed within the three sided cavity. The insert is a four sided insert and has an upper surface with a concave shape that matches the concave shape of upper surface of the toilet bumper and the insert has a lower surface that has a shape that matches the shape of bottom surface of cavity so that the insert can be inserted within cavity so that the toilet bumper is used as a unified structure.
[0014] Still further according to the present invention, the distance from where the upper surface of the toilet bumper intersects the rear wall of the toilet bumper is less than the distance from where the upper surface intersects the two side walls at the front corner of the toilet bumper.
[0015] Also according to the present invention, the bottom surface of the toilet bumper has a cylindrical bore extending towards the upper surface of the toilet bumper and the cylindrical bore has an outer bottom surface and an inner bottom surface wherein the outer bottom surface extends closer to the upper surface of the toilet bumper than the inner bottom surface. The cylindrical bore further includes a central bore projecting from the inner bottom surface towards the upper surface of the toilet bumper, the central bore having an insert with a threaded bore.
[0016] Yet further according to the present invention, the adjustable support leg includes a primary thin walled cylindrical shaped leg section open at opposite ends and having a threaded rod projecting through the primary cylindrical shaped leg section and wherein the threaded rod is mounted to an interior wall of the primary cylindrical shaped leg section. Also the adjustable support leg includes a secondary thin walled cylindrical shaped leg section, wherein the secondary thin walled cylindrical shaped leg section is open at one end and has a base portion closing the opposite end, and wherein the base portion has a threaded bore adapted to threadedly receive the threaded rod projecting through the primary cylindrical shaped leg section so that the secondary thin walled cylindrical shaped leg section is telescopedly receive within the secondary thin walled cylindrical shaped leg section.
[0017] Further according to the present invention, the support foot is a circular plate having a cylindrical thin walled connector secured thereto and adapted to be received within the open end of the secondary thin walled cylindrical shaped leg section.
[0018] Also according to the present invention, the toilet bumper is constructed of a silicon material.
[0019] According to the present invention, there is disclosed a method of supporting a wall mounted toilet, comprising the steps of: providing an apparatus for supporting a wall mounted toilet including a toilet bumper adapted to contact with the underside of the wall mounted toilet, an adjustable support leg having an upper end mounted to the toilet bumper and a support foot mounted a lower end of the adjustable support leg and being adapted to rest against a floor; placing the apparatus under the wall mounted toilet so that the toilet bumper is in contact with the underside of the wall mounted toilet; and adjusting the support leg so that the support foot is resting against a floor.
[0020] Still further according to the present invention, the method includes the steps of providing the toilet bumper with an upper surface with a concave shape; and disposing the upper surface with a concave shape against the bottom surface of the wall mounted toilet.
[0021] Further according to the present invention, the method includes the steps of providing the toilet bumper with an upper surface having a three sided cavity formed therein and an insert disposed within the three sided cavity wherein the upper surface of the insert has a concave shape that matches the concave shape of upper surface of the toilet bumper and the toilet bumper is used as a unified structure; and placing the apparatus under the wall mounted toilet so that the upper surface of the toilet bumper and the upper surface of the insert are in contact with the underside of the wall mounted toilet.
[0022] Yet further according to the present invention, the method includes the steps of providing the toilet bumper with a concave shaped upper surface having a three sided cavity having a bottom surface formed therein; and placing the apparatus under the wall mounted toilet so that the concave upper surface of the toilet bumper and the bottom surface of the insert are in contact with the underside of the wall mounted toilet.
[0023] Still further according to the present invention, the method includes the steps of retracting the support leg so that the support foot is not resting against the floor.
[0024] Further according to the present invention, the method includes the step of applying a bead of adhesive, such as silicone, between the toilet bumper and the bottom of the toilet bowl.
[0025] These and other advantages will be apparent from the following detailed description of preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The structure, operation, and advantages of the present invention will become further apparent upon consideration of the following description taken in conjunction with the accompanying figures (Figs.). The figures are intended to be illustrative, not limiting.
[0027] Certain elements in some of the figures may be omitted, or illustrated not-to-scale, for illustrative clarity. The cross-sectional views may be in the form of “slices”, or “near-sighted” cross-sectional views, omitting certain background lines which would otherwise be visible in a “true” cross-sectional view, for illustrative clarity.
[0028] In the drawings accompanying the description that follows, often both reference numerals and legends (labels, text descriptions) may be used to identify elements. If legends are provided, they are intended merely as an aid to the reader, and should not in any way be interpreted as limiting.
[0029] FIG. 1 shows a three dimensional view of the present invention being used with a wall mounted toilet.
[0030] FIG. 2A shows a close-up three dimensional view of the toilet bumper and telescoping leg according to the present invention present invention.
[0031] FIG. 2B shows a close-up three dimensional view of the toilet bumper with the insert removed according to the present invention present invention.
[0032] FIG. 3 shows a three dimensional bottom view of the toilet bumper according to the present invention.
[0033] FIG. 4 shows a cross-sectional view through line 4 - 4 of FIG. 3 .
[0034] FIG. 5 shows an isometric view of the telescope leg of the present invention.
[0035] FIG. 6 shows a cross-sectional view through line 6 - 6 of FIG. 5 .
[0036] FIG. 7 shows a cross-sectional view of the foot of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0037] FIG. 1 shows the use of the toilet support 100 of the present invention in use with a typical wall mounted toilet 102 . The mounted toilet 102 is secured to a carrier installed inside the wall (not shown) to which the toilet is attached with a plurality of bolts. The toilet support 100 includes a toilet bumper 104 , a support leg 106 and a support foot 108 . Toilet bumper 104 is shown in contact with the underside of the wall mounted toilet 102 . The toilet bumper 104 is mounted towards the front end of wall mounted toilet 102 so that the bumper can support the toilet in the event that a heavy person is sitting on the toilet. The adjustable support leg 106 is arranged so that an upper end portion 106 a is mounted to the toilet bumper 104 and a lower end portion 106 b is on the floor. Note that a support foot 108 is provided at the lower end 106 b of the adjustable support leg 106 and is adapted to rest against a floor.
[0038] FIG. 2A shows a detailed three dimensional view of the toilet support 100 of the present invention. As mentioned before, toilet support 100 is comprised of three main components, a toilet bumper 104 , a support leg 106 and a support foot 108 . With regard to the toilet bumper 104 , it has a three sided curved shape in plane view with a sidewall 118 including a rear wall 120 between two outside corners 122 , 124 of the bumper and two side walls 126 , 128 between the two outside corners and a front corner 130 . The sidewall 118 extends generally in a perpendicular direction (as shown in FIGS. 3 and 4 ) to a bottom surface 140 of the toilet bumper 104 .
[0039] As shown in FIGS. 2 and 3 , an upper surface 132 of toilet bumper 104 has a concave shape which is adapted to the shape of the bottom of a conventional wall mounted toilet. The bumper 104 is shaped so that when the bumper is mounted to the bottom of a toilet, the front corner 130 is higher than the rear further away than the outside corners 122 , 124 . This can be seen by referring to FIG. 4 , where the distance x from where the upper surface 132 intersects the rear wall 120 of the toilet bumper 104 to the bottom surface 140 is less than the distance y from where the upper surface intersects the two side walls 126 , 128 at the front corner 130 of the toilet bumper to the bottom surface 140 .
[0040] Sometimes, the underside of a toilet is shaped so that the concave shape of the upper surface 132 of bumper 104 does not sufficiently engage the underside of the toilet. To accommodate different shaped toilet bottoms, the toilet bumper 104 , as shown in FIGS. 2A and 2B , has a removable insert 150 which fits within a three sided cavity 152 formed in the toilet bumper. As shown in FIG. 213 , the cavity 152 has two side walls 152 a , 152 b , a forward wall 152 c and a bottom surface 152 d . The cavity 152 is formed so that a portion of rear wall 120 of toilet bumper 104 which is between the side walls 152 a and 152 b is narrower than the remainder of rear wall 120 .
[0041] The four sided insert 150 , as shown in FIGS. 2A and 2B , has two side walls 150 a and 150 b , a front wall 150 c and a rear wall 150 d . The upper surface 150 e of insert 150 has a concave shape that matches the concave shape of upper surface 132 of toilet bumper 104 . The lower surface 150 f of insert 150 has a shape that matches the shape of bottom surface 152 d of cavity 152 . The insert 150 can be inserted within cavity 152 as shown in FIG. 2A so that the toilet bumper 104 is used as a unified structure to support wall hanging toilet 102 . Alternatively, insert 150 can be remove from cavity 152 as shown in FIG. 2B . It is also within the terms of the present invention to remove only a portion of insert 150 so that the bumper 104 can accommodate a particular shape of a wall hanging toilet.
[0042] Both the toilet bumper 104 and the insert 150 are preferably constructed of a chemical and stain resistant non-porous rubber material such as silicon which can absorb shock created by a heavy individual sitting on toilet 102 and loading the toilet support 100 .
[0043] Referring to FIGS. 3 and 4 , there is shown the bottom of toilet bumper 104 . There is shown a bottom surface 140 that would be substantially parallel to a floor on which the toilet support 100 is used. A cylindrical bore 160 extends from bottom surface 140 towards the upper surface 132 of the toilet bumper 104 . There is an outer bottom surface 162 of cylindrical bore 160 and an inner bottom surface 154 . The outer bottom surface 162 extends closer to the upper surface 132 of the toilet bumper 104 than the inner bottom surface 164 . Also, a central bore 166 projects inward from the inner bottom surface 164 towards the upper surface 132 of the toilet bumper 104 . The central bore 166 opens to an insert 168 with a threaded bore 170 .
[0044] Referring to FIGS. 5 and 6 , there is shown the adjustable support leg 106 . Support leg 106 includes a primary thin walled cylindrical shaped leg section 172 open at opposite ends 174 and 176 . A threaded rod 178 projects through the primary cylindrical shaped leg section 172 and is mounted to an interior wall 180 of the primary cylindrical shaped leg section by any means, such as an integral cylindrical sleeve 182 . One end of rod 178 projects from end 174 and the other end of rod 178 projects from end 176 primary thin walled cylindrical shaped leg section 172 .
[0045] The adjustable support leg 106 includes a secondary thin walled cylindrical shaped leg section 184 . The secondary thin walled cylindrical shaped leg section 184 is open at one end 186 and has a base portion 188 closing the opposite end 190 . The base portion 188 has a threaded bore 192 extending there through and adapted to threadedly receive the threaded rod 178 projecting through the primary cylindrical shaped leg section 172 so that the secondary thin walled cylindrical shaped leg section 184 is telescopedly receive within the primary thin walled cylindrical shaped leg section. By rotating either the primary leg section 170 or the secondary leg section 184 , the height (length) of support leg 106 is adjusted.
[0046] The end of threaded rod 178 that projects from end 174 of the primary cylindrical shaped leg section 172 is received within the threaded bore 170 of insert 168 . As the primary leg section 170 is rotated, the threaded rod 178 moves through threaded insert 168 , thereby securing the leg 106 to the toilet bumper 104 . Preferably, the primary leg section 170 is rotated until the end cylindrical wall 174 is received in the outer bottom surface 162 of cylindrical bore 160 and the inner bottom surface 164 can be against the integral cylindrical sleeve 182 so that the leg 106 is securely attached to the toilet bumper 104 .
[0047] In operation, the toilet support 100 may be affixed to toilet 102 by applying adhesive, silicone adhesive or caulking to bumper 104 (note that the bumper can be formed of a silicon material.) Leg 106 is affixed to bumper 104 by the threaded screw 178 engaging screw insert 168 as described herein before. The lower leg member 106 a is then rotated until foot 110 makes contact with the floor surface. The lower leg 106 a can be rotated in an opposite direction to raise it when cleaning the floor. This provides the cleaning advantages of a wall mounted toilet, with the weight capacity properties of a floor mounted toilet.
[0048] It should be noted that no bolts or fittings need to be adjusted on the wall mounted toilet 102 when installing toilet support 100 . The bumper 104 can be molded in a color to match the toilet 102 , providing a discrete toilet support that blends in with the toilet itself.
[0049] Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, certain equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described components (assemblies, devices, etc.) the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiments of the invention. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several embodiments, such feature may be combined with one or more features of the other embodiments as may be desired and advantageous for any given or particular application.
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The present invention relates to an apparatus and method for supporting a wall mounted toilet with a toilet bumper in contact with the underside of the wall mounted toilet; an adjustable support leg having an upper end mounted to the toilet bumper; and a support foot mounted a lower end of the adjustable support leg and being adapted to rest against a floor.
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BACKGROUND OF THE INVENTION
[0001] (a) Technical Field of the Invention
[0002] The present invention relates to a winch, and in particular, a winch which can control the disengagement of a speed-reducing device and motor from a rolling cylinder such that the rolling cylinder is rotated without load and the cable of the winch can be manually pulled out conveniently.
[0003] (b) Description of the Prior Art
[0004] [0004]FIGS. 1, 2 and 2 A show a conventional winch structure, wherein on one side of the rolling cylinder 11 a first gear box 12 and a rotating knob 13 and the first gear box 12 makes use of a transmission shaft 14 to mount in sequence a pushing plate 131 , a first sun gear 121 , two planetary gear sets 122 . The rolling cylinder 11 has a second gear box 15 and a motor 16 . In this conventional structure, if the cable 112 on the rolling cylinder 111 is pulled manually, the rolling cylinder 111 is engaged in sequence with the first gear set 122 and therefore the pulling of the cable is laborious and the speed of pulling is rather slow. Further, the gears may sometime in engagement when pulling of the cable which further causes time-consuming during the process of pulling.
[0005] Accordingly, it is an object of the present invention provide an improved structure of a cable winch used in vehicle which mitigate the above drawbacks.
SUMMARY OF THE INVENTION
[0006] Accordingly, it is an object of the present invention to provide an improved structure of a cable winch used in vehicle, wherein when the user turns the control button to position a protruded peg at the top edge of the through hole of the gear box, the control button will tow the transmission shaft and the moving gear thereon and the worm-like spring, thereby the moving gear disengages from the teeth portion of the rolling cylinder and the rolling cylinder is unloaded and rotates freely, and the cable of the winch can be rapidly and conveniently pulled out.
[0007] One aspect of the present invention is to provide an improved structure of a cable winch used in vehicle, comprising a rolling cylinder component having one end being mounted with a gear speed-reducing device and the other end being mounted with a motor so as to transmit the power of the motor to the rolling cylinder component by the gear speed-reducing device, and the speed-reducing device including a control button, a transmission shaft, a gear box, a sun gear, a plurality of planetary gear sets, a clutch and planet gear set, and a fastening ring, characterized in that
[0008] the interior of the control button is provided with a protruded tubular section and the center of the tubular section is provided with an inner hole, and the circumferential edge thereof is arranged with protruded pegs;
[0009] the transmission shaft is a hexagonal rod body having one end being inserted into the inner hole of the control button using the fastening ring and a recessed ring is provided close to the middle section thereof;
[0010] the bottom surface of the gear box is provided with a through hole and the inner circumferential edge of the through hole is provided with a recess to match with the protruded peg of the control button;
[0011] the clutch and planet gear set includes a planet gear train 361 , a front cover, a moving gear, a worm-like spring, and a fixing board, and the center of the front cover is pressed into a protruded section surrounded with teeth hole and the board surface of the front cover is provided with an engaging hole and by means of the fixing board to mount the moving gear and the worm-like spring so that the moving gear is extendable and retractable within the protruded section of the front cover;
[0012] the surface of the fixing board is provided with crooked leg to correspond with the engaging hole of the front cover so that the moving gear and the worm-shaped gear are mounted on the front cover; and the center of the rotating shaft of the motor is provided a polygonal insertion hole with external diameter substantially the same as the transmission shaft, the transmission shaft is inserted into the inner hole of the control button and is locked with the fastening ring, and the tubular section of the control button is inserted at the position of the through hole of the gear box and the protruded peg of the control button is in alignment with the recess of is the gear box and the transmission shaft is extended to the center of the gear box and in sequence the transmission shaft is mounted with the pad, the sun gear, a plurality of planetary gear set and the clutch and planet gear set, thereby in releasing the cable, the control button is pulled and turned so that the protruded peg urges the top edge of the through hole of the gear box and the button pulls the transmission shaft and the fastening ring compresses the moving gear and the worm-like spring so that the moving gear disengages with the teeth section of the rolling cylinder, and the rolling cylinder is dislocated from the clutch and planet gear set and rotates freely, and the cable is retracted rapidly and conveniently
[0013] Other object and advantages of this invention will become more readily appreciate as the same becomes understood by reference to the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a perspective view of a conventional winch.
[0015] [0015]FIG. 2 is a sectional exploded view of the conventional winch.
[0016] [0016]FIG. 2A is a perspective view of the
[0017] [0017]FIG. 3 is a sectional view of the conventional winch.
[0018] [0018]FIG. 4 is a sectional view showing the disengagement of the transmission shaft from the first sun gear of a conventional winch.
[0019] [0019]FIG. 5 is a perspective view of an improved structure of a cable winch used in vehicle of the preferred embodiment of the present invention.
[0020] [0020]FIG. 6 is an exploded perspective view of an improved structure of a cable winch used in vehicle of the present invention.
[0021] [0021]FIG. 7 is an exploded perspective view of the clutch and planet gear of the present invention.
[0022] [0022]FIG. 8 is a perspective view of the motor of the present invention.
[0023] [0023]FIG. 9 is a perspective partial sectional view of an improved structure of a cable winch used in vehicle of the present invention.
[0024] [0024]FIG. 10 is a sectional view of an improved structure of a cable winch used in vehicle of the present invention.
[0025] [0025]FIG. 11 is a sectional perspective view showing the clutch and planet gear disengaged from the gear box of an improved structure of a cable winch used in vehicle of the present invention.
[0026] [0026]FIG. 12 is a sectional view showing the clutch and planet gear disengaged from the gear box of an improved structure of a cable winch used in vehicle of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] Referring to FIGS. 5 and 6, there is shown an improved structure of a cable winch used in vehicle, comprising a rolling cylinder component 20 having one end being mounted with a speed-reducing device 30 and the other end being mounted with a motor 40 so as to transmit the power of the motor 40 to the rolling cylinder component 20 by the speed-reducing device 30 . In accordance with the present invention, the speed-reducing device 30 includes a control button 31 , a transmission shaft 32 , a gear box 33 , a sun gear 34 , a plurality of planetary gear sets 35 , a clutch and planet gear set 36 , and a fastening ring 37 , wherein the interior of the control button 31 is provided with a protruded tubular section 311 and the center of the tubular section 311 is provided with an inner hole 312 , and the circumferential edge is arranged with protruded pegs 313 ; the transmission shaft 32 is a hexagonal rod body having one end being inserted into the inner hole 312 of the control button 31 using the fastening ring 321 and a recessed ring 322 is provided close to the middle section thereof; the interior of the gear box 33 is a cavity and the inner wall is provided with inner ring teeth 331 , and the bottom surface being a through hole 332 and the inner circumferential edge of the through hole 332 is provided with a recess 333 to match with the protruded peg 313 of the control button 31 . The sun gear 34 and the planet gear set 35 are obvious and further description thereof is not needed.
[0028] Referring to FIGS. 6 and 7, the clutch and planet gear set 36 includes planet gear train 361 , a front cover 362 , a moving gear 363 , a worm-like spring 364 , and a fixing board 365 , wherein the center of the front cover 362 is pressed into a protruded section 3621 surrounded with teeth hole 3622 and the board surface of the front cover 362 is provided with an engaging hole 3623 , and the inner lateral face of the front cover 362 between the planet gear train 361 is provided with the moving gear 363 and the worm-like spring 364 using a fixing board 365 and the teeth hole 3622 of the front cover 362 and the moving gear 363 match with each other, so that the moving gear 363 is extendable and retractable within the protruded section 3621 ; the surface of the fixing board 365 is provided with crooked leg 3651 to mount with the engaging hole 362 of the front cover 362 so that the moving gear 363 and the worm-shaped gear 364 are mounted on the front cover 362 .
[0029] As shown in FIGS. 6 and 8, the center of the rotating shaft 41 of the motor 40 is a non-circular insertion hole 42 having an exterior diameter substantial the same as that of the transmission shaft 32 .
[0030] The combination of the winch of the present invention is shown in is FIGS. 6 to 10 . One end of the transmission shaft 32 is inserted into the inner hole 312 of the control button 31 and a fastening ring 321 is used to fasten. The tubular section 311 of the control button 31 is pivotally inserted into the through hole 332 position of the gear box 33 and the protruded peg 313 is matched to the recess 333 of the gear box 33 . The transmission shaft 32 is mounted at the center of the gear box 33 and the transmission shaft 32 of the gear box 33 is then mounted in sequence with a corrugated pad 38 , sun gear 34 , a plurality of planetary gear set 35 and the clutch and planet gear set 36 . A fastening ring 37 is used to fasten the moving gear 363 at the recess 322 of the transmission shaft 32 . The sun gear 34 and the planetary gear set 35 and the clutch and planet gear 36 can accept the input power from the transmission shaft 32 , and the planetary gear set 35 and the clutch and planet gear set 36 are in engagement and driven with the inner circular teeth 331 of the gear box 33 to form planetary gear-reducing device 30 . The gear box 33 is locked at one end of the rolling cylinder 20 with screw bolt 334 and the moving gear 363 of the clutch and planet gear set 36 is in engagement with the teeth portion 23 of the rolling cylinder 22 , and the transmission shaft 32 passes through the rolling cylinder 22 . The other end of the rolling cylinder 20 is pivotally mounted to the rotating shaft 41 of the mounted with a corrugated pad and a seal 44 and a screw bolt 45 is used to lock the motor 40 to the other end of the rolling cylinder 20 and the insertion hole 42 of the rotating shaft 41 is in engagement with the end terminal of the transmission shaft 32 and obtain power output from the motor 40 .
[0031] In accordance with the present invention, the operation of the winch is as follows:
[0032] (1) Rolling of the cable: As shown in FIG. 10, the motor 40 is turned on and the rotating shaft 41 drives the transmission shaft 32 , the sun gear 34 , the respective planetary gear set 35 and the clutch and planet gear set 36 , the planetary type of gear speed-reducing rotation within the gear box 33 is obtained. At this instance, the moving gear 363 will drive the rolling cylinder 22 of the rolling cylinder set 20 for use in the rolling of cable 21 . (II) Releasing of the cable 21 : Referring to FIGS. 11 and 12, the control button 31 is rotated so that the protruded peg 313 urges the top edge 335 of the through hole 332 of the gear box 33 , the control button 31 will drive the transmission shaft 32 and the fastening ring 37 to compress the moving gear 363 and the worm-like spring 364 , and the moving gear 363 is disengaged from the teeth section of the rolling cylinder 22 . Thus, the rolling cylinder 22 is disengaged from the clutch and planet gear set 36 and free to rotate, i.e., the cable 21 can be lightly, conveniently pulled out for use. If the control button 31 is released, the cable 21 will be returned to its original position, as shown in FIG. 10.
[0033] It will be envisioned that various substitutions and modifications of the preferred embodiment illustrated in the drawings and described above can be made without departing from the invention as defined in the claims. It will be understood that persons skilled in the art will envision various substitutions of functionally equivalent structure for the structural elements described without departing from the invention.
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An improved structure of a cable winch used in vehicle is disclosed. The present cable winch provides the user to turn the control button to position a protruded peg at the top edge of the through hole of the gear box, and the control button will pull the transmission shaft and the moving gear thereon and the worm-like spring, thereby the moving gear disengages from the teeth portion of the rolling cylinder and the rolling cylinder is unloaded and rotates freely, and the cable of the winch can be rapidly and conveniently pulled out.
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BACKGROUND
This application claims the priority benefit under 35 U.S.C. § 119 of Japanese Patent Application No. 2005-334311 filed on Nov. 18, 2005, which is hereby incorporated in its entirety by reference.
1. Field
The disclosed subject matter relates to a white LED illumination device, and in particular, relates to a white LED illumination device having a white LED as a light source. The white LED has an LED chip and a wavelength conversion material. The LED chip can emit light having a peak wavelength in, for example, the blue wavelength range. The wavelength conversion material such as a fluorescent material is excited by the light from the LED chip and performs wavelength conversion to emit, for example, yellow or yellowish green fluorescence which is a complementary color of blue.
2. Brief Description of the Related Art
LED chips generally emit light that has steep spectral characteristics (spectral distribution). Humans typically recognize the light as light with a tone approximately corresponding to its peak wavelength λp (wavelength at which maximum emission intensity is achieved). Accordingly, the LED chip emits light in an intrinsic tone caused by the material, composition, structure, and the like of the LED chip. This emitted light is generally not white light (natural light) with superior color rendering properties like that produced by the sun (which includes a wavelength component in a wide wavelength range throughout the ultraviolet, visible, and infrared regions).
There are some methods to obtain white light by using the LED chip emitting light with such spectral characteristics as a light source. In one method, three kinds of LED chips, that is, an LED chip emitting red light (red LED chip), an LED chip emitting green light (green LED chip), and an LED chip emitting blue light (blue LED chip) are employed. They are turned on at the same time, and as a result, white (W) light with a desired tone can be generated by means of additive color mixture. The tone can be adjusted by independently controlling the respective amounts of red (R) light, green (G) light, and blue (B) light which are the three primary colors and are emitted by the respective LED chips.
This method has a disadvantage in that three driving circuits are necessary to independently control the respective amounts of light emitted by the LED chips. However, there is also an advantage in that the tone of light generated by means of the additive color mixture can be successively controlled.
Another method uses a fluorescent material serving as a wavelength conversion material. This method utilizes a principle in which when a fluorescent material is irradiated with light, the fluorescent material is excited and emits light with a longer wavelength than that of the excitation light.
Specifically, for example, the fluorescent material such as YAG, TAG, or orthosilicate is available. When blue light (light having a peak wavelength in the blue wavelength range) is emitted from an LED chip made of a semiconductor material such as ZnSe, InGaN, GaN, ZnO, etc., excites the fluorescent material, the fluorescent material emits, via wavelength conversion, yellow and/or yellowish green fluorescence which are complementary colors of the blue light. Yellow light, which is generated by wavelength conversion when part of the blue light emitted from the LED chip excites the fluorescent material, can be added to or mixed with part of the blue light emitted from the LED chip to generate white light by means of the additive color mixture.
In another example, when an LED chip emits blue light, a mixture of two kinds of fluorescent materials can be employed, which emit green and red fluorescence, respectively, by wavelength conversion when excited by the blue light. Green light and red light, which are generated by wavelength conversion when part of the blue light emitted from the LED chip excites the fluorescent materials can be mixed with or added to part of the blue light emitted from the LED chip to generate white light by means of additive color mixture.
When an LED chip emits ultraviolet light, a mixture of three kinds of fluorescent materials can be employed, which emit blue, green, and red fluorescence, respectively, by wavelength conversion when excited by the ultraviolet light. Blue light, green light, and red light, which are generated by wavelength conversion when part of the ultraviolet light emitted from the LED chip excites the fluorescent materials, can be mixed together and generate white light by means of additive color mixture.
Furthermore, when the wavelength of light emitted from an LED chip and a kind of fluorescent material are appropriately selected and combined, light in various tones other than white light can also be generated.
FIG. 1 is an example of such an LED. In this LED, part of the light emitted from a light source excites a fluorescent material for wavelength conversion and generates light different in tone from the light emitted from the light source. The LED has a printed circuit board 53 in which conductive patterns 52 a and 52 b are formed on an insulating substrate 51 . A lamp house 56 is attached to the printed circuit board 53 . The lamp house 56 is provided with a bowl-shaped recessed portion 55 having a reflective surface 54 opening upward and outward. A blue LED chip 58 , which can emit blue light, is mounted on the conductive pattern 52 a formed on an inner bottom 57 of the recessed portion 55 (on the printed circuit board 53 ) via a conductive adhesive 59 to electrically connect a lower side electrode of the blue LED chip 58 to the conductive pattern 52 a . An upper side electrode of the blue LED chip 58 is electrically connected to the conductive pattern 52 b through an overhead wired bonding wire 60 . Furthermore, a transparent resin 62 , into which a fluorescent material 61 is mixed, is filled into the recessed portion 55 . The blue LED chip 58 and the bonding wire 60 are sealed by the resin to be shielded from air. In this instance, when the blue light excites the fluorescent material 61 , the fluorescent material 61 can emit via wavelength conversion yellow or yellowish green fluorescence, which are complementary colors of blue.
In the LED 50 with such a structure, the light emitted from the blue LED chip 58 reaches a light emitting surface 63 through the transparent resin 62 into which the fluorescent material 61 is mixed. In this case, the optical path and optical path length of the light differ according to an emission direction of the light from the blue LED chip 58 . To be more specific, when L 1 represents light emitted from the blue LED chip 58 in an optical axis X direction (upward) of the blue LED chip 58 toward the light emitting surface 63 , d 1 represents its optical path length. L 2 represents light emitted from the blue LED chip 58 in a slanting upward direction from the blue LED chip 58 toward the light emitting surface 63 , and d 2 represents its optical path length. L 2 is longer than L 1 , and therefore, the difference of the optical paths is represented by d 2 -d 1 .
Such difference in the optical path means that there is difference in a ratio of wavelength conversion of the light from the blue LED chip 58 by the fluorescent material. In other words, the light L 1 reaching the light emitting surface 63 through the short optical path has a blue tone because it is subjected to a low ratio of wavelength conversion by the fluorescent material. On the contrary, the light L 2 reaching the light emitting surface 63 through the long optical path has a yellow tone because it is subjected to a high ratio of wavelength conversion by the fluorescent material.
Accordingly, this LED emits bluish white light in a front direction and emits yellowish white light in the slanting upward direction. Also, the bluish white light is emitted from the center of the light emitting surface of the LED and the yellowish white light is emitted from the periphery of the light emitting surface of the LED. Thus, the LED has an optical characteristic with an uneven tone because the emitted white light has different tones according to its emission direction and emission portion.
By the way, it is conventionally known that a light source that evenly emits light in every direction, like the above-described LED, is optically regarded as a point source of light. This is true when the size of the light source is much smaller than the distance from which it is observed (observation distance is approximately five times or more of the size of the light source).
Consider that an illumination device for illuminating a position that is approximately five times or more of the size of the light source away is configured using the above-described LED as a light source. In this case, it is necessary to secure the illuminance of an illumination surface and improve unevenness in the tone of the light source by applying certain light-gathering means to the wide directional light emitted from the light source.
To cope with this, as shown in FIG. 2 , there is an LED in which a condenser lens is provided in front of the LED in a light emission direction to collect the light to an illumination surface and even the tone of illumination light in the illumination surface.
Bluish white light emitted in a front direction of an LED 80 is refracted by an upper incident surface 82 of a lens 81 and introduced into the lens 81 while collected. The bluish white light reaches a center emitting surface 83 after passing through the lens 81 , and is refracted by and gathered at the center emitting surface 83 , and is emitted to the outside of the lens 81 . Yellowish white light emitted in a side direction of the LED 80 , on the other hand, is refracted by a side incident surface 84 of the lens 81 and introduced into the lens 81 . The yellowish white light reaches a peripheral reflective surface 85 after passing through the lens 81 . The light reflected (totally reflected) by the peripheral reflective surface 85 reaches a peripheral emitting surface 86 , provided on the periphery of the center emitting surface 83 , after passing through the lens 81 . Then, the yellowish white light is emitted to the outside of the lens 81 from the peripheral emitting surface 86 . In this instance, the yellowish white light emitted in the side direction of the LED 80 and emitted to the outside from the peripheral emitting surface 86 is gathered at the center of an illumination region, and is mixed with the bluish white light, which is emitted in the front direction of the LED 80 and emitted to the outside from the center emitting surface 83 . Therefore, it is possible to obtain white light in even tone (for example, please see Japanese Patent Laid-Open Publication No. 2005-216782 and U.S. Patent Publication No. 2005-179064, which are hereby incorporated in their entirety by reference).
The white light in the different tones emitted in the different directions of the LED 80 are mixed on the illumination surface and the unevenness in tone is resolved so that it is possible to obtain even white light. The white light in the different tones emitted from the different sections of the LED 80 , however, are incident on the illumination surface as-is. In addition to this, they are magnified through an optical system in which the light emitting surface of the LED 80 is composed of the lens 81 , so that the unevenness in tone is not resolved. As a result, white light with unevenness in tone is still emitted through the illumination surface.
SUMMARY
Accordingly, the presently disclosed subject matter has been devised in view of the foregoing and other problems and considerations. According to an aspect of the disclosed subject matter, a white LED illumination device can be provided which uses a white LED that has an unevenness in tone and which can irradiate even white light with high color rendering properties on an illumination surface.
According to another aspect of the presently disclosed subject matter, a white LED illumination device can include a white LED and an optical lens which are arranged so that optical axes of both are approximately aligned with each other. In this white LED illumination device, the white LED can have an LED chip which emits light having a peak wavelength in a predetermined wavelength range and a wavelength conversion material which is excited by the light emitted from the LED chip. The wavelength conversion material emits light via wavelength conversion which has a complementary color to a color of the light emitted from the LED chip. The optical lens can have a light incident surface for introduction of the light emitted from the white LED and can have a light emitting surface for emitting light to the outside. The light incident surface can include a convex portion with a convex surface that faces towards the white LED. The light emitting surface can include a convex portion with a center portion and a periphery portion thereof being formed into different shapes or curvatures.
In the white LED illumination device, the white LED can include a portion that emits white light of which the color is near the color of light of the LED chip and which is emitted from the center of the light emitting surface of the white LED. The white LED can also include a portion that emits white light of which the color is near a complementary color to the color of light of the LED chip and which is emitted from the periphery of the light emitting surface of the white LED. The light emitted from the center of the white LED is introduced into the optical lens through the convex surface of the light incident surface thereof, led through the optical lens, and is then emitted to the outside from the center of the convex portion of the light emitting surface. The light emitted from the periphery of the white LED is introduced into the optical lens through the convex surface of the light incident surface thereof, led through the optical lens, and is then emitted to the outside from the periphery of the convex portion of the light emitting surface. Furthermore, the white light of which the color is near the color of light of the LED chip and the white light of which color is near the complementary color to the color of light of the LED chip, both of which are emitted from the convex portion of the light emitting surface, are mixed to be applied on a surface to be illuminated.
According to another aspect of the presently disclosed subject matter, a white LED illumination device can include a white LED and an optical lens which are arranged so that optical axes of both are approximately aligned with each other. The white LED can include an LED chip which emits light having a peak wavelength in a predetermined wavelength range, a wavelength conversion material which is excited by the light emitted from the LED chip to emit light by wavelength conversion which has a complementary color to a color of the light emitted from the LED chip, and a light emitting surface. The optical lens can have a light incident surface for introduction of the light emitted from the white LED, a light emitting surface for emitting light to the outside, and a totally reflective surface for reflecting the light introduced from part of the light incident surface toward the light emitting surface. The light incident surface can have a recessed shape which faces the white LED. An inner bottom of the recessed shape can have a convex shape in part which faces the white LED. The light emitting surface can have a convex portion with a center portion and a periphery portion thereof being formed into different shapes or curvatures, and an approximately flat surface surrounding the convex portion. The totally reflective surface can have a curved surface that has a focus in the vicinity of an inner peripheral surface of the recessed portion of the light incident surface or in the vicinity of a periphery of the light emitting surface of the white LED.
The white LED can emit white light of which the color is near the color of light emitted by the LED chip and which is emitted from the center of the light emitting surface of the white LED, and white light of which the color is near the complementary color to the color of light emitted by the LED chip and which is emitted from the periphery of the light emitting surface of the white LED. Furthermore, part of the light emitted from the center of the white LED can be introduced into the optical lens through the convex surface of the inside bottom of the recessed portion of the light incident surface thereof, led through the optical lens, and emitted to the outside from the center of the convex portion of the light emitting surface. Part of the light emitted from the periphery of the white LED can be introduced into the optical lens through the convex surface of the inside bottom of the recessed portion of the light incident surface thereof, led through the optical lens, and emitted to the outside from the periphery of the convex portion of the light emitting surface. Then, the white light of which the color is near the color of light emitted by the LED chip and the white light of which the color is near the complementary color to the color of light emitted by the LED chip, both of which are emitted from the convex portion of the light emitting surface, can be mixed and directed to a surface to be illuminated. Also, part of the light emitted from the center of the white LED can be introduced into the optical lens through the inner peripheral surface of the recessed portion of the light incident surface thereof, led through the optical lens, reflected by the totally reflective surface, and emitted to the outside from the approximately flat surface surrounding the convex portion of the light emitting surface. Part of the light emitted from the periphery of the white LED can be introduced into the optical lens through the inner peripheral surface of the recessed portion of the light incident surface thereof, led through the optical lens, reflected by the totally reflective surface, and emitted to the outside from the approximately flat surface surrounding the convex portion of the light emitting surface. Then, the white light of which the color is near the color of light emitted by the LED chip and the white light of which the color is near the complementary color to the color of light emitted by the LED chip, both of which are emitted from the approximately flat surface surrounding the convex portion of the light emitting surface, can be mixed and directed to a surface to be illuminated.
It should be appreciated that, in any of the abovementioned white LED illumination devices, the LED chip can emit light having a peak wavelength in a blue wavelength range, and the wavelength conversion material can be excited by the blue light and can emit yellow or yellowish green light by wavelength conversion.
According to an aspect of the disclosed subject matter, a white LED and an optical lens are arranged so that the optical axes of both are substantially aligned with each other. The white LED can include an LED chip which emits light having a peak wavelength in the blue wavelength range and a wavelength conversion material such as a fluorescent material which can be excited by the light emitted from the LED chip and can emit via wavelength conversion yellow or yellowish green fluorescence which are complementary colors of blue. The optical lens can include a convex light incident surface and a convex light emitting surface for which the center and periphery thereof can be formed into different shapes or curvatures.
The bluish white light can be emitted from the center of the light emitting surface of the LED and the yellowish white light can be emitted from the periphery of the light emitting surface of the LED. The bluish and/or yellowish white light introduced into the lens from the convex surface of the light incident surface of the optical lens can be emitted to the outside from the convex portion of the light emitting surface and then mixed.
As a result, the white light in both tones is gathered into a single route of optical path and mixed, so that the light directed to an illumination surface becomes white light with high color rendering properties and with less unevenness in tone.
Furthermore, according to another aspect of the disclosed subject matter, a white LED and an optical lens can be arranged so that the optical axes of both are substantially aligned with each other. The white LED can include an LED chip which emits light having a peak wavelength in a blue wavelength range and a wavelength conversion material such as a fluorescent material which is excited by the light emitted from the LED chip and which can emit via wavelength conversion yellow or yellowish green fluorescence which are complementary colors of blue. The optical lens can include: a recessed light incident surface having a convex inside bottom with a convex surface; a light emitting surface composed of a convex portion with center and periphery portions being formed into different shapes or curvatures and a flat surface surrounding the convex section; and a totally reflective surface made of a curved surface having a focal point in the vicinity of an inner peripheral surface of the recessed portion of the light incident surface or in the vicinity of the periphery of the light emitting surface of the white LED.
Of the bluish white light emitted from the center of the light emitting surface of the LED and the yellowish white light emitted from the periphery of the light emitting surface of the LED, the bluish and/or yellowish white light that is introduced into the lens via the convex surface of the inside bottom of the recessed portion of the light incident surface of the optical lens can be emitted to the outside from the convex portion of the light emitting surface and then mixed. The bluish and/or yellowish white light introduced into the interior of the lens via the inner peripheral surface of the recessed portion of the light incident surface of the lens can be reflected by the totally reflective surface, emitted to the outside from the flat surface of the light emitting surface, and mixed together.
As a result, white light that includes both tones can be gathered into a single route of optical path and mixed, so that the light directed to the illumination surface becomes white light with high color rendering properties and with less unevenness in tone.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other characteristics, features, and advantages of the disclosed subject matter will become clear from the following description with reference to the accompanying drawings, wherein:
FIG. 1 is a sectional view of a conventional LED light source composed of an LED illumination device;
FIG. 2 is a sectional view of a conventional white LED illumination device and lens;
FIG. 3 is a sectional view of an exemplary embodiment of a white LED illumination device made in accordance with principles of the presently disclosed subject matter;
FIG. 4 is a drawing showing tracks of light rays according to the exemplary embodiment of the white LED illumination device of FIG. 3 ;
FIG. 5 is another drawing showing tracks of light rays according to the exemplary embodiment of the white LED illumination device of FIG. 3 ; and
FIG. 6 is a drawing showing tracks of light rays according to another embodiment of a white LED illumination device made in accordance with principles of the presently disclosed subject matter.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
Hereinafter, exemplary embodiments of the presently disclosed subject matter will be described in detail with referring to FIGS. 3 to 6 (the same reference numbers refer to identical and/or similar structures or references). The exemplary embodiments described herein are specific examples of the presently disclosed subject matter, and thus various technical features are included. However, the scope of the present invention is not limited to these embodiments.
FIG. 3 is a sectional view showing parts of a white LED illumination device according to an exemplary embodiment of the presently disclosed subject matter. The exemplary embodiment includes a white LED 1 and an optical lens 2 . The optical lens 2 can include an optical system that is configured to control an optical path of light emitted from the white LED 1 . The white LED 1 can be disposed above the white LED 1 in a light emission direction. In this instance, the optical axis of the white LED 1 approximately coincides with that of the optical lens 2 .
In this case, when viewed as a whole, the white LED (hereinafter abbreviated as “LED”) 1 , as shown in FIG. 3 , emits bluish white light in a front direction and yellowish white light in a slanting upward direction. When viewed in detail, the LED emits the bluish white light from the center of a light emitting surface of the LED and the yellowish white light from the periphery of the light emitting surface of the LED. Thus, the LED has an optical characteristic with unevenness in tone because the emitted white light has different tones according to emission direction and emission portions in the light emitting surface of the LED.
The optical lens 2 can have a convex portion 4 opposed to a light emitting surface 3 of the white LED 1 such that a convex surface 6 faces towards the LED 1 and a wall portion 5 protrudes to/from an edge of the convex portion 4 . The convex surface 6 of the convex portion 4 can serve as a light incident surface through which light that is emitted upward from the light emitting surface 3 of the LED 1 is introduced into the optical lens 2 . An inner peripheral surface 7 of the wall portion 5 can serve as a light incident surface which introduces light that is emitted sideways from the light emitting surface 3 of the LED 1 into the optical lens 2 . A light emitting surface that is configured to emit light to the outside can be formed at a position opposed to the convex portion 4 of the light incident surface of the optical lens 2 . A convex portion 10 can be formed at the center of the light emitting surface. The convex portion 10 can have an approximately flat surface 8 in the center thereof and part of an approximately ellipsoid of revolution 9 having a focus in the vicinity of the convex portion 4 . An approximately flat surface 11 can be located about the periphery of the convex portion 10 .
The curvature of the convex portion serving as the light emitting surface can be smaller than the curvature of the convex portion serving as the light incident surface in general. This is because the light emitting surface of the LED optically conjugates with the convex portion serving as the light emitting surface of the optical lens, and the convex surface serving as the light incident surface optically conjugates with an illumination pattern. Thus, the optical lens can be described as a biconvex lens.
Furthermore, it is possible to make the curvature and shape different between the center and the periphery of the convex portion which serves as the light emitting surface. If the curvatures are made different, the center may be designed so as to have a curvature for controlling the bluish white light, and the periphery may be designed so as to have a curvature for controlling the yellowish white light. The shapes are made different in this exemplary embodiment. For example, the center of the convex portion 10 is formed into the approximately flat surface 8 to diffuse the bluish white light. The periphery is composed of part of the approximately ellipsoid of revolution 9 having a focus in the vicinity of the convex portion 4 in which the convex surface 6 serving as a light incident surface is formed in order to concentrate the yellowish white light towards the center.
The shape of an outside surface 12 can be a reflective (e.g., totally reflective) surface for directing the light that is led into the optical lens 2 to the light emitting surface. The shape of surface 12 is not limited to that of the convex portion 10 , and can be variously changeable. Various characteristics of the shape of the outside surface 12 will be hereinafter described.
In the case of realizing an optical lens with relatively high light-gathering power, the outside surface 12 of the optical lens 2 can be formed by an approximately parabolic curve as viewed in cross section. In this case, when a focus position is set in the vicinity of the light emitting surface 3 of the LED 1 , the light emitting surface 3 of the LED 1 is formed as an image on the illumination surface as-is, and hence unevenness in tone existing in the light emitting surface 3 of the LED 1 conspicuously appears on the illumination surface. Accordingly in this exemplary embodiment, the focus position of the outside surface 12 of the optical lens 2 is set to be located in the vicinity of the inner peripheral surface 7 of the wall portion 5 . In this instance, the shape of the inner peripheral surface 7 of the wall portion 5 is projected on the illumination surface. Since the wall portion 5 can be several mm away from the light emitting surface 3 of the LED 1 , the light emitted from the light emitting surface 3 of the LED 1 reaches the illumination surface in a condition with little unevenness in tone. Therefore, the light without unevenness in tone is applied on the illumination surface on which the inner peripheral surface 7 of the wall portion 5 is projected.
FIGS. 4 and 5 are sectional views of the exemplary embodiment of FIG. 3 . FIGS. 4 and 5 show exemplary tracks of both the bluish white light that is emitted from the center of the light emitting surface 3 of the LED 1 and the yellowish white light that is emitted from the periphery of the light emitting surface 3 of the LED 1 . Both types of light can be introduced into the lens 2 via the light incident surface of the optical lens 2 , led through the optical lens 2 , and emitted to the outside from the light emitting surface.
With regard to the bluish white light emitted from the center of the light emitting surface 3 of the LED 1 , as shown in FIG. 4 , light heading for the convex surface 6 of the convex portion 4 of the optical lens 2 on the side of the light emitting surface 3 of the LED 1 can be refracted by the convex surface 6 and introduced into the optical lens 2 while being gathered. The light is led through the optical lens 2 , and reaches the approximately flat surface 8 in the center of the convex portion 10 formed in the center of the light emitting surface. Then, the light is emitted to the outside while diffused by the approximately flat surface 8 . With regard to the yellowish white light emitted from the periphery of the light emitting surface 3 of the LED 1 , light heading for the convex surface 6 of the convex portion 4 of the optical lens 2 on the side of the light emitting surface 3 of the LED 1 is refracted by the convex surface 6 and introduced into the optical lens 2 in a like manner. The light is led through the optical lens 2 , and reaches the approximately ellipsoid of revolution 9 on the periphery of the convex portion 10 formed in the center of the light emitting surface. Then, the light is emitted to the outside while being refracted by the approximately ellipsoid of revolution 9 . The light is gathered at the upper portion of the center of the convex portion 10 .
As a result, the bluish white light emitted from the approximately flat surface 8 of the convex portion 10 formed in the center of the light emitting surface of the optical lens 2 is mixed with the yellowish white light emitted from the approximately ellipsoid of revolution 9 in the upper portion of the center of the convex portion 10 , so that white light with high color rendering properties is formed.
Accordingly, the above-described exemplary embodiment uses a biconvex lens that is formed only by two convex portions, that is, the convex portion 4 of the optical lens 2 on the side of the light emitting surface 3 of the LED 1 and the convex portion 10 formed in the center of the light emitting surface. This biconvex lens can provide white light with high color rendering properties by mixing the bluish white light emitted from the center of the light emitting surface 3 of the LED 1 and the yellowish white light emitted from the periphery of the light emitting surface 3 of the LED 1 .
As shown in FIG. 5 , the bluish white light emitted from the center of the light emitting surface 3 of the LED 1 that is directed towards the inner peripheral surface 7 of the wall portion 5 of the optical lens 2 is introduced into the optical lens 2 from the inner peripheral surface 7 , and heads for the outside surface 12 that is shown as being formed by an approximately parabolic curve in cross section. When the light is led through the optical lens 2 , and reaches the outside surface 12 through the optical lens 2 , the light can be totally reflected by the outside surface 12 and head for the light emitting surface. Then, the light reaches the approximately flat surface 11 located around the convex portion 10 that is formed in the light emitting surface. Then, the light is emitted to the outside while being diffused by the approximately flat surface 11 .
By contrast, the yellowish white light that is emitted from the periphery of the light emitting surface 3 of the LED land is directed towards the inner peripheral surface 7 of the wall portion 5 of the optical lens 2 can be emitted to the outside through approximately the same optical path as the above-described bluish white light which is emitted from the center of the light emitting surface 3 and also directed towards the inner peripheral surface 7 of the wall portion 5 of the optical lens 2 .
As a result, in an upper portion of the periphery of the convex portion 10 that is formed in the light emitting surface, the bluish white light and the yellowish white light which are emitted from the approximately flat surface 11 around the convex portion 10 that is formed in the center of the light emitting surface of the optical lens 2 are mixed, and hence white light with high color rendering properties can be formed.
Accordingly, the above-described light path uses only three portions (surfaces) of an optical lens, that is, the inner peripheral surface 7 of the wall portion 5 of the optical lens 2 , the approximately flat surface 11 around the convex portion 10 formed in the light emitting surface, and the outside surface 12 . This optical lens can provide the white light with high color rendering properties by mixing the bluish white light emitted from the center of the light emitting surface 3 of the LED 1 with the yellowish white light emitted from the periphery of the light emitting surface 3 of the LED 1 .
Thus, overlaying the tracks of light rays shown in FIGS. 4 and 5 , the white light with high rendering properties, into which the bluish white light and the yellowish white light are mixed, can be formed above both of the center and periphery of the optical lens 2 (that is, above the whole optical lens 2 ). Accordingly, this LED illumination device can emit white light with high rendering properties and with little unevenness in tone from the illumination surface.
FIG. 6 shows another exemplary embodiment which can realize an LED white light emitting device with higher converging properties. The optical lens of FIG. 6 has almost the same shape as the optical lens shown in FIGS. 3 to 5 , but the height of the optical lens 2 is made higher than the optical lens in the previously described embodiment. In addition, the inner peripheral surface 7 of the wall portion 5 is inclined towards a direction that is parallel to the light emitting surface 3 of the LED 1 (the inner peripheral surface 7 can be extended to be substantially horizontal).
When the focus of the outside surface 12 of the optical lens 2 serving as the totally reflective surface is set at the center of the light emitting surface 3 of the LED 1 , the bluish white light and the yellowish white light are separated. Therefore, the present exemplary embodiment sets the focus thereof in the vicinity of the periphery of the light emitting surface 3 of the LED 1 .
By inclining the inner peripheral surface 7 of the wall portion 5 to the direction parallel to the light emitting surface 3 of the LED 1 , light, which is emitted from the light emitting surface 3 of the LED 1 and refracted by the inner peripheral surface 7 of the wall portion 5 , is introduced into the optical lens 2 . Then, the light is led through the optical lens 2 , and reaches an end portion of the outside surface 12 . In other words, since an optical path of the light that is emitted from the light emitting surface 3 of the LED 1 and which extends to the light emitting surface of the optical lens 2 becomes long, the light emitted from the light emitting surface of the optical lens 2 to the outside forms a narrow directional orientation pattern.
The directivity of light emitted above the center of the optical lens 2 depends on both the focal length of the convex portion 10 that is formed in the light emitting surface of the optical lens 2 and the curvature of the convex surface 6 of the convex portion 4 located adjacent the light emitting surface 3 of the LED 1 . Therefore, increasing the height of the optical lens 2 makes it possible to realize an LED white light emitting device that has narrow directivity.
The white LED has not been described in detail. However, the kind of the white LED is not limited to any particular one, and combinations of particular color tone LED chip and corresponding wavelength conversion materials may be used, as appropriate.
While there has been described what are at present considered to be exemplary embodiments of the present invention, it will be understood that various modifications may be made thereto, and it is intended that the appended claims cover such modifications as fall within the true spirit and scope of the present invention.
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A white LED illumination device can include a white LED that has unevenness in tone and is used as a light source. The white LED illumination device can emit white light with high color rendering properties without unevenness in tone and can include the above noted white LED located adjacent an optical lens. The white LED and optical lens can be arranged so that the optical axes of both are substantially aligned with each other. The white LED can include an LED chip which emits light having a peak wavelength in the blue wavelength range and a fluorescent material which can be excited by the light emitted from the LED chip to emit yellow or yellowish green fluorescence (i.e., complementary colors to blue) by use of wavelength conversion. The optical lens can have a recessed light incident surface having an opening, a light emitting surface, and a totally reflective surface positioned between the light incident surface and the light emitting surface. The inner bottom of the recessed light incident surface can include a convex shape having a convex surface. The light emitting surface can be composed of a convex portion having a center and a periphery that can be formed in different shapes or curvatures, and can include a flat surface surrounding the convex portion.
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[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/872,010, filed Aug. 30, 2013.
FIELD OF THE PRESENT INVENTION
[0002] The present invention pertains to the field of wood siding for buildings, and more particularly, it pertains to a wood siding system that has a relatively thin overlap, and ventilation gaps around every board to prevent a retention of moisture behind the wood siding boards.
BACKGROUND OF THE PRESENT INVENTION
[0003] An old-fashion wood clapboard is approximately ¼ inch thick at the lower edge tapering to a very thin top edge. Old-fashion wood clapboards were made to match the exposed surface and thickness of traditional cedar shingles. Wood clapboards were easier to install and to paint than shingles, and therefore this type of wall cladding became very popular during the last century.
[0004] Old-fashion clapboard-like siding is coming back in style with speciality wood products that are available at the present time. Wood siding products are being manufactured with stained or pre-painted wood boards, and with other torrefied or pressure treated wood products.
[0005] Experience gained with old-fashion clapboards, however, has dictated a number of improvements to be applied to the newer siding products. A first improvement is to install the wood boards without nail to avoid cracking the boards along the thin edges of the boards. A second improvement is to provide ventilation between the siding boards and the supporting structure to prevent the absorption of moisture into and behind the boards. Such moisture is known to cause expansion of the boards, wood decay and discolouration and blistering of the painted surfaces of the boards.
[0006] A search in the prior art has not given any suggestion for a contemporary wood siding system including all the desired improvements, while maintaining the appearance of old-fashion clapboards. As examples, the following documents describe the various siding systems that have been found in the prior art.
U.S. Pat. No. 2,276,170, issued to A. Elmendorf on Mar. 10, 1942; U.S. Pat. No. 2,292,984, issued to A. Alvarez, Jr., on Aug. 11, 1942; U.S. Pat. No. 2,308,129, issued to S. H. Tummins on Jan. 12, 1943; U.S. Pat. No. 2,354,639, issued to H. T. Seymour on Jul. 25, 1944; U.S. Pat. No. 2,928,143, issued to L. J. Newton on Mar. 15, 1960; U.S. Pat. No. 3,015,193, issued to J. Amoruso on Jan. 2, 1962; U.S. Pat. No. 3,173,229, issued to E. Weber on Mar. 16, 1965; U.S. Pat. No. 3,237,360, issued to T. W. Mills on Mar. 1, 1966; U.S. Pat. No. 3,261,136, issued to T. L. Abner et al., on Jul. 19, 1966; U.S. Pat. No. 3,866,378, issued to G. Kessler on Feb. 18, 1975; U.S. Pat. No. 4,117,644, issued to R. N. Weinar on Oct. 3, 1978; U.S. Pat. No. 4,281,494, issued to R. N. Weinar on Aug. 4, 1981; U.S. Pat. No. 5,501,050, issued to R. Ruel on Mar. 26, 1996; U.S. Pat. No. 5,564,245, issued to R. J. Rademacher on Oct. 15, 1996; U.S. Pat. No. 6,055,787, issued to M. Gerhaher et al., on May 2, 2000; U.S. Pat. No. 6,298,626, issued to E. P. Rudden on Oct. 9, 2001; U.S. Pat. No. 6,843,032, issued to S. Hikai on Jan. 18, 2005; U.S. Pat. No. 7,748,188, issued to T. Ito on Jul. 6, 2010; U.S. Pat. No. 7,797,902, issued to S. Hikai et al., on Sep. 21, 2010; US Publication 2002/0046536, by R. Hotta, dated Apr. 25, 2002; US Publication 2009/0241459, by B. Bryan, dated Oct. 1, 2009; US Publication 2010/0263316, by L. Bruneau, dated Oct. 21, 2010; CA Patent 1,283,522, issued to K. Kelly on Apr. 30, 1991; CA Patent 2,167,097, issued to R. Ruel on Dec. 14, 1999; CA Patent Application 2,290,914, by M. Watanabe on May 30, 2005; CA Patent Application 2,649,123, by J. Koessler et al., on Jul. 21, 2009; CA Patent Application 2,663,469, by L. Bruneau on Oct. 21, 2010.
[0034] In view of these documents, it is believed that there remains a market demand in the field of wood siding industry for a wall siding system that has the appearance and stiffness of old-fashion clapboards; which can be installed without nails through the boards, and which has aeration gaps between and behind the siding boards. More particularly, there is a market demand for a wall siding system that retains its appearance of high-quality old-fashion wood siding despite expansion or shrinkage.
SUMMARY OF THE PRESENT INVENTION
[0035] In the present invention, there is provided a wood siding system that has air circulation gaps between overlapping siding boards and between the siding boards and the supporting wall. The wood siding system has the appearance of old-fashion clapboards; a limited flexibility that closely imitates a solid wall, and means to control the direction of shrinkage of the boards to preserve the visual appeal of the wood siding.
[0036] In a first aspect of the present invention, there is provided a wood siding system comprising upper and lower wood siding boards mounted to a supporting wall. Each of the wood siding boards has a front surface, a back surface, an upper edge; a lower edge, and a tapered cross-section. The lower edge of each board has an apron strip and a shoulder. The apron strip of the upper wood siding board overlaps the upper edge of the lower wood siding board. The apron strip of the upper wood siding board is held at a distance for the front surface of the lower wood siding board such that a ventilation gap is maintained under the apron strip and above the front surface of the lower siding board.
[0037] The back surfaces of the wood siding boards are held parallel and in a same plane with each other and at a same distance from the supporting wall, such that a ventilation space is maintained behind the boards.
[0038] The shoulder of the upper wood siding board is held at a distance from the upper edge of the lower wood siding board such that an air circulation gap is maintained between the upper wood siding board and the lower wood siding board. Because of these air circulation gaps, a good ventilation is maintained between and behind the wood siding boards, to keep the siding boards and the supporting structure dry.
[0039] Because the back surfaces of the siding boards are held parallel to the supporting wall, a relatively thin ventilation gap can be maintained such that the supporting wall provides a backing support to the siding boards for preventing excessive deflection in the siding boards. When a siding board is accidentally pushed inward, a slight deflection causes it to rest against the supporting wall, suggesting that the siding boards are part of a solid structure.
[0040] In another aspect of the present invention, a metal retainer is mounted between the upper and lower wood siding boards. This metal retainer has a gauge lip extending vertically and forming a spacing gauge between the shoulder of the upper siding board and the upper edge of the lower siding board for maintaining an ideal distance between the shoulder of the upper siding board and the upper edge of the lower siding board. Because of these metal retainers and gauge lips, the upper siding board is easily installed over the lower siding board, without the need for a measuring tool. The metal retainers are simply loosely placed and spaced apart along the upper edge of a first siding board and nailed to the supporting wall. The shoulder on the bottom edge of a next wood siding board is manually force-fitted down into the metal retainers, and the process is repeated for the next wood siding board.
[0041] In another aspect of the present invention, the gauge lip on each metal retainer has a sharp edge for penetrating the upper edge of the lower wood siding board during swelling of the lower wood siding board. The metal retainer also has a tight-fit ridge therein, extending along the shoulder of the upper wood siding board for retaining the shoulder into the metal retainer, during shrinking of the upper wood siding board.
[0042] In yet another aspect of the present invention, a wood grain pattern on the front surface of the upper wood siding board is a mirror image of a wood grain pattern on the front surface of the lower wood siding board.
[0043] This brief summary has been provided so that the nature of the invention may be understood quickly. A more complete understanding of the invention can be obtained by reference to the following description of the preferred embodiment thereof in connection with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] FIG. 1 is a partial perspective view of the siding system according to the preferred embodiment of the present invention, under construction;
[0045] FIG. 2 is an end view of a wood board and a preferred separation thereof into two siding boards;
[0046] FIG. 3 is a first end view of a metal retainer that is used in the wood siding system according to the preferred embodiment of the present invention;
[0047] FIG. 4 is an end view of two siding boards in the wood siding system according to the preferred embodiment of the present invention;
[0048] FIG. 5 is an enlarged view of the overlap between the two siding boards as shown in FIG. 4 .
[0049] FIG. 6 is a second, enlarged end view of the metal retainer illustrated in FIGS. 1 , 3 - 5 ;
[0050] FIG. 7 is an assembly of three extrusions snappily engaged to each other for shipping, handling and for cutting to length therefrom, a plurality of metal retainers.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0051] The preferred embodiment of the wood siding system according to the present invention is described herein below with reference to the attached drawings.
[0052] Referring to FIG. 1 , the overall arrangement of the preferred siding system is illustrated. The wood siding boards 20 have straight back surfaces 22 that are held in a coplanar arrangement with each other, parallel to the supporting structure 24 . The wood siding boards 20 are held to the supporting structure 24 by spaced-apart metal retainers 26 . The metal retainers 26 are preferably installed at intervals of 12 to 24 inches along the top edge of each wood siding board 20 . A continuous length of metal retainer 26 (not shown) can also be used to support the bottom edge 28 of the lowermost wood siding board 20 on a wall.
[0053] Each wood siding board 20 has a tapering front surface 30 with a thicker lower edge. The lower edge has a shoulder 32 , a slot 34 and an apron-like strip 36 formed thereon, on its front surface. The apron-like strip 36 herein after referred to as the apron strip 36 has the thickness of an old-fashion clapboard. This thickness is approximately ¼ inch. The apron strip 36 of one siding board 20 overlaps the upper edge of a lower siding board 20 . The thickness of this overlap is the thickness of the apron strip 36 plus the thickness of an air circulation gap that is maintained under the apron strip 36 . This air circulation gap will be explained later. The vertical length of this overlap is a same distance or slightly more than the projection of the overlap; that is ¼ inch plus the thickness of the air circulation gap.
[0054] The shoulder 32 has substantially a same thickness as the upper edge 38 of the siding board 20 , such that when the siding boards 20 are mounted on a supporting wall 24 , their back surfaces 22 are straight, coplanar and parallel to the supporting wall 24 .
[0055] In order to further enhance the visual appearance of the preferred siding boards 20 , pairs of grain-matching siding boards 20 are sawn from a single wood board 40 as shown in FIG. 2 . For example, a one inch thick by 5½ inch wide board 40 can be profiled on a moulder and sawn by thin-kerf bandsaw along the saw line 42 . The saw line 42 corresponds to the front surfaces 30 of both siding boards 20 . It is believed that the aforesaid overall overlap projection 44 of about 5/16 inch or slightly more together with the board width of about 5½ inch, give the appearance of old-fashion clapboard siding.
[0056] The preferred method of sawing of siding boards 20 as illustrated in FIG. 2 produces pairs of siding boards with one board having a wood grain pattern that is a mirror image of the other. These mirror images are especially apparent when the boards are made of pine, ash or oak wood species for examples. These mirror images are referred to herein as “matching wood grain patterns”, and such “matching wood grain patterns” carry an impression of a carefully selected base material for manufacturing the preferred siding boards 20 . “Matching wood grain patterns” technique is well known in the field of high quality cabinet making and furniture manufacturing. When applied to wood siding as explained above, this technique carries a similar attribute of quality craftsmanship.
[0057] Both boards in a pair of “matching wood grain pattern” boards follow each other closely in the manufacturing process and remain at close proximity of each other in bundles of wood siding boards delivered to clients. It becomes relatively easy for a carpenter to find boards in a same pair and install them at close proximity from each other to obtain the aforesaid high quality craftsmanship appearance. It becomes relatively easy for a carpenter to install each board above, alongside, staggered or in alternate row from its “mirror image” match for example, to obtain a “signature” or “trademark” siding appearance.
[0058] Referring now to FIG. 3 , the preferred metal retainer 26 will be described. The metal retainer 26 is preferably cut from a bar of extruded aluminium profile. Several bars can be used in their full lengths to retain the lower siding board 20 on a wall as mentioned before. Bars of extruded aluminium profile are cut to individual short pieces as desired, to obtain metal retainers 26 of shorter lengths. Metal retainers 26 of two inches long, spaced apart twelve to twenty four inches are considered appropriate for most applications. Slightly longer metal retainers 26 , say three inch length or more, may be used to support vertical joints in the siding boards.
[0059] Each metal retainer 26 has a H-like formation. This H-like formation is made of a pair of U-shaped cavities 50 , 52 superimposed over one another with the bottom one 52 being oriented downward. Both U-shaped cavities 50 , 52 have a same opening width. These U-shaped cavities 50 , 52 are made to enclose the shoulder 32 and the upper edge 38 , respectively, of overlapping wood siding boards 20 .
[0060] Each metal retainer 26 has a backing structure 58 which is made of two superimposed C-shaped formations 60 , 62 . The top C-shaped formation 60 extends above the upper U-shaped cavity 50 . The top C-shaped formation 60 faces forward and has a nail-guiding groove 64 therein. The top C-shaped formation 60 has sufficient depth to conceal the heads of nails that are used to fasten the metal retainer 26 to a wall 24 .
[0061] The purpose of both C-shaped formations 60 , 62 is to provide a backing structure 58 that has stiffening ribs and a sufficient thickness “A”. The thickness “A” is preferably about ⅛ inch. The thickness “A” of the metal retainer's backing wall 58 constitutes the thickness of the air circulation gap 68 between the siding boards 20 and the supporting wall 24 .
[0062] The common front wall 54 of both U-shaped cavities 50 , 52 is a planar wall with a thickness “B” of about 1/16 of an inch or slightly less. In use, the upper half of this front wall 54 is nested in the aforesaid slot 34 , and the lower half of this front wall 54 constitutes a spacer to form an air circulation gap 56 between the apron strip 36 of one siding board 20 and the front surface 30 of the siding board 20 underneath. It will be appreciated that the air circulation gap 56 mentioned above extends between the metal retainers 26 . The thickness of the front wall 54 is preferably kept at 1/16 inch or slightly less such that the total projection of the overlap 44 does not exceed about 5/16 inch, and such that the appearance of old-fashion clapboard siding is maintained.
[0063] The function of the upper portion of the front wall 54 and the associated slot 34 in which this portion is fitted, is to retain the lower shoulder 32 of the upper wood siding board to the supporting wall 24 . The function of the lower portion of the front wall 54 is to retain the upper edge 38 of the lower siding board to the supporting wall 24 .
[0064] The advantage of this installation is that the air gap 68 between the siding boards 20 and the supporting wall 24 can be maintained to a very small distance to prevent excessive or uneven deflection in the siding boards 20 , should they be accidentally pushed against the supporting wall 24 .
[0065] Referring again to FIG. 3 , the lower U-shaped cavity 52 has a gauge lip 66 formed on the bottom thereof. This gauge lip 66 is used as a spacing gauge to obtain a proper spacing between the shoulder 32 of one siding board 20 and the top edge 38 of the siding board 20 below it. When a wall is being covered with wood siding boards 20 , the metal retainers 26 are loosely placed on the top edge 38 of the last-installed siding board 20 , and it is nailed to the supporting wall 24 without measurement.
[0066] The gauge lip 66 ensures that a proper air circulation spacing 70 is maintained between rows of siding boards 20 to allow for swelling of the boards in high humidity conditions for example. This vertical air circulation gap 70 between siding boards 20 also constitutes an air passage communicating with the air circulation gap 56 and the vertical gap 68 .
[0067] The gauge lip 66 has a depth “C” that is a function of the total board width, and the potential swelling of each siding board 20 . The gauge lip 66 has a relatively sharp lower edge for penetrating the upper edge 38 of a siding board 20 with ease, during swelling of that siding board 20 , without splitting the upper edge 38 of that board.
[0068] Referring now to FIGS. 4 and 5 , the air circulation gaps between and behind the siding boards 20 will be explained. Because the back surfaces 22 are held in a coplanar arrangement parallel to the supporting wall 24 at a very small distance from the supporting wall surface 24 , an effective ventilation (without air flow resistance) of the siding boards 20 is achieved. The arrow 72 in FIG. 5 , illustrates the air flow pattern through the air circulation gap 56 , through the board spacing 70 and along the vertical air circulation gap 68 along the supporting wall 24 .
[0069] Also because the back surfaces 22 are held in a coplanar arrangement, parallel to the supporting wall 24 , at a very small distance from the supporting wall surface 24 , an effective backing support against excessive bending or twisting is obtained. When a siding board 20 is pushed inward toward the supporting wall 24 , it quickly touches the supporting wall 24 to prevent breaking or splitting of the siding board 20 .
[0070] Another feature that is provided to enhance the visual appearance of the present wood siding system, is that the apron strip 36 of each siding board 20 overlaps the front wall 54 of a metal retainer 26 by a distance “D” as illustrated in FIG. 5 , of about ⅛ inch. Because of this overlap “D”, the metal retainers 26 are not visible at a glance when looking at a wall made with the wood siding system according to the preferred embodiment of the present invention.
[0071] Also for the purpose of maintaining a high quality appearance of the wood siding, a tight-fit ridge 80 is provided along the inside edge of the upper U-shaped cavity 50 . The purpose of this ridge 80 is to create a tight fit in the U-shaped cavity 50 for receiving and retaining by friction force, the lower shoulder 32 of a board inside the cavity 50 . Because of these tight-fit ridges 80 , the bottom edges of all wood siding boards 20 are held down relative to the metal retainers 26 for concealing the metal retainers 26 from view even when there is some degree of shrinkage along the height of the wood siding boards 20 .
[0072] In another feature of the preferred metal retainers 26 , the front wall 54 thereof has a width ‘F’ that is a same dimension as the width inside the C-shaped formation 62 . As can be seen in FIG. 6 , this C-shaped formation 62 has ridges 82 and 84 on respective edges thereof, for snappily receiving and retaining the front wall 54 of another metal retainer 26 inside the C-shaped formation 62 , substantially as illustrated in FIG. 7 . Several extrusion profiles 86 can be assembled together as a bundle as shown in FIG. 7 , to facilitate the handling and shipping of the extrusions to a client, or for handling the extrusion profiles in a cut-off saw when manufacturing metal retainers 26 of a same length.
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The wood siding system has air circulation gaps between overlapping siding boards and between the siding boards and a supporting wall. The wood siding system has the appearance of old-fashion clapboards; a limited flexibility that closely imitates a solid wall, and metal retainers with installation gauge, and lips and ridges to control the direction of shrinkage and swelling of the wood boards to preserve the visual appeal of the wood siding. A wood grain pattern on the front surface of each siding board is a mirror image of a wood grain pattern on the front surface of another siding board.
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BACKGROUND OF THE INVENTION
The present invention relates to security systems with devices for detecting the location of an object between one and a plurality of different locations. More specifically, the present invention relates to security systems with infrared devices for detecting an open door or window, and to wireless security systems utilizing such devices.
Security systems presently known to the art detect open doors or windows in a number of ways. Hard wire systems generally utilize magnetic switches having mating parts mounted on and adjacent to a door or window which separate when the door is open, thereby actuating the alarm. Such hard wire systems require careful installation and are costly to install. Another type of device for detecting the opening of a door is an ultrasonic unit in which ultrasonic energy is made to impinge upon the door and the reflected energy utilized to indicate a closed door condition. Ultrasonic systems have been sensitive to temperature changes and external noise, and often have been difficult to install so as to avoid false triggering. Infrared detectors have been utilized to detect the presence of a warm body passing through an open door, or a change in temperature caused by the opening of a door. The presence of ambient light or heat have tended to make such systems unreliable.
DESCRIPTION OF PRIOR ART
Infrared intrusion systems have been known to the art for a considerable period of time. Herbert L. Berman obtained U.S. Pat. No. 3,703,718 entitled INFRARED INTRUSTION DETECTOR SYSTEM on Nov. 21, 1972. This patent discloses a passive infrared detector in that it detects the change in infrared radiation in an area caused by the presence of an intruder and attempts to focus this radiation and isolate it from background energy. U.S. Pat. No. 3,839,640 of John A. Rossin entitled DIFFERENTIAL PYROELECTRIC SENSOR was granted on Oct. 1, 1974 to another type of passive infrared detector which utilizes a differential type detecting unit.
A further improvement in such passive infrared detectors is disclosed in U.S. Pat. No. 3,928,843 of James Cole Sprout and Herbert L. Berman entitled DUAL CHANNEL INFRARED INTRUSION ALARM SYSTEM granted Dec. 23, 1975. Herbert L. Berman further developed passive infrared detectors as disclosed in U.S. Pat. No. 4,195,234 entitled INFRARED INTRUSION ALARM SYSTEM WITH TEMPERATURE RESPONSIVE THRESHOLD LEVEL dated Mar. 25, 1980. Also, improvements in infrared detectors as such are disclosed in U.S. Pat. No. 4,258,259 of Hiroshi Obara and Tetuaki Kon entitled INFRARED DETECTOR dated Mar. 24, 1981 and U.S. Pat. No. 4,258,260 of Hiroshi Obara; Tetuaki Kon; and Naohiro Murayama entitled PYROELECTRIC INFRARED DETECTOR of the same date.
Infrared energy has also been utilized in other types of transducers. A. R. Johnston published a paper entitled Proximity Sensor Technology From Manipulator End Effects in Mechanism and Machinery Theory, 1977, Volume 12, pages 95 through 109, Pergamon Press, Great Britain, in which a pulsed infrared LED source was utilized in connection with an optical system and an array of infrared detectors for a proximity sensor for use with a remotely actuated manipulator.
The present invention provides an improved detection means for determining whether a door or window is open or closed. A pulsed source of infrared is directed on a reflective surface associated with the door or window and the scatter radiation from the reflective surface is detected by an infrared responsive cell. Pulse signals from the cell are utilized only when such pulses occur coincidentally with pulses of infrared radiation to achieve greater reliability. When this construction is combined with a radio frequency transmitter in a single unit, installation of the unit becomes merely a matter of placement with respect to the door or window, and hence the construction is very advantageous for wireless security systems.
DESCRIPTION OF DRAWINGS
FIG. 1 is a block diagram of a security system constructed according to the teachings of the present invention, FIG. 1 illustrating schematically a hinged closure operatively associated with the security system;
FIG. 2 is a sectional view of the hinged closure taken along the line 2--2 of FIG. 3;
FIG. 3 is a vertical elevational view of the security system of FIG. 1 in association with the hinged closure;
FIG. 4 is a transverse sectional view of the infrared sensitive cell diagramatically illustrated in FIG. 1;
FIG. 5 is an exploded view of the transmitter assembly diagramatically illustrated in FIG. 1;
FIG. 6 is a fragmentary schematic electrical circuit diagram of a portion of the transmitter module illustrated in FIG. 1;
FIG. 7 is an electrical circuit diagram illustrating another type of infrared detector which may be utilized with the other elements of the transmitter unit of FIG. 1;
FIG. 8 is a modified physical form of the transmitter unit of FIG. 1;
FIG. 9 is a subassembly view illustrating a portion of the transmitter unit of FIG. 1 in exploded form; and
FIG. 10 is a sectional view taken along the line 10--10 of FIG. 9.
DESCRIPTION OF PREFERRED EMBODIMENT
As illustrated in the figures, a security device according to the present invention consists of a control unit 20 and a transmitter unit 22. The control unit 20 has a receiver 24 with an antenna 26 and is adapted to receive radio frequency signals from the transmitter unit 22. The receiver 24 is connected to switch means 28, and the switch means is electrically connected to an alarm 30. When the receiver 24 receives a radio frequency signal from the transmitter unit 22, the receiver will actuate the switch means 28, causing the alarm 30 to be actuated. Rather than an audible device, the alarm may be a nonaudible notification means to personnel to investigate the security breach thus reported. The alarm 30 contemplates the use of telephone lines with a dialer system, a private telephone line to a control station, or a coaxial cable to a control station, as well as lights, bells, sirens, and the like. Further, the receiver 24 may be provided with means to distinguish between signals received from the transmitter, and actuate the switch means 28 only responsive to an intrusion, or the detection of a fire, or the like.
The transmitter unit has a pulse generator 32 which produces a chain of substantially square wave pulses, and these pulses are impressed upon a driver 34 which is electrically connected to an infrared light emitting diode 36. Responsive to each pulse of the generator 32, the diode 36 emits infrared radiation. The diode 36 is disposed within an enclosure 38 provided with an aperture 40 in order to produce a beam 42 of infrared radiation.
FIG. 3 illustrates the transmitter unit 22 disposed within a casing 44 and mounted directly above a wall closure 46, such as a door or window. The wall closure 46 is pivotally mounted on the wall 48 of a structure by means of a hinge 50 with leaves 52 and 54 mounted on the wall and wall closure, respectively, the leaves 52 and 54 being interconnected by a pin 56. The top 58 of the wall closure 46 is provided with a flat reflector 60 which may be a sheet of reflective metal which protrudes from the wall closure 46, or may be a layer of reflective tape mounted on the surface of the top 58 of the wall closure. As illustrated in FIGS. 2 and 3, the reflector 60 is a metal sheet secured to the top 58 of the wall closure by pins 62, although adhesive could also be employed.
The transmitter unit also has an infrared detector 64 which contains an enclosure 66 provided with an aperture 68. The aperture 68 also confronts the reflector 60, and the enclosure is positioned within the casing 44 of the transmitter unit to receive scattered radiation from the reflector 60, that scattered radiation generally following the path of the beam 70. An infrared responsive cell 72 is disposed within the enclosure 66 of the detector 64. The aperture 68 in the enclosure 66 is closed by a filter plate 74 which is generally transparent to infrared radiation but opaque to light radiation of other frequencies, thereby minimizing the effect of the ambient light on the response of the cell 72. Gel filters have been found to be suitable for such uses.
The infrared responsive cell is preferably a photo diode responsive to infrared radiation. This cell is generally used in a smoke detector, but functions in the present application. Such photo diodes are responsive over relatively short ranges, of the order of ten to twenty inches, and hence the cell 72 must be placed at a distance no greater than twenty inches from the light reflecting surface, and preferably at a distance of from two to six inches. Since the photo diode is not sensitive over a long range, a person walking through a door such as the closure 46, will not be close enough to the photo diode to cause false triggering.
Much greater range can be achieved with a cell of the type illustrated in FIG. 4. This cell utilizes a hollow cylindrical segment to form a collar 76 which supports a film 78 of polyvinylidene fluoride (PVF 2 polymer), the film being stretched tightly across the collar 76. The film 78 carries a thin layer 80 on one surface and a second thin layer 82 on the opposite surface, the layers 80 and 82 made of nickel with a thickness of about 100 UM and deposited by evaporation techniques. The layers 80 and 82 constitute electrodes for conductors 84 and 86. This type of infrared detector is capable of functioning over greater distances and responds to the infrared radiation of a body coming within its range. The infrared responsive cell of FIG. 4 is suitable for use as the cell 72 in the circuit of FIG. 1.
The cell 72 is connected in a series circuit with a DC source 88 and a resistor or sink 90. Radiation impinging upon the cell 72 will result in the flow of current through this circuit developing a potential across the sink 90, and since the beam 42 of infrared energy impinging upon the reflector 60 is a pulsed source, the potential developed in response to scattered radiation from that beam will appear across the sink 90 as a chain of pulses. These pulses are passed through a capacitor 92 to an amplifier or receiver 94. A latch circuit 96 is electrically connected between the receiver 94 and a transmitter 98. A pulse from the receiver 94 could be used to actuate the transmitter 98 in an intermittant fashion, that is, cause the transmitter to transmit only during periods in which the pulse is present. In the particular embodiment, the transmitter 98 is amplitude modulated by the pulse from the latch 96. The transmitter is actuated directly by a pulse from the pulse generator 32 so that the transmitter is in the "on" condition during all periods in which the infrared source is generating radiation.
The pulse generator 32 is designed to produce a pulse of no more than one second duration at least every thirty seconds. This pulse is impressed upon the latch circuit 96, and no signal will be passed from the latch circuit 96 to the transmitter 98 unless it is coincident with the pulse from the pulse generator 32. As a result, infrared energy impinging upon the cell 72 during periods between pulses from the pulse generator 32 will not be conducted to the transmitter 98 and result in false alarms. Further, the output of the latch 96 is connected to a terminal 100 of the pulse generator 32 to cause the pulse generator to speed up its frequency in order to confirm the occurrence of an event which requires an alarm, and the pulse generator 32 will repeat its pulses every two seconds during periods in which a signal from the latch 96 appears on the terminal 100. The transmitter 98 is coupled to the receiver 24 by radio frequency signals transmitted through an antenna 102.
In the embodiments set forth in FIG. 1, the infrared responsive cell 72 receives pulses of scatter radiation 70 during all periods in which the wall closure 46 is in closed condition. The latch 96, however, is responsive to the absence of coincidence between the pulses from the receiver and the pulses from the pulse generator to amplitude modulate the transmitter 98 and to latch the pulse generator 32. Accordingly, the transmitter unit 22 reports the condition of the door closure 46 as being open, but makes no response when the door closure 46 is closed.
The latch 96 may also be connected to pass pulses from the receiver 94 directly to the transmitter if coincidence with pulses from the pulse generator 32 occurs. In that case, the reflector 60 must be totally hidden in the opening of the wall 48 for the wall closure 46, as is the case of an adhesive reflective strip attached to the top 58 of the wall closure 42.
It will be recognized that the control unit 20 may be placed in a convenient position within a structure, substantially out of sight, and that the control unit may have the convenience features available in security systems known to the art. For example, the control unit may be placed at a telephone line terminal and provide communication to an external control room in response to signals from the transmitter unit 22. At the same time, the transmitter unit may be self contained, utilizing a battery power source, and positioned directly above, or at the side of, any wall closure desired without the use of interconnecting wires. The transmitter unit 22 may itself be secured to the wall 48 by means of an adhesive strip, and since the scatter radiation from the reflector will not require critical adjustment of the diode 36 with respect to the infrared responsive cell 72, the installation itself becomes simple and noncritical.
FIG. 6 illustrates the electrical circuits for the light emitting diode 36 and driver 34, and the electrical circuits for the infrared responsive cell 72 and receiver 94. The square wave pulse from the pulse generator 32 is transmitted through terminal 104 to a transistor inverter 106. The inverted pulse is impressed upon a switch having a transistor 108 with a base-emitter circuit connected in a series circuit with the infrared emitting diode 36, a resistor 110, and a direct current power source, said series combination being bridged by a capacitor 112. The resistor 110 and capacitor 112 provide a proper time constant to discharge the diode 36 upon opening of the transistor switch 108.
The scattered radiation from the reflector 60 passes through the gel filter 74 to the infrared sensitive diode 72. The output of the cell 72 is transmitted through the condensor 92 to two amplifiers 114 and 116 connected in cascade. The output of the amplifier 116 is in the form of a substantially square wave pulse, and it is transmitted to the transmitter 98 to amplitude modulate the transmitter.
The pulse generator 32 impresses a pulse through the transistor amplifier 118 to the transistor switch 120. The transistor switch is thus closed during periods of pulses from the pulse generator 32 to provide DC power for the amplifiers 114 and 116, thereby producing an output on the amplifier 116 only during the critical time periods.
FIG. 7 illustrates a passive infrared detector which may be utilized in place of the detector of FIG. 6. The output of the passive detector, such as the cell of FIG. 4, designated 72A, is transmitted through a transistor amplifier 122 to the terminal 124A. It will be noted that the terminal 124A corresponds to the output terminal of the amplifier 116, designated 124. In like manner, the circuit of FIG. 7 has a terminal 104A corresponding to the terminal 104 for receiving a pulse from the pulse generator 32. The output of the cell 72A is connected to the transistor amplifier 122 through a diode 128, and no signal will pass to the amplifier unless a signal is also present on the terminal 104A. Hence, the circuit of FIG. 7 also will not respond to infrared radiation except during periods in which a pulse is generated by the pulse generator 32.
FIG. 5 is an exploded view of a particular construction of a transmitter unit 22, designated 22A. The unit is mounted on a base 130 which is provided with a pair of protruding posts 132 and 134 to accommodate a battery 136. The base is also provided with a plurality of posts 138 which are positioned to engage the perimeter of a printed circuit board 140 which contain the elements of the transmitter electronic circuits. It will be noted that the infrared emitting diode 36 is positioned on the printed circuit board 140 adjacent to the detector 64. The printed circuit board 140, with its assembled components is secured on the base 130 in engagement with the posts 138. A cover 142 is positioned over the printed circuit board 140 and battery 136 and secured in position on the base by means of a screw not shown which passes through an opening 144 in the cover to engage a threaded hub 146. The cover is also provided with a slot 148, and the slot accommodates the filter plate designated 74A.
FIGS. 8 through 10 illustrate another embodiment of the transmitter unit of the present invention. In this embodiment, the electronic components and battery are housed within a casing 150 which comprises a cover 152 and a base 154. The cover is provided with a cutout 156, and an insert 158 is disposed in the cutout. The insert is shown in FIG. 9. The insert contains the light emitting diode 36 which projects a beam designated 160. The insert also contains the diode detector 64 which is provided with restrictive means to limit reception of the detector to an axis designated 162. The axis of reception 162 crosses the axis of radiation 160 at a point designated 164. In practice, this point should be approximately on the plane of the reflector 60.
Sensitive axes 160 and 162 are achieved by means of the structure illustrated in FIG. 10. FIG. 10 illustrates the detecting diode 64, mounted on a printed circuit board 166 which forms a part of the insert 158. It is to be understood that the diode 36 may be substituted for the diode 64. A shround 168 extends from the printed circuit board about the diode 64 to form a limiting aperture 170. The limiting aperture 170 will restrict the beam 160 of radiation, or the reception axis 162. Further restriction is achieved by narrowing the aperture with a double convex lens 172 which is mounted in the aperture 170.
From the foregoing disclosure, those skilled in the art will devise many uses for the present invention beyond that here disclosed. Further, those skilled in the art will devise modifications within the intended scope of the present invention. It is therefore intended that the present invention be not limited by the foregoing specification, but rather only by the appended claims.
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A security device for determining the opening or closed condition of an access gate, such as a door or window hinged within an opening in a wall, has a detector unit mounted on the wall adjacent to the opening and linked to a remote control unit by a radio transmitter in the detection unit and a radio receiver in the control unit. The detection unit has an infrared generator and an infrared detector isolated from the generator, the detector and generator confronting a reflector mounted on the access gate when the access gate is closed. The reflector is translated from the field of the infrared generator when the access gate is open. The infrared generator is excited by a pulse generator to produce pulses of infrared radiation, and the scattered radiation from the reflector is detected by the infrared detector to produce electrical pulses coincident with the pulse generator. A coincidence circuit determines the presence of the detected pulse, and the absence of coincidence results in the transmission of a radio wave from the detector unit to the control unit to establish alarm conditions.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an automatic stacker with mechanical or magnetic heads, which is able to stack in an ordered manner in alternate upright and inverted layers rolled metal sections cut to commercial length.
2. Discussion of the Background
Automatic stackers of the aforesaid type are well known to the expert of the art, for example from EP 0099863, EP 0196685 and EP 0318722.
In these stackers the rotary heads, for example magnetic, withdraw an ordered layer of sections from a transport system and position it inverted on a layer of sections previously deposited in an upright position, on a descending platform provided in a forming region for the stack to be packed.
Generally the rotary heads cooperate with to-and-fro moving carriages provided with lances to withdraw from said transport system, alternately with the magnetic heads, those layers of sections to be deposited on the descending platform in an upright position.
In these known stackers, the rotary heads are rotated by complex, costly linkages which, being of rigid geometry, are able to cause the magnetic heads to approach to within only a certain distance from the top of the last layer of sections deposited on the descending platform, from which distance the layer of sections is allowed to drop by demagnetizing the magnetic heads and with the aid of expulsion means.
Dropping of the layer of sections from a certain distance can result in their disordered stacking, and hence a badly made pack, which must be prevented for evident commercial reasons.
In addition, a disordered top layer of sections can interfere with the magnetic head movement, with consequent breakage, jamming and machine stoppage.
Precisely to avoid said interference, the movement path of the magnetic heads is maintained at a certain distance from the top of the lastly deposited layer on the descending piatform, but with said risk of depositing the sections in an imperfectly ordered manner. In addition, the movement of the head carrying a layer of inverted sections towards the layer of upright sections already deposited in the stack formation region takes place along an axis which is not perfectly perpendicular to the plane in which the layer of upright sections lies, this not facilitating the nesting of those sections having more difficultly stackable shapes.
Stackers of a known type also occupy a considerable space above the section transport line, making the operating region difficultly accessible, both from above and laterally (see for example IT 1247451).
Finally, the complexity of the linkages driving the rotary heads means that a multiplicity of manoeuvres are required, leading to a too lengthy stacking time, incompatible with the continuously increasing productivity of modern rolling mills.
SUMMARY OF THE INVENTION
The general object of the present invention is to obviate the aforesaid drawbacks of the known art by providing a rotary head stacker able to deposit gently, and in a short time, an inverted layer of sections on a previously deposited upright layer, so as to prevent disordered section stacking, and hence a badly made pack, and the danger or interference with the moving head. A further object of the invention is to provide a stacker comprising a rotary head maneuvring system which is structurally simple and hence economical, and occupies no space above or to the side of the section transport line.
These objects are attained by a stacker having the characteristics defined in the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The structural and operational characteristics of the invention and its advantages over the known art will be more apparent from an examination of the description given hereinafter with reference to the accompanying schematic drawings, in which:
FIGS. 1 to 12 show in succession the various operating stages of two different methods of operation of a stacker formed in accordance with the inventive principle, while FIGS. 13 to 19 show a further possible embodiment of the invention. In the drawings:
FIGS. 1 to 6 are schematic vertical sections showing a first method of operation of a stacker according to the invention;
FIGS. 7 to 12 are views similar to FIGS. 1 to 6, but showing a second method of operation of the same stacker; and
FIGS. 13 to 19 are schematic vertical sections illustrating a further possible embodiment of a stacker according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIGS. 1-12, the reference numeral 10 indicates overall a stacker according to the invention arranged to stack, on a descending platform 11, a plurality of superposed layers 12 of sections originating from a rolling mill and cut to commercial length.
The stacker according to the invention is formed structurally from a plurality of side-by-side heads 13, of a known type, each of which is pivoted at 14 to one end of an arm 15. The head 13 can be of either a mechanical or magnetic type.
The arm 15 is fixed, at the opposite end to 14, to the free end of a lever 16 the opposite end of which is pivoted at 17 to a support 18.
The arm 15 can be fixed directly on and project from the lever 16, or can be pivoted to the latter and supported laterally by guides (not shown).
The lever 16 is caused to rotate about a hinge member 17 in the directions of the arrow 19 by a motorized cam 20 via a cam follower 21 floating about hinge 22, so as to cause the head 13 to move vertically substantially parallel to itself, in the directions of the arrow 38.
The head 13 can be rotated through 180° from the position shown in FIG. 1 to the position shown in FIG. 5, and vice versa, by a geared motor unit 23, indicated schematically, via a linkage consisting of a plurality of mutually engaged gearwheels 24.
Other drive systems of different types can however, be used. With the magnetizable head 13 there cooperates a carriage 25 driven in the directions of the arrow 26 and carrying a lance 27 which rotates about hinge 28 and is arranged to withdraw the layers 12 from the transport line 29 indicated schematically.
The lance 27 is made to rotate about hinge 28 by an actuator 30 via a lever 31 rotating about hinge 32.
Lowerabie pawls 33 determine the formation of the layers 12 of sections along the transport line 29, by halting them and/or allowing them to advance.
Reference numeral 34 indicates a table rotating about hinge 35, for parking the sections 12 originating from the rolling mill.
With reference to FIGS. 1-6 of the drawings, in a first method of operation the stacker of the invention withdraws the first layer 12 of sections on the transport line 29 by rotating the lance 27 (from the position shown in FIG. 1 to the position shown in FIG. 2) and conveys it by advancing the carriage 25 (from the position of FIG. 1 to the position of FIG. 3) to above the descending platform 11, on the top of which the layer 12 is rested by lowering the lance 27. The lowered lance returns from the position shown in FIG. 3 to its original position (as shown in FIG. 4) and the magnetized head 13 (driven by the cam 20, via the lever 16 and arm 15, to move vertically upwards in the direction of the arrow 38 parallel to itself) withdraws the second layer 12a of the sections which has been formed on the transport line 29 and inverts it (by counter-clockwise rotation, as shown in FIG. 5, provided by the geared motor 23 via the gearwheels 24) above the first layer 12, to deposit it thereon by demagnetizing the head 13 and with the possible aid of expellers of a known type. After this, the head returns to its original position (as shown in FIG. 6), the lance 27 having already withdrawn a third layer 12b of sections to repeat the described operational stage, and so on until the desired stack has been formed, which is then packaged in a known manner.
The structural and operational simplicity of the separate linkages which control in correct sequence the vertical movement of the head 13 in the directions of the arrow 38 and its rotation should be noted, by which the layers 12 of sections from the transport system 29 can be inverted and brought perfectly above the last layer arranged on the descending platform 11 and deposited there by a movement along an axis perfectly perpendicular to the plane on which said layers lie, so thus facilitating correct stacking of sections of the most various configurations, even those which are difficult to nest together.
With reference to FIGS. 7 to 12, the stacker of the invention can also operate in such a manner as to transfer two layers 12 of sections at a time from the transport line 29 to the descending platform 11.
In this method of operation, a first layer 36 of sections is formed at the end of the transport line 29 and a second layer 37 is overturned onto said first layer 36 by the magnetic head 13, in accordance with the sequence shown in FIGS. 8 and 9. After this, the head 13 returns to its original position whereas, as shown in FIG. 10, the lance 27 withdraws the two layers 36, 37 and by a translational movement (FIG. 11) followed by lowering (FIG. 12), deposits both the layers onto the top of the descending platform 11.
FIGS. 13-19 show a further possible embodiment of the invention. in which the components equal and/or equivalent to those already described with reference to FIGS. 1-12 carry the same reference numerals plus 100.
In this further embodiment, the arm 115 is pivoted at 140 to the lever 116 so as to be able to be rotated in the directions of the arrow 141 between the end positions shown in FIGS. 13 and 16, 17 respectively.
As can be clearly seen from the drawings, the rotation of the arm 115 about 140 is controlled by the presence of two articulated telescopic tie bars 142, 143 which interconnect the arm 115 and the lever 116.
The tie bars 142, 143, the length of which is previously screw-adjustable, are pivoted together at 144, and are pivoted to the arm 115 and lever 116 at 145 and 146 respectively.
In correspondence with the pivotal axis 146 there is provided an input for motion originating from a geared motor unit indicated schematically by 147, which rotates the arm 115 about 140.
Operation of this further embodiment of the invention is apparent from FIGS. 13-19 and is briefly explained as follows.
At commencement of the cycle, the magnetized head 113 is in the position shown in FIG. 13, below a second layer 112a of sections lying on the transport line 129, a first layer 112 of sections being in an advanced position ready to receive the second layer 112a thereon. The magnetized head 113 (driven in the manner already described with reference to FIGS. 1-12) is raised into the position shown in FIG. 14, so as to withdraw the second layer 112a of sections from the transport line 129. After this the head 113 is overturned through about 180° (by counter-clockwise rotation) into the position shown in FIG. 15, so as to bring the second layer 112a of sections into correspondence with and above the first layer 112.
In this stage the lance 127 is raised from the position shown in FIG. 14 to the position shown in FIG. 15, so as to withdraw the first layer 112 of sections from the transport line 129 and nest it onto the second layer 112a of sections carried by the magnetized head 113.
In this manner the two layers 112, 112a of sections are perfectly nested, clamped between the lance 127 and the magnetized head 113, which carries them both.
The lance 127 can now be lowered into the position shown in FIG. 16 and the magnetized head 113, carrying both the layers 112, 112a of sections, is moved into correspondence with the descending platform 111 (by operating the geared motor unit 147 and via use of the articulated tie bars 142, 143).
From the position shown in FIG. 16 the head 113 is lowered into the position shown in FIG. 17 and demagnetized, so as to deposit the two superposed layers 112, 112a of sections onto the descending platform 111, after which the system is returned to its initial position by overturning the head 113 into the position shown in FIG. 18, moving it into the position shown in FIG. 19 and advancing two further successive layers of sections through one step so that they lie above the lance 127 and above said head 113 respectively.
The system is hence ready for a further cycle for transporting two superposed layers of sections onto the descending platform 11 in the manner already described.
The objects stated in the introduction to the description, of providing a stacker of small size, with a very simple and hence economical drive system for the magnetic heads, in which the section layers are deposited softly and rapidly with precision, one on the other on the top of the descending platform.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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An automatic stacker with rotary heads for stacking in an ordered manner in alternate upright and inverted layers rolled metal sections originating from a rolling mill via a transport line is characterised in that each head also undergoes vertical translational movement in the directions of the arrow substantially parallel to itself, such movement being provided by a second drive mechanism independent of a first providing rotation of the head itself. In this manner, the head deposits softly and with precision each layer of sections on the layer placed below, thus avoiding jamming and improper stacking.
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FIELD OF THE INVENTION
The present invention relates to a reinforcing material compounded in a polymer like rubber or synthetic resin.
BACKGROUND OF THE INVENTION
Conventionally, a compounding material has been added to a polymer like rubber or synthetic resin so as to improve its physical characteristics of tensile strength, rigidity modulus, hardness, elasticity, frictional coefficient, or etc. Such compounding material is called as a reinforcing compounding material. For these reinforcing materials, there has been used carbon, light hydroxycalcium carbonate, silicon oxide, colloidal calcium carbonate, or etc. Recently, an increasing amount of a polymer material like synthetic rubber in industrial application has increased need of carbon black, silica (white carbon) and clay as a reinforcing material compounded in the polymer.
Such increasing need of reinforcing compounding materials like carbon black has kept them in a higher price. This has restricted that products made of a polymer material like rubber or synthetic resin with the reinforcing materials become lower in production cost.
SUMMARY OF THE INVENTION
The present invention aims to eliminate such disadvantage. That is, an object of the present invention is to provide a reinforcing material, which has a reinforced strength not less than known reinforcing materials such as carbon black, with a lower cost.
For achieving the object, the inventor of this application has made a research and found that a natural zeolite, which has been surface-treated by a silane coupling agent, has a reinforcing strength not less than the known reinforcing materials like carbon black. This led to the present invention.
That is, a reinforcing compounding material according to the invention includes a zeolite that has been surface-treated by a silane coupling agent.
The zeolite may be a natural zeolite.
The zeolite may have a grain diameter not more than 6 μm.
The zeolite may be a pre-dried zeolite.
The silane coupling agent may have a chemical formula described hereunder:
R—Si(OR′) 3 ,
in which R is one selected among amino-, vinyl-, epoxy-, mercapto-, chlorine-, and methacryl-; R′ is one selected among methyl-, ethyl-, and β-methoxyethyl-.
The silane coupling agent may be a α-aminopropyltriethoxysilane.
BRIEF DESCRIPTION OF THE ACCOMPANIED DRAWINGS
FIG. 1 is a graph showing a grain diameter distribution of a natural zeolite that is used in a comparative example 1 and embodiments 1 to 4 of the present invention; and
FIG. 2 is a graph showing tensile strength (MPa) and elongation ratio (%) of test pieces A to E regarding the comparative example 1 and the embodiments 1 to 4.
DESCRIPTION OF PREFERRED EMBODIMENT
A zeolite used in the present invention is preferably a not expensive natural zeolite and may be a synthetic zeolite.
A silane coupling agent used in the present invention is a compound selected among γ-(2-aminoethyl)aminopropyltrimethoxysilane, γ-(2-aminoethyl)aminopropylmethyldimethoxysilane, β-methoxyethyivnyltrimethoxysilane, vinyltriacetoxysilane, γ-glycidoxypropyltrimethoxysilane, γ-mercaptopropyltrimethoxysilane, γ-chloropropyltrimethoxysilane, γ-methacryloxypropyltrimethoxysilane, and etc. However, the silane coupling agent is not limited within the above-described compounds, but may be another compound related to the present invention.
COMPARATIVE EXAMPLE 1
Test piece A (called as “A” hereinafter) was made by uniformly mixing 100 weight units of an ethylene-propylene-diene ternary polymerization elastomer (called as “EPDM” hereinafter), 50 weight units of a natural zeolite, 80 weight units of a talc, 60 weight units of a paraffin oil, 2 weight units of stearic acid, 5 weight units of zinc oxide, 4 weight units of a cross linking agent, and 0.5 weight units of sulfur.
The zeolite has been obtained by crushing and classifying a natural zeolite, which has the grain diameter distribution shown in FIG. 1 . In the graph of FIG. 1, an average grain diameter (μm) of each column is equal to 1.64, 1.94, 2.31, 2.75, 3.27, 3.89, 4.62, or 5.50 sequentially from left to right. The zeolite has been pre-dried (but called as “natural zeolite” hereinafter).
Regarding “A”, a break tensile strength (called as “tensile strength” hereinafter) and a break elongation ratio (called as “elongation ratio” hereinafter) were measured. The tensile strength was 10.0 (MPa) and the elongation ratio was 668.
EMBODIMENT 1
Test piece B (called as “B” hereinafter) was made by uniformly mixing 100 weight units of EPDM, 50 weight units of a not pre-dried natural zeolite that has been surface-treated by a solution including one weight % of γ-aminopropyltriethoxysilane under a normal room temperature, 80 weight units of the talc, 60 weight units of the paraffin oil, 2 weight units of stearic acid, 5 weight units of zinc oxide, 4 weight units of the cross linking agent, 0.5 weight units of sulfur. “B” was measured in tensile strength and elongation ratio. The tensile strength was 11.2 (MPa) and the elongation ratio was 708.
EMBODIMENT 2
Test piece C (called as “C” hereinafter)was made by uniformly mixing 100 weight units of EPDM, 50 weight units of a pre-dried natural zeolite that is surface-treated at a 100° C. temperature by a solution including one weight % of γ-aminopropyltriethoxysilane, 80 of weight units of the talc, 60 weight units of the paraffin oil, 2 weight units of stearic acid, 5 weight units of zinc oxide, 4 weight units of the cross linking agent, and 0.5 weight units of sulfur. “C” was measured in tensile strength and elongation ratio. The tensile strength was 13.3 (MPa) and the elongation ratio was 727.
EMBODIMENT 3
Test piece D (called as “D” hereinafter) was made by uniformly mixing 100 weight units of EPDM, 50 weight units of a pre-dried natural zeolite that is surface-treated at a 100° C. temperature by a solution including two weight % of γ-aminopropyltriethoxysilane, 80 of weight units of the talc, 60 weight units of the paraffin oil, 2 weight units of stearic acid, 5 weight units of zinc oxide, 4 weight units of the cross linking agent, and 0.5 weight units of sulfur. “D” was measured in tensile strength and elongation ratio. The tensile strength was 12.3 (MPa) and the elongation ratio was 721.
EMBODIMENT 4
Test piece E (called as “E” hereinafter) was made by uniformly mixing 100 weight units of EPDM, 50 weight units of a pre-dried natural zeolite that is surface-treated at a 100° C. temperature by a solution including four weight % of γ-aminopropyltriethoxysilane, 80 weight units of the talc, 60 weight units of the paraffin oil, 2 weight units of stearic acid, 5 weight units of zinc oxide, 4 weight units of the cross linking agent, and 0.5 weight units of sulfur. “E” was measured in tensile strength and elongation ratio. The tensile strength was 11.8 (MPa) and the elongation ratio was 722.
FIG. 2 is a graph showing the tensile strength (MPa) and elongation ratio (%) regarding test pieces A to E that are the comparative example 1 and the embodiments 1 to 4. As shown in FIG. 2, a polymer compounded by a carbon black is 12.0 (MPa) in tensile strength. It is noted that the natural zeolite surface-treated by a silane coupling agent can give a higher tensile strength than not surface-treated one without decreasing its elongation ratio as shown in FIG. 2 . It should be also noted that the natural zeolite is better pre-dried and that the natural zeolite is better surface-treated at about 100° C. temperature by the silane coupling agent. In addition, the solution preferably includes one to four weight % of the silane coupling agent, and particularly one weight % is best. Moreover, the natural zeolite surface-treated by the silane coupling agent can provide a tensile strength not less than a carbon black that has been conventionally utilized.
Thus, according to the present invention, a natural zeolite is surface-treated by the silane coupling agent, which enhances the zeolite to be better combined with a polymer material like rubber or synthetic resin. This enables to attain a reinforced strength not less than a reinforcing material such as carbon black regarding the polymer material, achieving a lower cost thereof.
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The reinforcing compounding material includes a natural zeolite that has been surface-treated by a silane coupling agent. The zeolite may have a grain diameter not more than 6 μm and may be a pre-dried zeolite. The silane coupling agent may have a chemical formula described hereunder: R—Si(OR′) 3 , in which R is one selected among amino-, vinyl-, epoxy-, mercapto-, chlorine-, and methacryl-; R′ is one selected among methyl-, ethyl-, and β-methoxyethyl-. The silane coupling agent may be a αaminopropyltriethoxysilane.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Divisional of U.S. application Ser. No. 11/481,861, filed Jul. 7, 2006, now U.S. Pat. No. 7,486,139, and claims priority under 35 U.S.C. §119 on Japanese Patent Application No. 2005-198623 filed in Japan on Jul. 7, 2005 and Japanese Patent Application No. 2006-110550 filed in Japan on Apr. 13, 2006, the entire contents of each of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a differential amplifier circuit, and more particularly, to a variable transconductance circuit formed on a semiconductor integrated circuit, and an optical disk device having such a variable transconductance circuit placed on a signal processing path.
A conventional transconductance circuit disclosed in Japanese Laid-Open Patent Publication No. 11-68477 will be described with reference to FIG. 15 .
MOS transistors M 50 and M 51 constitute an input differential pair biased with a current Io. When a voltage signal Vi is input, MOS transistors M 56 and M 57 respectively drive gate voltages of MOS transistors M 52 and M 53 so that the gate-source voltages thereof are constant. At this time, the input voltage signal Vi is converted to a current ΔI 1 with a resistance R connected between the sources of the MOS transistors M 50 and M 51 , and the current ΔI 1 flows to the MOS transistors M 52 and M 53 . This relationship is represented by Expression (1) below. The current ΔI 1 is output from the drains of MOS transistors M 54 and M 55 .
Δ
I
1
=
Vi
R
(
1
)
The output current ΔI 1 is input into the drains of MOS transistors M 58 and M 59 . The gate and drain of each of the MOS transistors M 58 and M 59 are connected to each other via a resistance Rg, and the gates thereof are common-connected. At this time, since the equal current flows to the MOS transistors M 58 and M 59 , the current ΔI 1 of Expression (1) flows to the resistances Rg, generating a voltage (V + -V − ) at both ends of the resistances Rg. With this voltage (V + -V − ), the gates of MOS transistors M 60 and M 61 are driven. A drain current difference ΔI 2 between the MOS transistors M 60 and M 61 at this time is represented by Expression (2):
Δ I 2 = k β [ ( V + - Vth ) 2 - ( V - - Vth ) 2 ] = 4 k β · Io · Rg · Δ I 1 = 4 k β · Io · Rg R · Vi ( 2 )
where β=charge mobility×capacity of gate oxide film/2, k=(transistor size of MOS transistors M 60 and M 61 )/(transistor size of MOS transistors M 58 and M 59 ), and Vth is a transistor threshold voltage.
From Expression (2), the transconductance (gm) is represented by Expression (3):
gm = 4 k β · Io · Rg R ( 3 )
which indicates that gm is allowed to vary sequentially by varying Io.
Gm is proportional to the square root of lo according to Expression (3). Therefore, to allow gm to vary up to 10 times its minimum value, it is necessary to vary Io up to 100 times its minimum value. In general, the gate-source voltage Vgs and the operating current Io of a MOS transistor have a relationship (Vgs-Vth) ∝√{square root over ( )}Io, in which if lo is increased by 100 times, Vgs-Vth will increase by 10 times. Since Vgs-Vth must be about 0.2 V at minimum to operate the MOS transistor in the saturation region, Vgs-Vth will be 2V at maximum. Low power supply voltage operation is therefore difficult, and also the 100-fold current variation will increase current consumption. Thus, wide-range gm variation and low power consumption are in a trade-off relationship.
To solve the problem described above, Japanese Laid-Open Patent Publication No. 2001-292051 discloses a configuration of connecting a plurality of transconductors in parallel to enable wide-range gm variation and low power supply voltage operation. However, this configuration still has problems in current consumption and on-board circuit area.
In optical disk devices such as DVDs, for example, a filter circuit used for signal processing must respond to a wide range of signals including a high-speed signal about 100 times as fast as the lowest-speed signal. Also, a variable gain amplifier, which normalizes a variation in signal amplitude caused by a medium and an optical pickup before performing signal processing, is required to provide a wide range of gains including a gain 10 to 20 times as large as the smallest gain. To achieve such a filter circuit and variable gain amplifier, a variable gm circuit serves as an important component. However, with a power supply voltage as low as just about 3V, the conventional variable gm circuit can only secure a variable range up to about five times the gm lowest value for one circuit. Therefore, a plurality of such variable gm circuits are connected in parallel or in series to achieve a filter circuit and variable gain amplifier. This causes the problems of increase in power consumption and on-board circuit area.
SUMMARY OF THE INVENTION
The variable transconductance circuit according to the present invention includes: a voltage-current conversion circuit for outputting a current signal linear with an input voltage signal (Vi); first and second MOS transistors (M 1 , M 2 ) for converting the current signal received to a square-root compressed voltage signal; and third and fourth MOS transistors (M 3 , M 4 ) for converting the square-root compressed voltage signal to a linear current signal, wherein transconductance is controlled by varying a bias current (Ia) for the first and second MOS transistors (M 1 , M 2 ) and a bias current (Ia) for the third and fourth MOS transistors. Thus, by providing two control parameters (Ia, Ib), gm can be varied in a wide range. For example, a variation up to about 20 times its minimum value can be achieved with a power supply voltage as low as about 3 V.
Preferably, in the variable transconductance circuit described above, the voltage-current conversion circuit comprises: two operational amplifiers into which the input voltage signal (Vi) is input; and a resistance (R) interposed between outputs of the two operational amplifiers, each of the outputs of the two operational amplifiers serves as a source follower biased with a first current source ( 1 ) or a second current source ( 2 ), and the current signal is taken from a drain of the source follower, gates of the first and second MOS transistors (M 1 , M 2 ) are grounded with a predetermined bias voltage, and the current signal output from the voltage-current conversion circuit is input into sources of the first and second MOS transistors, sources of the third and fourth MOS transistors (M 3 , M 4 ) are common-connected, a third current source ( 3 ) is connected to the common-connected sources, and a gate of the third MOS transistor (M 3 ) is connected to a source of one of the first and second MOS transistors (M 1 , M 2 ) while a gate of the fourth MOS transistor (M 4 ) is connected to a source of the other first or second MOS transistor (M 1 , M 2 ), the variable transconductance circuit uses drains of the third and fourth MOS transistors (M 3 , M 4 ) as current outputs, and controls transconductance by varying the current (Ia) from the first and second current sources ( 1 , 2 ) and the current (Ib) from the third current source ( 3 ).
Preferably, in the variable transconductance circuit described above, the voltage-current conversion circuit includes: fifth and sixth MOS transistors (M 5 , M 6 ) constituting an input differential pair into which the input voltage signal (Vi) is input; and a resistance (R) interposed between sources of the fifth and sixth MOS transistors (M 5 , M 6 ), each of the fifth and sixth MOS transistors (M 5 , M 6 ) is biased with a first current source ( 1 ) or a second current source ( 2 ) connected to a drain of the fifth or sixth MOS transistor, the source of the fifth MOS transistor (M 5 ) is connected to a drain of one of the first and second MOS transistors (M 1 , M 2 ) while the source of the sixth MOS transistor (M 6 ) is connected to a drain of the other first or second MOS transistor (M 1 , M 2 ), a gate voltage of each of the first and second MOS transistors (M 1 , M 2 ) is driven with a drain voltage of the fifth MOS transistor (M 5 ) or the sixth MOS transistor (M 6 ) whichever is connected to the drain of the first or second MOS transistor, sources of the third and fourth MOS transistors (M 3 , M 4 ) are common-connected, a third current source ( 3 ) is connected to the common-connected sources, and a gate voltage of the third MOS transistor (M 3 ) is driven with the drain voltage of one of the fifth and sixth MOS transistor (M 5 , M 6 ) while a gate voltage of the fourth MOS transistor (M 4 ) is driven with the drain voltage of the other fifth or sixth MOS transistor (M 5 , M 6 ), and the variable transconductance circuit uses drains of the third and fourth MOS transistors (M 3 , M 4 ) as current outputs, and controls transconductance by varying the current (Ia) from the first and second current sources ( 1 , 2 ) and the current (Ib) from the third current source ( 3 ).
Preferably, in the variable transconductance circuit described above, each of the first and second MOS transistors (M 1 , M 2 ) or the third and fourth MOS transistors (M 3 , M 4 ) is composed of a plurality of MOS transistors connected in parallel, and transconductance is controlled by switching. With this configuration, a further wide range of transconductance variation (for example, up to about 100 times the minimum gm) can be achieved.
Preferably, the variable transconductance circuit described above further includes a transconductance control circuit for generating the bias currents (Ia, Ib), wherein the transconductance control circuit includes: a square circuit ( 20 ) comprising a trans-linear loop circuit including vertically-connected seventh and eighth MOS transistors (M 101 , M 102 ) with a gate and drain of each transistor being connected to each other, a ninth MOS transistor (M 103 ) of which gate is connected to the gate of the eighth MOS transistor (M 102 ), and a tenth MOS transistor (M 104 ) of which gate is connected to a source of the ninth MOS transistor (M 103 ), the square circuit comprising a supply means for increasing a current flowing through each of the ninth and tenth MOS transistors (M 103 , M 104 ) by several times and supplying the resultant current to the seventh and eighth MOS transistors (M 101 , M 102 ), the square circuit using a drain of the eighth MOS transistor (M 102 ) as a current input, and connecting one of the ninth and tenth MOS transistors (M 103 , M 104 ) to a fourth current source ( 13 ) while outputting a current flowing through the other ninth or tenth MOS transistor as a current mirror output, and the current mirror output serves as the bias current (Ia or Ib). With this configuration, transconductance control according to linearity or exponential can be achieved.
Preferably, in the variable transconductance circuit described above, the supply means includes a current mirror for increasing a current flowing through each of the ninth and tenth MOS transistors (M 103 , M 104 ) by several times and supplying the resultant current to the seventh and eighth MOS transistors (M 101 , M 102 ).
Preferably, in the variable transconductance circuit described above, the mirror ratio of the current mirror output is variable. With this configuration, transconductance control characteristics according to desired linearity or exponential can be achieved.
Preferably, in the variable transconductance circuit described above, the current value of the fourth current source is variable. With this configuration, transconductance control according to desired linearity or exponential can be achieved.
The optical disk device according to the present invention includes a filter including the variable transconductance circuit described above and a capacitance element or a variable gain amplifier including the variable transconductance circuit described above and a resistance element, placed on a signal processing path.
Effects of the variable gm circuit according to the present invention will be briefly described.
The first effect is that a variable gm circuit permitting a wide range of variation with a low power supply voltage can be attained in a small scale. The reason for this is that the current change amount required for varying gm can be reduced to enable a wide range of gm variation with one circuit.
The second effect is that high gm can be attained with low power consumption. The reason for this is that gm can be determined with the current ratio.
The variable transconductance circuit according to the present invention is applicable to filter circuits and variable gain amplifiers for optical disk devices such as DVDs, for example.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a variable transconductance circuit of Embodiment 1 of the present invention.
FIG. 2 shows a variable transconductance circuit of Embodiment 2 of the present invention.
FIG. 3 shows a variable transconductance circuit of Embodiment 3 of the present invention.
FIG. 4 shows an example of configuration of an operational amplifier shown in FIG. 3 .
FIG. 5 shows an alteration to a square root expansion section 11 shown in FIGS. 1 to 3 .
FIGS. 6A and 6B show examples of a transconductance control circuit provided for any of the variable transconductance circuits of FIGS. 1 to 3 .
FIG. 7 shows an example of configuration of a square circuit included in the transconductance control circuit of FIG. 6B .
FIG. 8 shows another example of configuration of the square circuit included in the transconductance control circuit of FIG. 6B .
FIG. 9 shows transconductance control characteristics.
FIG. 10 shows an example of connection between the variable conductance circuit of FIG. 2 and the square circuits.
FIG. 11 shows an approximate error of the transconductance control characteristics.
FIG. 12 shows an example of configuration of an optical disk device.
FIG. 13 shows an example of configuration of a data signal generation circuit in FIG. 12 .
FIGS. 14A and 14B show examples of configurations of a variable gain amplifier and a low-pass filter, respectively, using the variable transconductance circuit according to the present invention.
FIG. 15 shows a conventional variable transconductance circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings. Note that the same or equivalent components are denoted by the same reference numerals.
Embodiment 1
FIG. 1 shows a variable transconductance circuit of Embodiment 1. In a linear voltage current conversion section, which is configured as described in the prior art, an input voltage signal Vi is converted to a current with an inter-source resistance R between MOS transistors M 5 and M 6 , to give a drain current for MOS transistors M 1 and M 2 . At this time, the gate voltage difference between the MOS transistors M 1 and M 2 is represented by expression (4):
Δ Vg = ( Ia + Vi R k 1 · β - Ia - Vi R k 1 · β ) . ( 4 )
where k 1 =gate width/gate length of MOS transistors M 1 and M 2 and β=charge mobility×capacity of gate oxide film/2.
The gate voltages of the MOS transistors M 1 and M 2 are driven with the sources of MOS transistors M 7 and M 8 each constituting a source follower. If a substrate bias effect of the MOS transistors M 7 and M 8 is neglected, the above value ΔVg is equal to the gate voltage difference between the MOS transistors M 7 and M 8 , that is, the drain voltage difference between the MOS transistors M 5 and M 6 . The drain voltages of the MOS transistors M 5 and M 6 are respectively input into the gates of MOS transistors M 4 and M 3 . A current source 3 for supplying a current Ib is connected to the common-connected sources of the MOS transistors M 3 and M 4 . The drains of the MOS transistors M 3 and M 4 are connected to MOS transistors M 9 and M 10 of which gates are common-connected. When ΔVg is input, a current ΔIout output from the drains of the MOS transistors M 3 and M 4 is represented by expression (5):
Δ Iout = k 2 · β · Δ Vg · 2 · Ib k 2 · β - Δ Vg 2 ( 5 )
where k 2 is the gate width/gate length of the MOS transistors M 3 and M 4 .
Substitution of Expression (4) into Expression (5) yields Expression (6):
Δ Iout = 2 · k 3 · ( Ia + Vi R - Ia - Vi R ) · I b k 3 - Ia + Ia 2 - ( Vi R ) 2 ≅ Vi R 2 · k 3 · I b Ia ( First - order approximation ) ( 6 )
where k 3 =k 2 /k 1 . From the above, gm is represented by Expression (7):
gm
=
1
R
2
·
k
3
·
I
b
Ia
(
7
)
It is found from the above expression that by varying Ia and Ib up to 10 times their minimum values (Ia×1/10, Ib×10), gm is allowed to vary up to 10 times its minimum value. Therefore, gm is allowed to vary over a wide range with a current variation smaller than that in the prior art discussed with reference to Expression (3), that is, with a low power supply voltage. Also, since gm can be determined with the current ratio, it is advantageously possible to achieve high gm with a smaller operating current.
Embodiment 2
FIG. 2 shows a variable transconductance circuit of Embodiment 2. In the variable transconductance circuit of FIG. 1 , the gate voltages of the MOS transistors M 4 and M 3 are automatically determined with the gate-source voltages of the MOS transistors M 1 and M 7 and the MOS transistors M 2 and M 8 , respectively. Therefore, to allow operation of the MOS transistors M 3 and M 4 in the saturation region, the output dynamic range is automatically determined, and this restricts the degree of design freedom. To solve this problem, in the variable transconductance circuit of FIG. 2 , a level shift circuit 4 is interposed each between the gates of the MOS transistors M 1 and M 4 and between the gates of the MOS transistors M 2 and M 3 . By appropriately setting the DC level shift amount of each of the level shift circuits 4 , the degree of design freedom of the output dynamic range is improved. Alternatively, if the input impedance is sufficiently high, the level shift circuit 4 may be interposed each between the drain of the MOS transistor M 5 and the gate of the MOS transistor M 4 and between the drain of the MOS transistor M 6 and the gate of the MOS transistor M 3 in FIG. 1 .
Embodiment 3
In the configurations in FIGS. 1 and 2 , the MOS transistors M 1 , M 5 and M 7 or the MOS transistors M 2 , M 6 and M 8 constitute a negative feedback loop. The unity gain frequency f 0 of such a loop and Ia have the relationship of Expression (8) below, and thus the circuit frequency characteristic varies with gm.
f0∝√{square root over (Ia)} (8)
FIG. 3 shows a variable transconductance circuit of Embodiment 3 for solving the above problem. The MOS transistor M 5 and a current source 1 constitute an output source follower for an operational amplifier, and the MOS transistor M 6 and a current source 2 constitute another output source follower. The resistance R is connected between the outputs of the source followers. When the voltage signal Vi is input, the voltage difference of Vi also occurs at both ends of the resistance R, allowing flow of a signal current of Vi/R. This signal current, output from the drains of the MOS transistors M 5 and M 6 , is input into the MOS transistors M 1 and M 2 of which gates are grounded with Bias 1 . The gate-source voltage difference between the MOS transistors M 1 and M 2 at this time is as represented by Expression (4) above. Thus, the circuit of FIG. 3 can obtain the transconductance represented by Expression (7) above like the circuit operation described in Embodiment 1.
FIG. 4 shows an example of configuration of the operational amplifier shown in FIG. 3 . The unity gain frequency f 0 of the operational amplifier is as represented by Expression (9) below. As long as the frequency band of the source follower composed of the MOS transistor M 5 and the current source 1 is sufficiently high with respect to f 0 , the frequency characteristic of the transconductance circuit of FIG. 3 will not vary even if gm is varied.
f0∝√{square root over (Id)} (9)
Note that in FIGS. 1 , 2 and 3 , the case that input transistors were N-channel transistors was described. It is however needless to mention that the channel conductivity type of the transistors may be reversed.
Also, in FIGS. 1 , 2 and 3 , the resistance R may be replaced with a MOS transistor operating in the linear region, and the gate voltage of the transistor may be varied together with Ia and Ib. This permits gm to be variable in a wider range.
Embodiment 4
FIG. 5 shows an alteration to a square root expansion section 11 shown in FIGS. 1 to 3 . The gm of the variable transconductance circuits of FIGS. 1 to 3 depends on the transistor size ratio k 3 of the MOS transistors M 1 and M 2 to the MOS transistors M 3 and M 4 , as is found from Expression (7). In FIG. 5 , in place of each of the MOS transistors M 3 and M 4 , a plurality of MOS transistors are connected in parallel and switched with control signals φ 1 to φ 3 . This permits k 3 to vary, and thus gm can be made variable. Although the MOS transistors M 3 and M 4 were replaced in FIG. 5 , each of the MOS transistors M 1 and M 2 may be replaced with parallel-connected MOS transistors.
Embodiment 5
FIGS. 6A and 6B show examples of a transconductance control circuit 16 provided for any of the variable transconductance circuits of FIGS. 1 to 3 , denoted by 111 . First, the operation of square circuits 20 included in the transconductance control circuit 16 of FIG. 6B will be described with reference to FIG. 7 .
Referring to FIG. 7 , Iin denotes a current input and cnt denotes a square current output. N-channel transistors M 101 to M 104 constitute a trans-linear loop circuit, while P-channel transistors M 107 to M 110 constitute a current mirror circuit. The current mirror circuit is connected to the drains of the MOS transistor M 103 driven with a current source 13 and the MOS transistor M 104 of which source is grounded. The current mirror circuit multiplies the currents flowing through the MOS transistors M 103 and M 104 by k 1 and k 2 , respectively, sums the multiplied currents, and supplies the resultant current to the MOS transistors M 101 and M 102 . A MOS transistor M 105 constitutes a current mirror circuit that multiplies the current from the MOS transistor M 107 by a and outputs the resultant current. Assuming that the transistor size ratios of the MOS transistors M 102 , M 103 and M 104 to the transistor size of the MOS transistor M 101 as the reference are n 2 , n 3 and n 4 , respectively, Expression (10) below is established among currents I 0 , I 1 and I 2 shown in FIG. 7 .
I
0
+
I
0
n
2
=
I
1
n
3
+
I
2
n
4
(
10
)
By squaring both terms of the above expression and substituting I 0 =Iin+k 1 ·I 1 +k 2 ·I 2 into this expression, Expression (11) below is obtained:
( 1 + 1 n 2 ) 2 ( I i n + k 1 · I 1 + k 2 · I 2 ) = I 1 n 3 + I 2 n 4 + 2 · I 1 · I 2 n 3 · n 4 ( 11 )
By substituting Expression (12):
k 1 = 1 n 3 · ( 1 + 1 n 2 ) 2
k 2 = 1 n 4 · ( 1 + 1 n 2 ) 2 ( 12 )
into Expression (11) above and arranging the result, Expression (13) below is given, in which I 2 has a square characteristic with respect to the input current Iin.
I 2 = n 3 · n 4 4 · I 1 ( 1 + 1 n 2 ) 4 I i n 2 ( 13 )
Multiplying the above value by a gives the output current, and finally Expression (14) below is obtained.
I
out
1
=
I
out
2
=
E
·
Iin
2
E
=
a
·
n
3
·
n
4
4
·
I
1
(
1
+
1
n
2
)
4
(
14
)
From the above expression, it is found that since the circuit of FIG. 7 does not include a device parameter β and has a square characteristic determined with the parameters a, n 2 , n 3 and n 4 and the current I 1 having relative precision, the circuit is advantageously less susceptible to fabrication variation.
The current output may be made as shown in FIG. 8 depending on the polarity of the necessary output current. Alternatively, in the examples of FIGS. 7 and 8 , the transistor M 104 may be driven with a constant current to allow the current I 1 to be output as current mirror output. If it is desired to change the square characteristic of the square circuits of FIGS. 7 and 8 , this can be achieved by changing the transistor size ratio a or the current I 1 .
Next, control of the transconductance will be described with reference to FIGS. 6A and 6B , in the case of a circuit in which transconductance varies exponentially with a control signal.
In FIG. 6A , when a control signal x is changed to give Ia∝1+x and Ib∝1−x with a function generator 15 , the transconductance is represented by Expression (15) below from Expression (7) above.
gm ∝ 1 - x 1 + x ( 15 )
This expression can be approximated to gm ∝ e x in a specific range of x as shown in FIG. 9 . Therefore, the transconductance can be varied exponentially.
However, if the range of x is widened in an attempt of widening the variable width of gm, the approximation accuracy deteriorates. To solve this problem, in FIG. 6B , the transconductance control circuit 16 is provided with the square circuits 20 . FIG. 10 shows an example of connection of the square circuits 20 with the variable transconductance circuit 111 having the configuration of FIG. 2 , for example. When the control signal x is changed to give Iin 1 ∝1+x and Iin 2 ∝1−x with the function generator 15 , Ia∝(1+x) 2 and Ib∝(1−x) 2 are given. From Expression (7) above, the transconductance is represented by Expression (16):
gm ∝ 1 - x 1 + x ( 16 )
This expression can be approximated to gm ∝ e 2x in a specific range of x as shown in FIG. 9 . FIG. 11 shows an exponential approximation error between Expressions (15) and (16). By providing the square circuits 20 , the approximation accuracy can be enhanced even if the range of x is widened to widen the variable width of gm.
Embodiment 5
FIG. 12 shows an optical disk device of Embodiment 5. The optical disk device includes a spindle motor 101 , an optical pickup 102 , an address signal generation circuit 103 , an address decoder 104 , a servo controller 105 , a servo error signal generation circuit 106 , a data signal generation circuit 107 , a decoder 108 , a CPU 109 and a laser power control circuit 110 .
Hereinafter, as one of applications of the variable gm circuit according to the present invention, application thereof to the data signal generation circuit 107 in FIG. 12 will be described. Note however that the variable gm circuit according to the present invention is also applicable to the address signal generation circuit 103 , the servo error signal generation circuit 106 and the laser power control circuit 110 . FIG. 13 shows an internal configuration of the data signal generation circuit 107 .
A data signal obtained from an optical disk 100 must be subjected to amplitude normalization and noise removal to improve the readability thereof. To accomplish this, a variable gain amplifier 1071 and a low-pass filter 1072 are provided on the signal processing path as shown in FIG. 13 . The variable gain amplifier 1071 normalizes the signal amplitude with a gain switched in a gain control circuit 1074 in response to the signal amplitude value detected in a read channel circuit 1073 . The low-pass filter 1072 is allowed to change its cut-off frequency under the control of a pass band control circuit 1075 to attain invariably optimal noise removal in response to the medium type and speed of the optical disk 100 . FIGS. 14A and 14B show examples of the variable gain amplifier 1071 and the low-pass filter 1072 , respectively, made up of the variable gm circuit according to the present invention. As shown in FIG. 14A , a resistance is connected to the variable gm circuit 111 to give the variable gain amplifier 1071 , in which the gain is determined with Gm×R. As shown in FIG. 14B , a capacitance is connected to the variable gm circuit 111 to give the low-pass filter 1072 , in which the cut-off frequency Fc is determined with Gm/C. For simplification, the low-pass filter 1072 of FIG. 14B is of a first-order configuration. In actual optical disk devices, however, fifth- to seventh-order low-pass filters may be used.
While the present invention has been described in preferred embodiments, it will be apparent to those skilled in the art that the disclosed invention may be modified in numerous ways and may assume many embodiments other than that specifically set out and described above. Accordingly, it is intended by the appended claims to cover all modifications of the invention which fall within the true spirit and scope of the invention.
|
The variable transconductance circuit includes: a voltage-current conversion circuit for outputting a current signal linear with an input voltage signal; first and second MOS transistors for converting the current signal received to a square-root compressed voltage signal; and third and fourth MOS transistors for converting the square-root compressed voltage signal to a linear current signal. A bias current at the first and second MOS transistors and a bias current at the third and fourth MOS transistors are varied to control transconductance.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from provisional application Ser. No. 61/460,245, filed Dec. 29, 2010, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a process for producing (meth)acrylic acid and, more particularly, to a method for reducing fouling of equipment during separation and purification steps of acrylic acid production by removal of aldehyde impurities with a hydrazide compound well upstream of the separation and purification steps.
BACKGROUND OF THE INVENTION
[0003] (Meth)acrylic acid and its esters are industrially important for manufacturing polymers for a very wide range of applications including, but not limited to, adhesives, coatings, films, biomedical carriers and devices, and binders. (Meth)acrylic acid may be produced, among other methods, by catalytic gas-phase oxidation of alkanes, alkanols, alkenes or alkenals containing 3 or 4 carbon atoms. One widely practiced process is, for example, catalytic gas-phase oxidation of propene, acrolein, tert-butanol, iso-butene, iso-butane, iso-butyraldehyde or methacrolein. These starting materials are generally diluted with inert gases such as nitrogen, carbon monoxide, carbon dioxide, saturated hydrocarbons and/or steam, and then contacted with a mixed metal oxide catalyst (for example, containing one or more of molybdenum, vanadium, tungsten and iron), with or without molecular oxygen, at elevated temperatures (e.g., from 200° C. to 400° C.) to be oxidized into (meth)acrylic acid.
[0004] Since there are numerous parallel and subsequent reactions occurring in the course of the catalytic vapor phase oxidation, and because of the inert diluent gases used, the resulting mixed gas product contains not only (meth)acrylic acid, but also inert diluent gases, impurities, and byproducts, from which the (meth)acrylic acid has to be separated. Thus, the mixed product gas is next typically subjected to absorption to remove (meth)acrylic acid from some of the byproducts and impurities and form a (meth)acrylic acid solution. It is known to use an absorption solvent such as water or an hydrophobic organic liquid (e.g., without limitation, toluene, methyl isobutyl ketone (MiBK), and diphenyl ether) or the (meth)acrylic acid itself (e.g, as in a fractionating column) for the absorption step. The resulting (meth)acrylic solution is then subjected to further separation and purification steps, such as by azeotropic or simple distillation, or crystallization, or extraction, to produce a crude (meth)acrylic acid product which may or may not be subjected to further purification or reaction as desired, depending on the intended end-use.
[0005] Besides byproducts which are comparatively simple to remove from (meth)acrylic acid, such as acetic acid, the mixed gas product also contains aldehyde compounds, which are closely related to (meth)acrylic acid and, therefore, can be difficult to separate from (meth)acrylic acid. The aldehydes present in the oxidation product typically include, for example, one or more of the following: formaldehyde, acetaldehyde, acrolein, methacrolein, propionaldehyde, n-butyraldehyde, benzaldehyde, phthaldehyde, furfural and crotonaldehyde and possibly also maleic anhydride or its acid. The total amount of aldehyde compounds present in the mixed gas product may be up to, or even more than, about 2% by weight based on the total weight of the mixed gas product obtained from the oxidation reaction. Aldehyde compounds, especially the lower molecular C 1 to C 3 analogues (formaldehyde, acetaldehyde, and proprionaldehyde), have been reported to initiate polymerization of (meth)acrylic acid in separations equipment such as distillation columns, reboilers and heat exchanger equipment. In particular, formaldehyde has been shown in the art as contributing to solids when placed in contact with common polymerization inhibitors such as phenothiazine (PTZ), hydroquinone (HQ), and hydroquinone monomethyl ether (MeHQ) (see, U.S. Patent Application Publication No. US2007/0167650). Furfural (C 5 ) and acrolein have also been reported as fouling contributors in the processing of (meth)acrylic acid. U.S. Patent Application Publication No. US2001/0004960 teaches addition of hydrazine as an aldehyde scavenger in crude (meth)acrylic acid for removal of furfural and acrolein. U.S. Patent Application Publication No. US2005/0187495 describes the use of hydrazine, hydrazine hydrates and mixtures thereof for removal of aldehydes and maleic compounds from crude acrylic acid after separation and purification by azeotropic distillation using a heavy solvent such as MiBK, toluene, and the like. U.S. Pat. No. 5,961,790 teaches removal of aldehydes from (meth)acrylic acid by addition of hydrazides to crude acrylic acid
[0006] U.S. Pat. No. 6,179,966 discloses the addition of primary and secondary amines, hydrazines, and related derivatives and salts to aqueous acrylic acid, prior to “evaporation,” which is essentially vaporization, of the aqueous acrylic acid prior to its being subjected to the usual azeotropic distillation separations to produce crude acrylic acid.
[0007] U.S. Patent Application Publication No. US2001/0016668 describes a process for producing (meth)acrylic acid involving absorption of (meth)acrylic acid from a mixed product gas, followed by formation of crude (meth)acrylic acid by solvent extraction or azeotropic distillation. In this process, an aldehyde treating compound is added to the crude (meth)acrylic acid, which is then subjected to vacuum distillation to obtain high purity (meth)acrylic acid and the waste liquid generated by the vacuum distillation is returned to the absorbing or separating steps. The aldehyde treating agent is a primary amine and/or a salt thereof which may be a hydrazine hydrate or a phenyl hydrazine, among other specified amines.
[0008] U.S. Pat. No. 7,393,976 teaches addition of an aldehyde treating compound which may be, among others, sulfuric acid, hydrazine compounds, amine compounds, and hydrazide compounds, to one or more distillation columns, after absorption and water removal steps to produce concentrated aqueous (meth)acrylic acid.
[0009] Similarly, U.S. Pat. No. 5,482,597 describes addition of hydrazine or dihydrazine of a C 4 -C 8 dicarboxylic acid to one or more distillation columns, after absorption using a non-aqueous heavy solvent to produce a (meth)acrylic acid solution which is subjected to purification by distillation. U.S. Pat. Nos. 5,961,790 and 6,228,227 both teach addition of a primary amine or a salt thereof, such as a hydrazide of an organic carboxylic acid, to one or more distillation columns, in which a (meth)acrylic acid solution comprising an inert hydrophobic organic liquid solvent is subjected to purification by distillation.
[0010] The present invention provides a more effective and efficient method for reducing downstream fouling of separation equipment in a process for producing (meth)acrylic acid by removing aldehydes, such as formaldehyde, by adding a hydrazide compound, such as carbohydrazide, upstream of the water removal and distillation steps of the process.
SUMMARY OF THE INVENTION
[0011] The present invention provides a method for reducing fouling of equipment during purification of (meth)acrylic acid in a process which involves the steps of:
A) producing a mixed product gas comprising (meth)acrylic acid, one or more aldehyde compounds, one or more light end compounds each having a lighter boiling point than (meth)acrylic acid, and one or more heavy end compounds each having a higher boiling point than (meth)acrylic acid; B) producing aqueous (meth)acrylic acid from the mixed product gas comprising the (meth)acrylic acid, the one or more aldehyde compounds, the one or more light end compounds, the one or more heavy end compounds, and water; C) removing at least a portion of the water from the aqueous (meth)acrylic acid to produce a concentrated aqueous (meth)acrylic acid; D) purifying the concentrated aqueous (meth)acrylic acid by removing at least a portion of the one or more heavy end components; and E) optionally, purifying the concentrated aqueous (meth)acrylic acid by removing an additional portion of the one or more light end components.
[0017] More particularly, the method of the present invention comprises removing at least a portion of the one or more aldehyde compounds from the aqueous (meth)acrylic acid by adding at least one hydrazide compound either 1) during step B) of producing the aqueous (meth)acrylic acid; or 2) after step B), to the aqueous (meth)acrylic acid, and prior to any of the water removing and purifying steps C), D) and E); or 3) both 1) and 2).
[0018] The hydrazide compound has the following formula:
[0000] H 2 N—NHR 1
[0000] wherein R 1 is C(O)NH 2 ) or C(O)NHNH 2 .
[0019] In some embodiments, the hydrazide compound is semicarbohydrazide. In other embodiments the hydrazide compound is carbohydrazide.
[0020] The hydrazide compound is added in an amount of from 0.5 to 5 moles per 1 mole of aldehyde compound present in the aqueous (meth)acrylic acid.
[0021] The step producing aqueous (meth)acrylic acid from the mixed product gas may be accomplished by subjecting the mixed product gas to absorption with a solvent comprising water to remove at least a portion of the one or more light end compounds.
DETAILED DESCRIPTION OF THE INVENTION
[0022] As used herein, the term “(meth)acrylic acid” means acrylic acid or methacrylic acid.
[0023] Processes for the production of (meth)acrylic acid are, in general, well understood and practiced by persons of ordinary skill in the relevant art and tend to involve a similar sequence of process steps including production of a mixed gas product which comprises (meth)acrylic acid, capturing (meth)acrylic acid in a solution, and subjecting the (meth)acrylic acid solution to one or more further purification steps. The method of the present invention is advantageously applicable to production processes wherein the (meth)acrylic acid is captured by absorption to form an aqueous (meth)acrylic acid, which is then subjected to a water removal step prior to further separation and purification steps.
[0024] More particularly, the present invention provides a method for reducing fouling of equipment during purification of (meth)acrylic acid in a process for producing (meth)acrylic acid which generally involves a first step of producing a mixed product gas comprising (meth)acrylic acid, one or more aldehyde compounds, one or more light end compounds each having a lower boiling point than (meth)acrylic acid, and one or more heavy end compounds each having a higher boiling point than (meth)acrylic acid. While the method of producing the mixed product gas comprising (meth)acrylic acid is not particularly critical or limited, one method would be catalytic vapor phase oxidation of alkanes, alkanols, alkenes or alkenals containing 3 or 4 carbon atoms, such as propane, propene, acrolein, tert-butanol, iso-butene, iso-butane, iso-butyraldehyde or methacrolein. The starting materials for the oxidation reaction may be diluted with inert gases such as nitrogen, carbon monoxide, carbon dioxide, saturated hydrocarbons and/or steam, and then contacted with a mixed metal oxide catalyst (for example, containing one or more of molybdenum, vanadium, tungsten and iron), with or without molecular oxygen, at elevated temperatures (e.g., from 200° C. to 400° C.).
[0025] Aqueous (meth)acrylic acid is then recovered from the mixed product gas, such as by subjecting the mixed product gas to absorption using a solvent comprising water or the (meth)acrylic acid as would be common in a fractionating column. During absorption, at least a portion of the one or more light end compounds are separated from the mixed product gas. As expected, the resulting aqueous (meth)acrylic acid comprises (meth)acrylic acid, one or more aldehyde compounds, one or more light end compounds, one or more heavy end compounds, and water. Then, at least a portion of the water is removed from the aqueous (meth)acrylic acid to produce a concentrated aqueous (meth)acrylic acid, in preparation for separation steps more particularly designed to remove light and heavy end compounds from the (meth)acrylic acid. As known by persons of ordinary skill in the relevant art, water may be removed from the aqueous (meth)acrylic acid by any conventional method, such as, but not limited to, rectification, distillation, extraction, or crystallization.
[0026] In order to reduce formation of polymer solids which cause fouling of downstream separation equipment, at least a portion of aldehyde compounds such as, without limitation, formaldehyde, are removed from the aqueous (meth)acrylic acid by adding a hydrazide compound to the aqueous (meth)acrylic acid prior to the water removal step and prior to any further separation and purification steps.
[0027] In some embodiments, in accordance with the method of the present invention, the hydrazide compound may be added to the aqueous (meth)acrylic acid after its formation (e.g., by absorption). In some embodiments, the hydrazide compound may be added to the absorption step, i.e., during production of the aqueous (meth)acrylic acid (e.g., by absorption). In still other embodiments, in accordance with the present invention, the hydrazide compound may be added to both the absorption step, as well as to the aqueous (meth)acrylic acid after its formation by absorption, and prior to removing water to produce the concentrated aqueous (meth)acrylic acid.
[0028] The hydrazide compound has the following formula:
[0000] H 2 N—NHR 1
[0000] wherein R 1 is C(O)NH 2 ) or C(O)NHNH 2 . The hydrazide compound is selected from the group consisting of: semicarbohydrazide, carbohydrazide, and mixtures thereof. In one embodiment, the hydrazide compound is carbohydrazide. The hydrazide compound may suitably be added in an amount of from 0.5 to 5 moles per 1 mole of aldehyde compound present in the aqueous (meth)acrylic acid. For example, the amount of hydrazide compound added may be from 0.5 to 2 moles, or even from 0.5 to 1 mole, per 1 mole of aldehyde compound.
[0029] In contrast to amine based aldehyde scavengers, including hydrazine, which have shown similar efficacy at removing aldehydes, e.g., formaldehyde, from (meth)acrylic acid solutions, hydrazide compounds, such as carbohydrazide, is significantly benign from a health, safety and handling perspective.
[0030] When a hydrazide compound, such as carbohydrazide (CBZ), is allowed to come into contact with streams containing aldehydes and other carbonyl (non-acid) compounds, the carbonyls are consumed. For example, carbohydrazide appears to react preferentially with formaldehyde in solution with water, acetic acid, acrylic acid, and mixtures thereof.
[0031] Furthermore, by scavenging the aldehydes immediately downstream of the absorber (i.e., adding the hydrazide to the aqueous (meth)acrylic acid after its formation by absorption) which is the location of the highest concentration of formaldehyde, the method of the present invention may drastically improve the stability of the distillation columns, reducing fouling and allowing for increased asset utilization and operability. Surprisingly, it was also discovered that, contrary to previous reports concerning hydrazide scavenging of aldehydes, the products of carbohydrazide scavenging are soluble in the (meth)acrylic acid matrix. This obviates the need for either a heavy solvent or an organic sulfonic acid which was reported to greatly reduce deposits in U.S. Pat. No. 5,482,597.
[0032] After treatment with a hydrazide compound to remove at least a portion of the aldehyde compounds, the concentrated aqueous (meth)acrylic acid may then be subjected, in any suitable manner known to persons of ordinary skill in the relevant art, to further purification steps wherein at least some portions of the light and heavy end compounds are removed. For example, the concentrated aqueous (meth)acrylic acid may be purified by removing at least a portion of the one or more heavy end components, by any known method, such as for example, azeotropic or simple distillation. Furthermore, the concentrated aqueous (meth)acrylic acid may be purified by removing a portion of the one or more light end components, by any known method, such as for example, azeotropic or simple distillation.
[0033] It will be understood that the embodiments of the present invention described hereinabove are merely exemplary and that a person skilled in the art may make variations and modifications without departing from the spirit and scope of the invention. All such variations and modifications are intended to be included within the scope of the present invention.
[0034] The following examples are illustrative of the invention but are not intended to limit its scope.
EXAMPLES
Example 1
[0035] A production unit sample of aqueous acrylic acid was aliquoted and the individual fractions charged with carbohydrazide. The samples were each heated to 60° C. for 30 min and individual aliquots analyzed for formaldehyde, benzaldehyde, furfural and maleic acid. The results are provided in Table 1 below.
[0000]
TABLE 1
Wt/%
Carbohydrazide
0.000
0.025
0.051
0.094
0.253
0.455
1.003
Formaldehyde
0.557
0.511
0.441
0.379
0.256
0.109
0.017
Benzaldehyde
0.018
0.018
0.018
0.017
0.017
0.017
0.003
Furfural
0.013
0.013
0.013
0.013
0.013
0.012
0.003
Protoanemonin
0.009
0.009
0.009
0.009
0.009
0.008
0.002
Maleic acid
0.305
0.325
0.319
0.308
0.314
0.317
0.309
Example 2
[0036] A synthetic solution of aqueous acrylic acid was prepared by mixing flocculant grade acrylic acid (64.99 g), H 2 O (35.01 g), formaldehyde (0.50 g, as 1.35 g of a 37% formalin solution), maleic acid (0.50 g) and propionaldehyde (0.50 g). An aliquot (17.41 g) which contained formaldehyde (2.89 mmol), maleic acid (0.79 mmol) and propionaldehyde (1.59 mmol) was removed and carbohydrazide (97% purity, 0.178 g, 1.91 mmol) added. The solution was mixed and heated for 30 min. at 49.5° C. An aliquot was removed and analyzed by 1 H NMR and compared to the original stock solution. No formaldehyde signals were detected by NMR and the bulk of the propionaldehyde was consumed. The propionaldehyde loss was based on the disappearance of the methyl and methylene group.
Example 3
[0037] A solution of aqueous AA containing formaldehyde (0.557 wt. %, 0.468 eq. mol) was charged with carbohydrazide (0.768 eq. mol). The solution was kept at room temperature for 1 hour and analyzed by 1 H NMR. The sample was compared with an authentic sample and the formaldehyde and hydrate peaks at 5.4 and 4.95 ppm were found to be completely absent from the treated sample.
Example 4
[0038] A sample of aqueous AA from a commercial production unit containing formaldehyde (0.557 wt. %, 12.33 eq. mol), furfural (0.013 wt. %, 0.09 eq. mol) and benzaldehyde (0.018 wt. %, 0.11 eq. mol) was charged with carbohydrazide (3.77 eq. mol). The sample was heated at 30° C. for 30 min. and allowed to sit overnight. The sample was subjected to a single stage flash on a rotory evaporator and afforded formaldehyde in the overheads (0.164 wt. %, 2 eq. mol)) and bottoms (0.021 wt. %, 0.41 eq. mol). A similar analysis for furfural and benzaldehyde was conducted in the overheads (0.005 wt %, 0.02 eq. mol, 0.007 wt. %, 0.02 eq. mol, respectively) and the bottoms (0.016 wt. %, 0.009 eq. mol, 0.034 wt. %, 0.02 eq. mol, respectively).
Example 5
[0039] As a representative example, an aqueous acrylic acid solution comprising of acrylic acid (65 wt %), water (30 wt %), formaldehyde (0.65 wt %) was fed at a rate of 265 g/h to an azeotropic distillation column. The column is 33 mm in diameter and equipped with 30 Oldershaw trays. A steam heated reboiler loop was used to generate the vapor in the column. The feed was added to the middle section of the column, in this case tray 18. Methyl isobutylketone (MiBK) was added at the top as the reflux feed at a rate of 350 g/h. The overheads were condensed and allowed to phase separate and the organic layer returned as reflux. The aqueous layer was analyzed. The bottoms temperature was maintained via the steam controller and was set at 97-98° C. The column bottoms pressure was maintained at 200 mm Hg. A bottoms take-off in the reboiler loop afford the product. Hourly fractions were collected and analyzed for formaldehyde. The data in the table below show the values for the last hour of run time during a typical 5 h run (No additive).
[0040] In a separate experiment using the identical setup, an aqueous acrylic acid feed containing AA (65 wt %), water (30 wt %) and formaldehyde (0.65 wt %) was treated with carbohydrazide (0.29 mol). The mixture was stirred at room temperature for 16 hr and then fed to a azeotropic distillation column as described above. The results from the last hour are shown below in Table 2. Examination of the column during the distillation and after showed it to be free of any foulant or polymer.
[0000]
TABLE 2
Organic
Aqueous
Feed
Bottoms
Layer
Layer
No
.054
mol
0.00017 mol
0.0020
mol
0.0463
mol
additive
With
0.054
mol
3.32 ×
0.00046
mol
0.00344
mol
Additive
10−5 mol
Analytic Standards and Equipment
[0041] NMR data were obtained on a Varian Inova Instrument operating at 499.741 MHz. The one-dimensional 13 C spectra were obtained at 120.46 MHz with a spectral width of 35000 Hz with a 2 second acquisition time and a 90° pulse of 11.1 microseconds. Gas chromatography was conducted using an Agilent HP 6890 with an FID detector. Formaldehyde determination was conducted on an HP 6890 using a packed column.
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The present invention provides a method for reducing fouling of equipment during separation and purification steps of (meth)acrylic acid production by early removal of aldehyde impurities by adding a hydrazide compound well upstream of the separation and purification steps. In particular, carbodhydrazide may be added as an aldehyde scavenging agent to aqueous (meth)acrylic acid prior to dehydration and purification steps.
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FIELD OF THE INVENTION
The present invention relates generally to a measurement system including a smart sensor having data uniquely characterizing the sensor stored in a memory local to the sensor, and more particularly to a measurement system including a communications interface for use with a smart sensor.
BACKGROUND OF THE INVENTION
Many applications require accurate information about a property of a given environment, such as temperature, pressure, relative humidity, etc. A sensor in contact with an environment to be sensed, for example, can convey an electrical signal indicative of the temperature, e.g., in the environment to an indicating instrument. The indicating instrument converts the electrical signal into a temperature value for display or other output indicative of that temperature. Unfortunately, however, some temperature sensors do not provide acceptably accurate temperature readings because the sensors and/or the instruments are not adequately calibrated for use with one another.
Each sensor has unique operating characteristics that the indicating instrument must take into account to provide an accurate interpretation of the signal from the sensor. Smart sensors store this data in a memory local to the sensor. The smart sensor is connected to an input/output communications port in the indicating instrument. The communications port allows the indicating instrument to send and receive data and instructions, such as requesting the characterizing data from the sensor's memory, receiving calibration settings or outputting data, such as a temperature reading. The indicating instrument can thus be connected to an input or output device other than the smart sensor through the communications port, including a printer, a computer, a display, a keyboard, a mouse, etc. When the smart sensor is connected to the communications port, the sensor can communicate an analog signal indicative of the temperature and can communicate digitally between the indicating instrument and the memory of the smart sensor. The indicating instrument then analyzes the analog signal from the smart sensor in view of the characterizing data and outputs a value more accurately representative of the temperature.
The smart sensor and the indicating instrument generally have a predetermined relationship for communicating the characterizing data from the sensor to the instrument. The characterizing data is used by the instrument to adjust the calculated temperature value to provide a more accurate temperature reading. In a number of applications no predetermined relationship exists, particularly when the sensor manufacturer is not the instrument manufacturer. For example, the characterizing data may be in a different format (columns instead of rows, for example), have different data (such as the sensor manufacturer's serial number) and/or may incorporate offset functions that may or may not be expected to be compensated for by the manufacturer of the indicating instrument. Consequently, some sensors are incompatible with certain indicating instruments.
Additionally, sensors generally degrade over time and must be replaced periodically, particularly when the sensor is used in a harsh environment. In contrast, indicating instruments generally last for a relatively long time. Since the indicating instrument usually is much more expensive than the sensor, it is desirable to replace the sensor while continuing to use the indicating instrument. Because the replacement sensor must be compatible with the indicating instrument for accurate operation, the indicating instrument manufacturer generally also must be the manufacturer of the selected replacement sensor. Unfortunately, that manufacturer may not offer the best performing or most attractively priced sensor for a given application.
SUMMARY OF THE INVENTION
The present invention provides a sensing system that includes a smart sensor, an indicating instrument, and a smart interface device in communication with the smart sensor and the indicating instrument. The interface device advantageously allows a smart sensor to be used with any indicating instrument. The interface device can be preprogrammed to receive data characterizing the sensor, to develop calibration data based on the characterizing data, and to communicate the calibration data to the indicating instrument. The indicating instrument uses the calibration data to output a more accurate temperature reading. In effect, the interface device acts as a translator between the smart sensor and the indicating instrument. Thus a purchaser of a replacement smart sensor is not limited by the manufacturer of the indicating instrument with which it will be used.
More specifically, the present invention includes a system for providing an indication of an environmental property, such as temperature. Such a system includes an indicating instrument, a smart sensor and a programmable interface device. The smart sensor includes a sensor unit operable to sense the environmental property and a local memory unit with characterizing data stored therein. The sensor unit may be a temperature sensor, such as a resistance temperature device or a thermocouple. The characterizing data in the memory unit includes data characterizing the operation of the sensor unit.
The memory unit of the smart sensor is connected to the interface device by a first communication link, such as a wire, for communicating the characterizing data to the interface device. The sensor unit of the smart sensor is connected to the indicating instrument either directly or via the interface device by a second communication link for communicating to the indicating instrument a signal indicative of a sensed property. The indicating instrument is connected to the interface device by a third communications link for communicating to the interface device an estimated property value determined from the sensed property signal.
The interface device includes means for determining calibration data based on the characterizing data, including means for determining the calibration data based on the characterizing data and the estimated property value. The means for determining the calibration data may include a processor and a memory unit. The memory unit of the interface device may have software instructions for communicating with the smart sensor and the indicating instrument, or for determining the calibration data, such as a calibration offset. The memory unit may be in the form of an electrically erasable programmable read-only memory.
The indicating instrument includes means for determining indicated property data. The indicating instrument may include a processor. The indicating instrument processor determines the sensed property value based on the sensed property signal from the sensor unit. The indicating instrument processor also determines the indicated property data based on the estimated property value and the calibration data. In particular, the indicating instrument processor may be operable to determine the indicated property data by adding a calibration offset to the estimated property value.
The present invention also includes a method comprising the steps of (a) connecting an interface device between a smart sensor and an indicating instrument; (b) transmitting a sensed property signal from the smart sensor to the indicating instrument; (c) determining an estimated property value based on the sensed property signal; (d) transmitting the estimated property value to the interface device; transmitting characterizing data to the interface device including data characterizing the operation of the smart sensor; (e) determining calibration data from the estimated property value and the characterizing data; and (f) determining an indicated property value based on the estimated property value and the calibration data. The method may further include the steps of transmitting sensed property data from a sensor unit of the smart sensor to the indicating instrument, determining a calibration offset, and algebraically adding the calibration offset to the estimated property value and displaying the indicated property value.
The foregoing and other features of the invention are hereinafter fully described and particularly pointed out in the claims, the following description and annexed drawings setting forth in detail a certain illustrative embodiment of the invention, this embodiment being indicative, however, of but one of the various ways in which the principles of the invention may be employed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a system according to the present invention.
FIG. 2 is a schematic view of the system of FIG. 1 further illustrating internal components of each element.
FIG. 3 is a flowchart illustrating a method in accordance with the present invention.
DETAILED DESCRIPTION
Referring initially to FIGS. 1 and 2, the present invention provides a system 10 that includes a smart sensor 20 , an indicating instrument 30 , and a smart interface device 40 . The smart sensor 20 senses the temperature of a given environment and communicates the sensed temperature signal to the indicating instrument via a first communication link 50 . The indicating instrument converts the sensed temperature signal into an estimated temperature, and communicates the estimated temperature to the smart interface device over a second communication link 51 . The interface device also receives data characterizing the smart sensor via a third communication link 52 . The interface device then uses the estimated temperature and the characterizing data to determine calibration data. The interface device communicates the calibration data back over the second communication link to the indicating instrument. The indicating instrument uses the calibration data to determine and to output an indicated temperature.
The communication links between the smart sensor 20 , the interface device 40 and the indicating instrument 30 may be effected by wires or transmitters and receivers for infrared, radio or other electromagnetic signals. Clearly, at least the second communication link 51 is bidirectional.
Most temperature sensing systems have a means for adjusting or fine-tuning the measured temperature, such as by adjusting the estimated temperature by a scalar amount. It should be noted, however, that the signal produced by a temperature sensor may be nonlinear over a range of operating temperatures. Consequently, it is important to know the characteristics of each particular sensor to accurately the estimated temperature. This adjustment usually is referred to as the calibration offset and is meant to accommodate situations where a difference is known to exist between the temperature indicated by the sensor and the actual temperature of the environment. For instance, a sensor may be calibrated against a known reference standard to measure the variance in output from published specifications for a particular group of sensors. The variance from the standard then becomes the calibration offset for this sensor. The estimated temperature is adjusted by adding or subtracting the calibration offset. In an exemplary embodiment of the system 10 provided by the present invention, the calibration offset is determined automatically by the interface device 40 from the characterizing data and the estimated temperature.
Turning to each element of the sensing system 10 in detail, the smart temperature sensor 20 includes a sensor unit 60 for sensing the temperature of an environment with which it is in contact, directly or indirectly, and a memory unit or device 70 programmable to include data characteristic of the smart sensor. The sensor unit may include a thermistor, a thermocouple or a resistance temperature device (RTD), for example. The memory unit may be an electronic data storage device, including an erasable programmable read-only memory (EPROM) or an electrically erasable programmable read-only memory (EEPROM).
Each sensor unit 60 has operating characteristics that are unique to that sensor. The memory unit 70 is programmed by the sensor manufacturer with data that characterizes the smart sensor 20 and the sensor unit. This data might consist of a table of offset values at various temperatures, or a set of coefficients to a characterizing function for the offsets at various temperatures. The memory unit may include additional characterizing data, such as a time constant for the speed of the sensor's response, intended use data for sensor drift, the time and/or date the sensor was calibrated, an expected rate of sensor degradation, etc. The memory unit also may be programmed to include additional information not directly used to measure the temperature, including the name and address of the manufacturer, a model number, a serial number, maintenance data, etc. An exemplary smart temperature sensor is shown and described in commonly owned U.S. Pat. No. 5,857,777, the entire disclosure of which is hereby incorporated herein by reference.
The signal indicative of the sensed temperature is transmitted to the indicating instrument 30 via the first communication line 50 . The illustrated indicating instrument 30 has a communications port 75 for connecting the first and second communication links 50 , 51 to the indicating instrument 30 . In the case of a thermocouple sensor unit 60 , the two wire output forms the first communication link 50 , and the wires are connected to the communications port of the indicating instrument. The sensed temperature signal generally is an analog signal, and the indicating instrument converts the analog signal into a digital signal for analysis. The indicating instrument 30 also includes a processor 80 and a memory unit 90 . The processor 80 converts the sensed temperature signal (expressed in electrical units, such as voltage) into an estimated temperature (expressed in units of temperature, such as degrees Celsius). The indicating instrument 30 also includes or is connected to one or more output devices 100 , such as a display, and/or one or more input devices 110 , such as a keyboard. Additional functionality may be achieved by altering the software architecture resident in the indicating instrument. An exemplary indicating instrument is disclosed in the aforementioned U.S. Pat. No. 5,857,777, referred to therein as a field signal acquisition unit (FSAU).
Another exemplary indicating instrument 30 includes the Watlow 988 controller with a serial communications port, available from Watlow Controls of Winona, Minn. The indicating instrument includes means for adjusting its calibration offset, preferably digitally and more preferably this means uses one of a recognized standard for communication links, such as RS-485. The user can set up the indicating instrument for various inputs, outputs, control schemes, ranges, communication settings, engineering units, etc. The indicating instrument 30 may be configured via a keypad or for convenience via the communications port 75 to alter any of the setup parameters. The calibration offset may be set by sending a command to the indicating instrument 30 from the interface device 40 , for example, over the second communication link 51 .
Indicating instruments generally attempt to retrieve the characterizing data directly from the memory unit 70 of the smart sensor 20 . Unfortunately, indicating instruments produced by different manufacturers may assume that different information is present in the characterizing data received from the smart sensor and/or may assume that such data is being presented in a particular format. Consequently, a smart sensor from a particular manufacturer may or may not be operable with an indicating instrument from another manufacturer. Thus, prior to the present invention the selection of a replacement smart sensor has been limited to smart sensors that are operable with an indicating instrument from a particular manufacturer. The smart interface device 40 provided by the present invention allows smart sensors to be operable with otherwise incompatible indicating instruments.
The smart interface device 40 is programmed to retrieve and to translate, as necessary, the characterizing data from the smart sensor 20 into calibration data for use by the indicating instrument 30 . As used herein, the term “calibration data” includes characterizing data that has been recharacterized. Recharacterizing includes any change in how the data would appear to the indicating instrument 30 receiving the data from the interface device, whether it includes a change in the format and/or a change in the data values. As used herein, the term “calibration” does not necessarily require calculation, i.e., the data values do not have to change. For example, some indicating instruments may be compatible with certain smart sensors because the indicating instrument expects the data to be arranged in a table by column when the sensor manufacturer actually programmed the characterizing data into the memory of the sensor serially, comma delimited. In that case, the calibration data may differ from the characterizing data only in the arrangement of the data for presentation to the indicating instrument.
The interface device is connected to the memory unit 70 of the smart sensor via the third communications link 51 and to the processor 80 of the indicating instrument via the second communications link 52 . The interface device generally is mounted in or close to the indicating instrument.
The interface device 40 includes its own processor 120 , and a memory unit 130 that is connected to the processor. The interface device interfaces with the smart sensor 20 and the indicating instrument 30 over the second and third communications links 51 , 52 and automatically updates the calibration data. The memory unit 130 also may include a set of software instructions for communicating with the indicating instrument (for example to request the estimated temperature value or to send the calibration offset) and/or retrieving the characterizing data from the memory unit 70 of the smart sensor 20 .
Generally it is expected that the interface device 40 would be preprogrammed for use with a particular smart sensor and a particular indicating instrument. For example, at the time of placing an order for a replacement sensor, the user could also order an smart interface device for use with a particular indicating instrument. However, it also is expected that the interface device could be reprogrammed by the user for use with a different smart sensor and/or a different indicating instrument.
A method of practicing the present invention will be described with reference to FIG. 3 . Beginning at step 300 , the smart sensor 20 (FIG. 1) senses the temperature of an environment with which it is in contact. The sensor then provides a signal indicative of the sensed temperature to the indicating instrument 30 (FIG. 1) via the first communication link 50 (FIG. 1) at step 310 . At step 320 , the indicating instrument analyzes the sensed temperature signal and determines an estimated temperature. Meanwhile, at step 330 the characterizing data is communicated from the memory unit of the smart sensor to the interface device 40 via the third communication link 52 . The estimated temperature is then communicated from the instrument to the smart interface device at step 340 . Based on the characterizing data from the smart sensor and the estimated temperature from the indicating instrument, the smart interface device 40 automatically determines calibration data based on the characterizing data and the estimated temperature, at step 350 . At step 360 , the smart interface device 40 provides the calibration data to the indicating instrument 30 . At steps 370 and 380 , respectively, the indicating instrument 30 determines and outputs the indicated temperature based on the calibration data.
In particular, the processor of the indicating instrument 30 algebraically adds the calibration offset to the estimated temperature to determine the indicated temperature. The indicating instrument 30 then sends a signal representative of the indicated temperature to the display. The indicating instrument processor 80 can continuously or periodically monitor the sensed temperature signal and the calibration data to determine the indicated temperature and update the displayed temperature.
Because the indicating instrument 30 preferably requires no software or hardware modifications, the smart sensing system described herein can function in a broader range of applications. This includes systems where the instrument is already installed. It also includes systems where the sensor manufacturer and the instrument supplier are not the same. The system may also service those customers who find it economically advantageous to purchase stock components rather than custom designed components.
While the smart sensing features are available with no alteration of the standard indicating instrument, additional features may be made available with some slight modifications of the instrument's software. For instance if it is desired to know the manufacturing traceability of the sensor, a lot number could be stored in the sensor's memory unit for recall by the interface device and/or the indicating instrument. Since the instrument does not typically record this information, a software modification would be necessary in the instrument to access this piece of information. Such custom modifications can be made with minimal cost with the electronic architecture of most current instruments. In addition, although in the illustrated embodiment the calibration data includes an offset value or calibration offset, the calibration data might include characterizing data from the smart sensor reformatted as needed, and/or the estimated temperature adjusted by the offset value, i.e., the indicated temperature.
Furthermore, although the illustrated system is described as a temperature sensing system, the present invention includes systems capable of sensing other environmental properties, including pressure and relative humidity, for example.
Although the invention has been shown and described with respect to a certain illustrated embodiment, equivalent alterations and modifications will occur to others skilled in the art upon reading and understanding the specification and the annexed drawings. In particular regard to the various functions performed by the above described integers (components, assemblies, devices, compositions, etc.), the terms (including a reference to a “means”) used to describe such integers are intended to correspond, unless otherwise indicated, to any integer which performs the specified function (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated embodiment of the invention.
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A smart temperature sensing system and method for improved performance of smart temperature sensors when used in conjunction with an indicating instrument. This sensing system uses a microprocessor-based interface to send a signal to the indicating instrument via an existing communications port. The sent signal may consist of a calibration offset value to correct the indicated temperature in the instrument. This offset value is determined from data resident within a memory device in the temperature sensor.
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FIELD OF DISCLOSURE
[0001] The present disclosure generally relates to protective railings and, more specifically, to an assembly of extruded components that are infinitely configurable.
BACKGROUND
[0002] There are a wide variety of barriers, fences, guardrails and handrails currently available for industrial, commercial and residential applications. Although reconfigurable light-duty systems have been developed for directing and restricting pedestrian traffic, heavy-duty industrial systems are usually more permanently installed because their component parts tend to be heavier for impact resistance. Nonetheless, there is a need for a protective railing system having component parts that are sufficiently light to be reconfigured to meet a particular installation's various requirements. Such requirements may include impact resistance, floor layout, visibility, and rail height, all of which may change from one installation to another. Also, it may be desirable to have a protective railing that can be readily removed to temporarily clear a path that is otherwise obstructed by the railing.
SUMMARY
[0003] In some embodiments, a protective railing system includes an extruded post, an extruded bracket, and an extruded rail that can be selectively installed at an infinite number of elevations along the height of the post.
[0004] In some embodiments, the protective railing includes a post that is readily removable from a floor anchor without the need for tools.
[0005] In some embodiments, the position of a rail relative to a post is infinitely adjustable both vertically and circumferentially.
[0006] In some embodiments, an extruded rail-supporting bracket extends along most of the length of a port.
[0007] In some embodiments, the extruded post is cylindrical.
[0008] In some embodiments, the post includes an outer tube and an inner tube with ribs extending therebetween.
[0009] In some embodiments, a floor anchor extends up into the inner tube to support the post.
[0010] In some embodiments, the inner tube is substantially square.
[0011] In some embodiments, the extruded bracket has a curved surface for engaging the cylindrical post and a channel for engaging one or more rails.
[0012] In some embodiments, a fastener for attaching the bracket to the post is generally hidden between the rail and the bracket.
[0013] In some embodiments, two rails each have an interlockable channel for interconnecting the two rails or for supporting a panel, sign, or other type of spacer between two rails.
[0014] In some embodiments, two rails support a pliable sheet or screen therebetween.
[0015] In some embodiments, the protective railing system includes a set of rails that run horizontally to provide a barrier that can withstand greater impact than if the rails were to be installed in a vertical orientation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a front view a protective railing system.
[0017] FIG. 2 is a cross sectional top view taken along line 2 - 2 of FIG. 1 .
[0018] FIG. 3 is a front view similar to FIG. 1 but showing the rail's vertical adjustability.
[0019] FIG. 4 is a top view a protective railing system showing the system's layout configurability and rotational adjustability.
[0020] FIG. 5 is a front view of a rail/post/bracket assembly with a readily removable rail, wherein a front half of the bracket is cutaway to show detail that would otherwise be hidden.
[0021] FIG. 6 is similar to FIG. 5 but showing another embodiment.
[0022] FIG. 7 is similar to FIGS. 5 and 6 but showing another embodiment.
[0023] FIG. 8 is a front view similar to FIG. 1 but showing two spaced-apart rails mounted between two posts.
[0024] FIG. 9 is a front view similar to FIG. 1 but showing two adjoining rails mounted between two posts.
[0025] FIG. 10 is a front view similar to FIG. 1 but showing three spaced-apart rails mounted between two posts.
[0026] FIG. 11 is a front view similar to FIG. 1 but showing six rails mounted between two posts.
[0027] FIG. 12 is an exploded end view of two rails about to be connected by a rail coupler.
[0028] FIG. 13 is an end view of two rails connected by a rail coupler.
[0029] FIG. 14 is an end view of two rails with a spacer inserted between the two.
[0030] FIG. 15 is a front view of the two rails of FIG. 14 supported between two posts.
[0031] FIG. 16 is a front view of a fabric mesh installed between two spaced-apart rails.
[0032] FIG. 17 is an exploded perspective view of a post assembly.
[0033] FIG. 18 is a perspective view of a post assembly mounted to a floor anchor.
[0034] FIG. 19 is an exploded top view of a post assembly.
[0035] FIG. 20 is a front view of FIG. 19 .
[0036] FIG. 21 is a top view of an assembled post assembly.
[0037] FIG. 22 is a front view of FIG. 21
[0038] FIG. 23 is an exploded cross-sectional end view of a rail assembly.
[0039] FIG. 24 is a cross-sectional end view of an assembled rail assembly.
[0040] FIG. 25 is a front view of a protective railing system.
DETAILED DESCRIPTION
[0041] A protective railing system 10 , shown in FIGS. 1-4 , includes at least one rail 12 whose installation position relative to at least one post 14 is infinitely adjustable both vertically (arrows 16 and 18 of FIG. 3 ) and rotationally (arrow 20 of FIG. 4 ). Moreover, post 14 and rail 12 can be cut to any desired length. Thus, protective railing system 10 can be customized and universally applied to a wide variety of installations.
[0042] To maximize the protective railing system's strength-to-weight ratio, post 14 and rail 12 are hollow with internal reinforcing ribs (e.g., ribs 24 of FIG. 2 , and ribs 26 of FIG. 12 ). To minimize manufacturing costs, post 14 , rail 12 , and an interconnecting bracket 28 have an extrudably uniform cross-sectional area so that the part can be extruded of PVC or some other extrudable material. The term, “extrudably uniform” refers to a part that could be extruded even though the part may have been made by a process other than extrusion or may have a surface texture or some cross-drilled holes that could be added after the part was extruded. Extrudably uniform does not necessarily mean that the part has a perfectly uniform cross-sectional area or that it was even extruded.
[0043] Protective railing system 10 also includes a floor anchor 30 for securing post 14 to a floor 32 . In some embodiments, floor anchor 30 comprises a standard-size 1-inch or 1.25-inch square steel tube 34 welded to a base plate 36 that can be bolted to the floor. Tube 34 can be ten inches long or some other appropriate length.
[0044] To connect post 14 to floor anchor 30 , post 14 includes an inner tube 38 that can be integrally extruded along with the rest of post 14 . Inner tube 38 preferably has a square interior surface that matingly engages the square exterior surface of the anchor's tube 34 . Although the shape of tubes 34 and 36 may vary, a square or. rectangular shape helps prevent post 14 from rotating relative to floor anchor 30 . The vertically sliding fit between tube 38 and anchor 30 allows post 14 to be readily removed to provide temporary access to an area that is otherwise fenced off by system 10 . A series of posts 14 can be laid out along a floor in almost any desired pattern or spacing, as shown in FIG. 4 .
[0045] Once the posts are installed, brackets 28 can be attached to the posts using a suitable fastener 40 such as lag bolts, sheet metal screws, or some other appropriate fastener. Each bracket 28 includes a concave surface 42 for solidly engaging the generally cylindrical surface of post 14 and also includes a channel 44 for receiving rail 12 . Brackets 28 are installed such that channels 44 of adjacent posts 14 face each other. Rails 12 may then be cut to length, if necessary, so as to fit between two facing brackets 44 .
[0046] Rail 12 can be installed at any desired elevation along bracket 28 and can be held there by various means. Fasteners 40 , for example, can fasten rail 12 directly to bracket 28 , or rail 12 can be held in place as shown in FIGS. 5, 6 and 7 . In FIG. 5 , fastener 40 attaches an angle support 46 to bracket 28 and post 14 , and rail 12 rests upon support 46 . FIG. 6 is similar to FIG. 5 ; however, an additional fastener 40 connects rail 12 to angle support 46 . FIG. 7 is also similar to FIG. 5 ; however, angle support 46 is inverted so that fastener 40 is hidden between rail 12 and bracket 28 . With the setup shown in FIGS. 5 and 7 , rail 12 can be readily removed without the use of tools by simply lifting rail 12 off of supporting bracket 46 . FIG. 6 , however, shows how an additional fastener 40 screwed into rail 12 can hold the rail in place more securely.
[0047] FIGS. 1, 8 , 9 , 10 and 11 illustrate how one or more rails 12 can be installed in various configurations. FIG. 1 shows a single rail 12 supported between two posts 14 , FIG. 8 shows two spaced-apart rails 12 , FIG. 9 shows two rails to that lie up against each other, FIG. 10 shows three spaced-apart rails 12 , and FIG. 11 shows a full stack of rails 12 that provides a solid wall effect. Regardless of the number of rails, each rail can be held in place by any appropriate method including those described with reference to FIGS. 1, 5 , 6 and 7 .
[0048] When two or more rails are installed up against each other, as shown in FIGS. 9 and 11 , a rail coupler 48 can be installed to help hold two adjoining rails together as shown in FIGS. 12 and 13 . Each rail 12 , for example, may define an interlocking channel 50 in which coupler 48 is inserted. Coupler 48 can be slid lengthwise into channel 50 prior to installing the two or more rails 12 between brackets 28 .
[0049] When two or more rails are spaced apart to create a gap or opening between the two, an extra wide rail coupler (extra wide vertical dimension) or spacer can be installed between the two rails. In FIGS. 14 and 15 , for example, a spacer 52 comprises a generally rigid panel that in some cases may also serve as a sign. In FIG. 16 , a spacer 54 comprises a pliable sheet, such as a screen or fabric mesh.
[0050] FIGS. 17 and 18 show how a post 14 ′ can be created by press-fitting a post insert 14 a into a pipe 14 b , wherein pipe 14 b is a standard-size shedule-40 or shedule-80 PVC pipe. Insert 14 a is just a shorter and perhaps smaller diameter version of post 14 . Post 14 ′ can then be installed in the same manner as post 14 .
[0051] Instead of post 14 , an alternate post 56 can be made by interlocking two post segments 58 , as shown in FIGS. 19-22 . Each segment 58 has a T-flange 60 and a mating T-groove 62 . By axially sliding two identical segments 58 together, as shown in FIG. 20 , flange 60 of one segment 58 interlocks with the mating T-groove 62 of an adjoining segment 58 to create post 56 , which can then be installed and used like post 14 .
[0052] FIGS. 23 and 24 show an alternate rail assembly 64 that comprises an assembled stack of interlocking rails, which in this example includes one upper rail 66 and two lower rails 68 (any number of other combinations is also possible). The rails interlock with a tongue-in-groove connection 70 similar to the connection between T-flange 60 and T-groove 62 just described. Upper rail 66 can be provided with a suitably shaped handrail 72 . Other options include a reinforcing member 74 (e.g., steel square tubing, metal bar, etc.) that could make some areas of rail assembly 64 more rigid or stronger than other areas. In some cases, rail assembly 64 can be strengthened by inserting an elongate reinforcing member 76 through the length of one or more rails. Member 76 could extend from one post 14 to another and could connect any number of posts and rails together. In order for member 76 to extend through multiple rails, as shown in FIG. 25 , holes may need to be drilled through posts 14 to allow member 76 to pass through the posts. Some examples of elongate member 76 include, but are not limited to, a cable, strap, chain, rope, etc.
[0053] Another option is to use hollow rail 66 (or other rails and/or posts) to serve as an electrical conduit for carrying an elongate electrical conductor 78 , which has been schematically illustrated to represent any electrically conductive element. Examples of elongate electrical conductor 78 include, but are not limited to, a wire, cable, string of lights, rope light, antenna, sensor, etc. In order for member 78 to extend through multiple rails, as shown in FIG. 25 , holes may need to be drilled through posts 14 to allow member 78 to pass through the posts. If conductor 78 includes lights, rail 66 is preferably able to pass the light through openings in the rail or via the rail material itself being transparent or translucent. If conductor 78 is an antenna or a sensor serving as a proximity sensor, for instance, the material of rail 66 may need to be non-metallic.
[0054] Although the invention is described with respect to a preferred embodiment, modifications thereto will be apparent to those of ordinary skill in the art. Therefore, the scope of the invention is to be determined by reference to the following claims:
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A protective railing system includes at least two extruded posts, two post-mounted extruded brackets, and at least one extruded rail. The rail can be selectively installed with infinite adjustability both vertically and rotationally. Each post includes an outer tube and an inner tube with reinforcing ribs extending between the two. To secure the post to a floor, a floor-mounted anchor extends up into the inner tube. The anchor and inner tube are preferably rectangular to restrict relative rotation between the post and the anchor. When two or more rails are installed between two posts, the two rails can be interlocked, or the rails can be spaced apart to support a spacer therebetween. In some cases, the spacer is a sign or a fabric mesh.
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BRIEF SUMMARY OF THE INVENTION
This invention relates to the field of combined shock absorbers and air spring units. The advantages of such combined units are known, understood and appreciated. The present invention relates to a kit for adapting an existing available shock absorber to utilization as a combined shock absorber and air spring unit, the conversion being performable either by a manufacturer or by the ultimate user. The parts are designed and arranged to facilitate simple assembly to an existing shock absorber as well as simple disassembly for rebuilding of the air spring assembly, if that ever proves necessary, or for utilization of the air spring assembly on a different or replacement shock absorber if desired.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a combined shock absorber and air spring unit embodying certain of the principles of the present invention;
FIG. 2 is a fragmentary vertical cross sectional view of the structure of FIG. 1; and
FIG. 3 is an enlarged view of a portion of the structure illustrated in FIG. 2.
DETAILED DESCRIPTION
The assembly as illustrated in FIG. 1 of the drawings comprises a shock absorber 10 having lower and upper attachment means 12 and 14. An air spring subassembly 16 surrounds and cooperates with a portion of the shock absorber 10.
Shock absorber 10 is intended to represent any of a variety of commercially available shock absorbers which are not specially designed to serve as elements of a shock absorber-air spring combination. Such shock absorbers are well known and available and are adapted to be connected, through attachment means 12 and 14, between the sprung and unsprung masses of a vehicle, such as a motorcycle.
The shock absorber 10 includes a body 18, integral with the lower attachment means 12, and a piston rod or shock shaft 20 which cooperates with a conventional internal piston so as to be movable relative to body 18, with the shock absorber tending to control those relative movements. Piston rod 20 has an upper threaded end 22 accepting a shock lock nut 24, serving as a shoulder portion, and accepting the attachment portion 14 which is illustrated to be in the form of a customary top eye having a tapped bore to threadedly accept the threaded end of the piston rod 20. It will be appreciated that in normal usage of the shock absorber, as such, shock lock nut 24 would be in abutment with the top eye 14.
The shock body 18 is of conventional form, not specially designed to accept an air spring unit. Thus, as is illustrated in FIG. 2, the shock body 18 is assumed to have the illustrated circular cylindrical portion terminating in a flat end cap 26, with the piston rod 20 sliding through an aperture in that end cap 26. The exterior surface of the illustrated upper portion of the body 18 is assumed to be devoid of special grooves, indentations, lips or shoulders designed to specifically accommodate the addition of air spring assemblies.
The major operative element of the air spring assembly is a flexible, tubular, resilient boot 28 operating in the manner of a rolling-lobe diaphragm, as is well known in the air spring art. Boot 28 is provided with lower and upper enlarged lips or beads 30 and 32 each of which is substantially thicker than the thickness of the remainder of the body of the boot. The material therebetween is folded to define a rolling lobe 31. Beads 30 and 32 are further illustrated as having sloping transitions or shoulders 34 and 36 between the enlarged thickness of the bead portion and the free thickness of the remainder of the boot, at the neck portions of the beads at 38 and 40. To facilitate turning the boot inside out during manual assembly, boot 28 may be tapered, if desired. In one form, as an example, the tubular boot (with the beads directed inwardly) had an overall length of 71/4 inches, a bead body thickness of 0.200 inches, a bead height (excluding the tapered or beveled portion) of 1/2 inch, a free thickness of the wall of 1/8 inch, a slope of about 45° at the tapered chamfer 34 and 36 at the base of each bead, an outer diameter at the upper end (engaging cap 52) of 23/8 inches and an outer diameter at the lower end (engaging shock body 18) of 13/4 inches.
Bead 30 of boot 28 is sealingly secured to the body 18 of the shock absorber by retainer sleeve 42. Retainer sleeve 42 includes a tubular circular cylindrical portion 44 having a diameter just slightly larger than the diameter of the upper circular cylindrical portion of body 18, that is, the minimum internal diameter of production retainer sleeves should desirably be slightly larger than the largest diameter of the circular cylindrical upper portion of the shock absorber bodies of a given nominal diameter with which the air spring assembly is to be associated. As will be seen, the retainer sleeve should be hand forceable into its illustrated position in relation to the body 18.
At its upper end, retainer sleeve 42 terminates in an inwardly directed flange 46 terminating in a central aperture through which piston rod 20 projects. Flange 46 is brought into abutment with end face 26 of body 18 and serves to limit the downward movement (in the illustrated attitude of the unit) of the sleeve 42 relative to the body 18 during installation.
Below the cylindrical section 44, sleeve 42 enlarges in diameter to define an enlarged annular cavity 46 to accept the thickness of the bead 30 disposed circumferentially of the body 18. At the lower portion of the cavity 46, the sleeve 42 slopes downwardly and inwardly in a configuration substantially matching the slope of the face 34 of the bead 30, and terminates in a circumferential clamping edge 48 bearing against the neck 38 of the bead 30 and pinching that neck against the adjacent portion of the circular cylindrical body 18. The clamping edge is an interference fit with the combination of the body 18 and the neck 38, that is, the inner diameter of the clamping edge 48 is smaller than the outer diameter of the tube 28 plus the free dual thickness of the neck portion 38 of the bead 30 when that neck portion is in surrounding abutment with the body 18. The interference fit should be sufficient to provide proper sealing between the neck portion 38 and the body 18 while yet not unduly inhibiting the installation of the combination of the bead 30 and the sleeve 42 on the body 18. As an example, with units in which the diameter of the body 18 was about an inch and a half, the inner diameter of the clamping edge 38 was selected to be about 0.008 inches less than the sum of the diameter of the body 18 and the two thicknesses of the boot body 28 in the region of the neck 38. As a result, the clamping edge 38 tends to indent and pinch the neck 38 against the body 18 as is illustrated in FIG. 3 of the drawings. It will be seen that the effect of pressure within the boot 28 will be in a sense to tend to result in the continuing engagement of the inwardly directed flange 46 with the end face 26 of the shock body 18, so that with that force, coupled with the frictional engagement in the region of the clamping edge 38, there is no need to permanently secure or lock the retainer sleeve 42 in position and it may be readily removed, if necessary at any time, to permit rebuilding of the air spring assembly or replacement of the shock absorber, or otherwise. It will be observed that those same pneumatic forces also tend to aid in maintaining a seal at the neck of the bead 38, since the force on the boot, resulting from the air pressure, tends to draw a thicker section of the bead into the clamping area.
The upper bead 32 of the boot 28 is sealingly secured to the assembly including piston rod 20 by means of a master cap 52. Cap 52 is centrally apertured to accept the threaded stud portion 22 of the piston rod 20 and is trapped between the nut or shoulder 24 and the top eye 14. An annular groove in the upper surface of the master cap 52, surrounding the central aperture therein, accepts an O-ring seal 54 to constitute a sealing means to prevent the escape of air through the central aperture in the master cap 52.
Master cap 52 includes a tubular circular cylindrical skirt portion 56 terminating at its lower end in a lip 58 which flares at an angle directed outwardly from the skirt 56 and downwardly towards the rolling lobe 31 illustratively at an angle of approximately 45° . The outer face of the skirt 56 of the cap 52 substantially conforms in shape to the abutting face of the bead 32, and the outer face of the flared lip 58 substantially conforms to the abutting face of the sloping portion 36 of the bead 32.
A circular cylindrical tubular shell 60 surrounds and supports the outer wall of the boot 28 and is provided with an inwardly directed flange 62 overlying the upper surface of the bead 32. The upper exterior surface of the skirt 56 is threaded to constitute a fastening means accepting portion, and a nut 64, constituting a fastening means, is threadedly engaged thereby and clamps flange 62 against the upper surface of the bead 32.
It will be observed that the neck of the bead 40 is pinched or clamped between the external face of the flared lip 58 and the adjacent inner face of the shell 60. The inner diameter of the shell 60 should be greater than the outer diameter of the flared lip 58 by an amount less than two thicknesses of the boot 28 in the region of the neck 40, in the manner previously discussed with reference to FIG. 3 of the drawings.
A master cap 52 is apertured to accept a valve assembly 66 of a type including a conical resilient portion 68 which may be forced through the aperture and which will expand therewithin, said valve assemblies being similar to the type commercially available for use with tubeless tires.
To assemble the rebuildable air spring assembly to a shock absorber, the boot 28 is first turned inside out so that the beads 30 and 32 and the sloping surfaces thereat are on the exterior of the bead surface. The bead 30 is then inserted within the cavity 46 in the retainer sleeve 42, with the remainder of the boot depending downwardly therefrom. Prior to or following the aforesaid operations, the shock top eye 14 and the shock lock nut 24 (if provided) are removed from the shock absorber. The inverted boot 28 and the retainer sleeve 42, assembled together as above described, are then inserted over the piston rod 20 and moved downwardly around the shock body 18. To simplify and facilitate assembly it is recommended that the outer upper surface of the shock body 18 be at least wetted and preferably wetted with a soap and water solution to create a temporary lubricating action. The retainer sleeve 42 is moved downwardly (in the illustrated attitude of the parts) over the shock body 18 until the inwardly directed flange 46 abuts the end face 26, as illustrated in FIG. 2. After rethreading shock lock nut 24 on threads 22 (if a lock nut is provided with the shock absorber), the master cap 52 is inserted over the threaded portion 22 and into abutment with the shoulder means at the remote end of the piston rod 20, which shoulder means may be in the form of the lock nut 24. The shock top eye or attachment portion 14 is then screwed upon the threads 22 to clamp the master cap 52 in position. The lowermost end of the boot is then flipped and folded upwardly into the configuration illustrated in FIG. 2 of the drawings, bringing the bead 32 over the flared lip 58 into the illustrated position. Outer shell 60 is then inserted from the top into a position in which its flange 62 rests upon bead 32. Nut 64 is then inserted over master cap 52 and is screwed on the threads on the skirt 56 to clamp flange 64 between that nut and the bead 32. Valve 66 is then popped through the aperture therefore and the assembly is ready for pressurization and use.
It will be perceived that a reverse procedure may be employed to disassemble the air spring assembly from the shock absorber to permit replacement of parts of the air spring assembly or to permit replacement of the shock absorber.
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A supplementary air spring unit suitable for user installation on a damper or shock absorber having a generally cylindrical body in which one bead end of a resilient tubular rolling-lobe boot is removably sealingly secured on the shock absorber body by a sleeve retained in place by the air pressure in the unit and in which the other beaded end of the boot is removably sealingly pinched between a master cap and an external shell, with the shell and bead being removably retained in position by a fastening means on the cap.
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RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 07/625,457, filed on Dec. 11, 1990, which is set to issue on Jan. 28, 1992, as U.S. Pat. No. 5,084,354, and of U.S. application Ser. No. 07/601,409, filed on Oct. 23, 1990, now abandoned.
TECHNICAL FIELD
This invention relates generally to coating compositions for substrates, such as release paper. In particular, the present invention relates to a release paper and a method of its manufacture, and a primer coat for use with this release paper.
BACKGROUND OF THE INVENTION
Adhesive labels and similar adhesively-secured items are generally well-known in the art. These adhesive labels usually comprise a facing for graphics, an adhesive secured to the backside of this facing, and a release liner or release paper. The adhesive must hold the facing securely to the release paper, but must permit relatively easy breakaway of the facing from the release paper when that facing is pulled away from the release paper by the ultimate user. Generally, the amount of force necessary to pull the facing away from the release paper is measured in units of "grams per inch."
It is well-known in the prior art to construct a release liner by coating that liner with a silicone release resin. The silicone release resin is applied directly to the release paper base, such as a densified kraft paper.
A silicone release liner consists of a substrate such as a paper, polyethylene coated paper, or foil that has been coated with a silicone polymer that will allow inherently tacky materials such as pressure-sensitive adhesives (PSA), sealants, caulks or resins to be easily removed from the liner. Furthermore, the silicone polymer must be sufficiently cured and adhered to the substrate so that it will not be transferred to the materials it contacts.
The silicone polymers can be applied to the substrates by various coating techniques such as Meyer rod coating, Gravure coating or air knife coating. Coatings can be suitably applied from solvents, emulsions, or they can be applied as 100 percent solids. Once coated, the silicone must be cured or crosslinked to ensure that the coating is nonmigratory and adhered to the substrate. Most silicone release polymers are cured thermally at substrate temperatures greater than 250° F. At these temperatures, paper substrates lose moisture rapidly.
The physical properties of a paper substrate rely to a large extent on moisture content. The tensile, adsorption energy, suppleness, tear strength and dimensional stability all decrease if too much moisture is lost during the curing process.
Some manufacturers of silicone release polymers have addressed the problem of high cure temperatures by functionalizing the silicone polymer with acrylic ##STR1## groups. These polymers now can be cured with radiation techniques, such as electron beam radiation or ultraviolet light, through the assistance of a photoinitiator. To achieve adequate cure, atmospheric oxygen must be excluded from these coatings during the cure. This can be difficult to control and expensive to implement in production settings. Radiation-cured silicones of this type have not been used extensively on paper substrates because of problems associated with cure, poor performance with acrylic pressure-sensitive adhesive and the high cost of inerting and curing equipment.
In U.S. Pat. No. 4,273,668, issued to Crivello on Jun. 16, 1981, entitled "ARYLSULFONIUM SALT-SOLVENT MIXTURES," this problem was partially solved by functionalizing silicone polymers with epoxide groups which can be cured cationically under U.V. light using "onium" type photoinitiators. With this invention, manufacturers can now cure silicones with U.V. light without the expense of excluding oxygen during the cure. Silicones of this type perform well, if properly cured, with most pressure-sensitive adhesives (PSA), including acrylics. Proper cure is easily achievable on films and coated paper, but is difficult on porous substrates such as conventional release liner papers. Components of the silicone polymer or onium catalyst can penetrate the pores and capillaries of the paper and become immobilized, and are thus partially incapable of participating in the cure reaction.
In addition, the paper itself or the components introduced by the paper manufacturer during pulping and finishing processes can interfere with the cure chemistry of the silicone. An improperly cured silicone release polymer will not provide a premium release surface for PSA's, and will cause the PSA to become detackified by silicone transfer. Subsequently, this results in poor adhesive performance during readhering to other surfaces.
Until now, silicone has always been applied directly to the release paper base and cured by air or heat curing. No method existed for the ultraviolet curing or an ultraviolet-curable silicone onto a release paper base, and which permitted relatively easy release of the facing from that release paper base.
Photopolymerizable compositions similar to those used in the present invention have been described in the prior art. In particular, U.S. Pat. No. 4,593,051, issued to Koleske on Jun. 3, 1986, is entitled "PHOTOCOPOLYMERIZABLE COMPOSITIONS BASED UPON EPOXY AND POLYMER/HYDROXYL-CONTAINING ORGANIC MATERIALS." This patent shows 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexene carboxylate as a participant in photoinitiated oxonium ion intermediate addition reactions. The compositions in this patent are apparently directed to varnishes for use in the metal container, appliance, and/or automotive industries.
Other generally pertinent prior art includes U.S. Pat. No. 4,840,978, issued to Koleske et al. on Jun. 20, 1989, entitled "BLENDS OF CYCLIC VINYL ETHER CONTAINING COMPOUNDS AND EPOXIDES"; and U.S. Pat. No. 4,694,029, issued to Land on Sep. 15, 1987, entitled "HYBRID PHOTOCURE SYSTEM." Koleske et al. and Land disclose photopolymerizable compositions.
Heat-curable epoxy-styrene compositions are disclosed in U.S. Pat. No. 4,284,753, issued to Hewitt, Jr., on Aug. 18, 1981, entitled "HEAT CURABLE POLYEPOXIDE-UNSATURATED AROMATIC MONOMER RESIN COMPOSITIONS"; and U.S. Pat. No. 4,554,341, issued to Allen on Nov. 19, 1985, entitled "FIRE RETARDANT, FAST REACTING EPOXY RESIN."
U.S. Pat. No. 4,069,368, issued to Deyak, discloses ultraviolet-curable epoxy-functional silicones.
U.S. Pat. No. 4,533,600, was issued to Coughlin et al. on Aug. 6, 1985, and entitled "SEALANT SHEET MATERIAL." This patent is assigned to the assignee of the present application. The patent discloses a sheet material comprising a smooth grade of a kraft paper, a continuous coating of a resin composition on the kraft paper, and continuous film of silicone release agent on the surface of at least one of the resin composition coatings. The resin coating, however, consists essentially of a nitrile rubber modified polyvinyl chloride, and the silicone is an emulsion which is cured by heat.
Finally, U.S. Pat. No. 4,859,511, issued to Patterson et al., on Aug. 22, 1989, entitled "UNDERCOATED SILICONE RELEASE SHEET," describes release sheets having a low polar surface energy hydrocarbon undercoating. This undercoating, which has a low elastic modulus, is interposed between the substrate and a silicone release coating. As may be seen from the examples and claims, however, the undercoating of this patent is substantially different from the present undercoating or primer coat as described below.
SUMMARY OF THE INVENTION
The invention is a method of manufacturing a substrate treated with an ultraviolet light-curable silicone. The preferred substrate is a release paper base. The method comprises coating the release paper base with a primer coat, and it has now been discovered that this primer coat can be based upon an aromatic or aliphatic substance. The aromatic or aliphatic primer coat may be cured in a conventional manner, that is, with heat or air curing, or it may be alternatively cured with ultraviolet light. By treating the release paper base with an aromatic or aliphatic primer coat in accordance with the invention, the surface of the paper is properly prepared for an ultraviolet-curable silicone coating. After the ultraviolet-curable silicone coating is placed over the primer coat-treated substrate, the silicone coating itself is cured with ultraviolet light. For example, when an adhesively-secured facing is pulled away from a release paper treated in this manner, the force necessary to pull the facing away will not exceed 35 grams per inch, even after aging.
The invention is also an ultraviolet-cured substrate and the primer coat for that substrate. The substrate is a release paper comprising a primer coat that may be cured by ultraviolet radiation or by more conventional means, and an overlaying ultraviolet-curable silicone coating. When an adhesively-secured facing is secured to this treated release paper base, that facing may be removed from the release paper with a force not exceeding 35 grams per inch.
This invention describes a method of preparing a paper substrate to make it compatible for use with radiation-cured silicones as described in the literature by Crivello and others.
The method comprises coating a paper as supplied by the manufacturer with an aromatic or aliphatic primer coat. The primer coat serves to prevent the silicone coating from penetrating the paper, which can result in the silicone becoming unavailable for cure. The aromatic or aliphatic primer coat also insulates the silicone from deleterious cure-inhibiting components which can be introduced during the paper making process.
The composition of the aliphatic or aromatic primer coat can vary as long as it does not contain components deleterious to the cure for silicones. Further, the primer coat should be crosslinked to an extent so that it cannot be dissolved, swollen or fused by solvents. This allows for heat to be used in the adhesive coating for the finished liner, as the primer does not melt at temperatures in excess of 400° F.
The primer coat may be cured in a conventional manner, that is with heat or air curing or it may be alternately cured with ultraviolet light or other radiative processes such as electron beam curing methods. The radiation processes are preferred since they do not result in moisture loss from the paper substrates. As described earlier, moisture loss during cure can result in unstable or unusable paper liner.
Once cured on the paper on both sides, the primer is a barrier trapping moisture in the paper and preventing water and atmospheric moisture from invading the paper, which causes instability. The cured primer also serves to mechanically enhance the physical properties of the paper such as tensile strength, stiffness and dimensional stability.
The aromatic or aliphatic primer coat, because it seals and tensilizes the paper, allows the use of less expensive papers than could otherwise be used in a silicone coating operation.
The aromatic or aliphatic primer can be applied to one or both sides of the paper and be overcoated on one or both sides with the same U.V.-cured silicone. It can also be overcoated on one side with a U.V.-cured silicone with a stable release of less 35 grams per inch, and on the other with a U.V. silicone composition with a stable release value between 75 and 100 grams per inch, to produce a differential release liner with many industrial applications.
Liners of this type are used to produce self-wound adhesive transfer tapes, carbon composite structures, and many types of sealants or caulks.
Accordingly, an object of this invention is a method of treating a release paper base with a U.V.-curable silicone which permits relatively easy separation of an adhesively-secured facing from that release paper.
A further object of the invention is a primer coat and a release paper which, when treated, inhibits moisture loss and results in a more stable cellulosic substrate.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
This invention is a method of manufacturing an ultraviolet-cured substrate, such as a release paper. One suitable release paper is a densified kraft paper, such as XCT-157 densified kraft paper manufactured by the Nicolet Paper Company. Any similar kraft paper, however, whether bleached or unbleached, will be suitable. One ream of paper is 3,000 square fee, and XCT-157 has a weight of 60 pounds per ream.
EXAMPLE 1
A suitable primer coat is necessary to properly prepare this kraft paper for the subsequent ultraviolet-curable silicone coating. In this embodiment, the primer coat may be manufactured using an epoxy, a reactive diluent, a surfactant, and a catalytic blend that acts as the photoinitiator. One suitable primer is manufactured from the following components, each being listed by weight:
Components of Stabilizing Primer Coat
75.0 parts of epoxy
25.0 parts of reactive diluent
0.5 parts surfactant
3.0 parts photoinitiator (50% in propylene carbonate)
The epoxy may be either Araldite 6010, manufactured by Ciba-Geigy, or Shell Product No. 828. These formulations have the general formula: ##STR2## This composition is a glycidyl-type epoxide, preferably diglycidyl ethers of bisphenol A which are derived from bisphenol A and epichlorohydrin.
The reactive diluent is Cyracure 6200, manufactured by Union Carbide, or its equivalent. Cyracure 6200 comprises 50 percent by weight 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexene carboxylate: ##STR3## 45 percent 4-vinyl cyclohexene monoepoxide: ##STR4## and 5 percent polycapralactone.
The surfactant is Surfynol 104E, or an equivalent. Surfynol comprises 50 percent ethylene glycol and 50 percent: ##STR5##
Finally, the photoinitiator is Cyracure 6990, manufactured by Union Carbide, or a similar catalytic blend. Cyracure 6990 is a combination of 50 percent triphenyl sulfonium hexaflurophosphate and 50 percent propylene carbonate.
When these four components are combined, they are stirred with a magnetic stirrer or air mixer at room temperature, until a clear solution is obtained. A clear solution can usually be achieved within ten minutes. This combination is suitable for use as the prime coat, and is stable over a period of approximately one week. The coating composition comprising these four parts will be referred to as the "stabilizing prime coat."
A Nicolet XCT-157 densified kraft paper may be used to manufacture the substrate in accordance with the invention. It will be understood by those in the art, however, that any other similar paper, whether bleached or unbleached, may be used. Other suitable papers include machine glazed, machine finished, supercalendared, parchment, vellum, and any other paper having a Gurley porosity, when measured on a Gurley tester Model No. 4200, of at least 300 seconds per 100 cc. of air. In this embodiment, the XCT-157 kraft paper has a basis weight of 60 pounds per ream.
Using a Meyer No. 3 rod, the densified kraft paper is coated with the stabilizing prime coat described above in a coating weight of 2 to 5 pounds of stabilizing prime coat per ream of paper. The stabilizing prime coat is then cured in a Fusion System F-300 ultraviolet processor set at its full power of 300 watts per inch, and with the conveyor belt moving at a speed of 100 feet per minute.
After the stabilizing prime coat on one side of the substrate has been cured, the same stabilizing prime coat in the same amount is applied to the opposite side the substrate densified kraft paper. In this step, the stabilizing prime coat is again applied at 2 to 5 pounds per ream, and the treated substrate is again sent through the Fusion System F-300 processor at full power and with a conveyor belt speed of 100 feet per minute.
This densified kraft paper which has been coated with the stabilizing prime coat is then, in turn, coated on its first side with an ultraviolet-curable silicone, such as General Electric Silicone Product No. U.V. 9300. This U.V.-curable silicone may be applied, at 0.40-1.00 pounds per ream, to the treated densified kraft using a Euclid knife-over roll coater and at a knife pressure of 25 p.s.i. The Euclid coater is manufactured by Euclid Machines, Bay City, Mich. The silicone-coated side of the densified kraft paper is then cured in the Fusion System F-300 processor, again at full power and with a conveyor belt speed of 100 feet per minute. The paper is then reversed and treated on its second side with the General Electric ultraviolet light-curable silicone, using the same amount of silicone, the same apparatus, and the same knife pressure as described above for the ultraviolet coating on the first side of the kraft paper. The second side of the kraft paper is cured in the same manner as the first side of the paper, i.e., in the Fusion System F-300 U.V. processor at full power, and at a conveyor belt speed of 100 feet per minute.
As may be seen from the below Table I, kraft papers that are treated with the stabilizing prime coat, and kraft papers that are treated with both the stabilizing prime coat and the ultraviolet-curable silicone coating with the process described above, both show smaller width expansions, in the cross-machine (CM) direction, than Nicolet XCT-157 kraft which has not been so treated:
TABLE I______________________________________Neenah Expansimeter Expansions Percent (%)______________________________________Nicolet (densified kraft) 1.51XCT-15760 lbs./ream(densified kraft treated on both sides with .88stabilizing prime coat)(densified kraft treated on both sides with .88stabilizing prime coat and silicone coating,GE U.V. curable)______________________________________
The test procedure for determining the percent expansion of the untreated paper, the paper treated with a stabilizing prime coat, and the paper treated with both the stabilizing prime coat and the silicone is as follows:
Neenah Expansimeter Test Conditions
1. The samples are aged under TAPPI conditions of 70° F., 50 percent relative humidity for twenty-four hours. Samples are cut to 1 inch width and 11 inches in length.
2. The samples are then placed in a Neenah chamber set at 11 percent R.H., and 70° F. for twenty-four hours. At the end of this test interval, the sample length is measured with the caliper gauge within the Neenah unit. This dimension is M 1 .
3. The samples are then placed in the Neenah chamber set at 84 percent R.H., 70° F. for twenty-four hours. At the end of this test interval the sample length is measured with the caliper gauge within the Neenah unit. This dimension is M 2 .
4. The percent expansion is calculated as follows: ##EQU1## The lower the percent expansion, the less moisture the substrate adsorbed, and the more stable the paper for subsequent process applications. From this, it is apparent that the treated paper is superior to the untreated paper.
As may also be seen by Table II below, the silicone-coated and stabilized prime coat, densified kraft paper described above shows initial and aged release parameters well below those for the same paper which has not been treated with a stabilizing prime coat:
TABLE II______________________________________Release Data Initial Aged______________________________________Silicone Coated 16.8 grams/ 23.6 grams/Stabilized Prime Coat inch of width inch of widthDensified KraftSilicone Coated 50.0 grams/ 150.0 grams/Densified Kraft without inch of width inch of widthStabilizing Prime Coat______________________________________
The procedure used in measuring the release is as follows:
1. Ashland 1910 (acrylic) adhesive is applied over the silicone coated product produced in Example #2, with a laboratory knife-over-bed coater in which the gap is set at 0.008 inches. This results in a wet cast adhesive film 0.008 inches thick.
2. The adhesive coated product of Example #2, with the wet cast adhesive of Step 1, is cured at 150° F. for 10 minutes.
3. The cured adhesive is laminated to 0.001 inch thick polyester equivalent to DuPont "mylar."
4. After lamination, samples are cut into strips 1 inch width and 11 inches in length.
5. At least two such strips are evaluated for release initially using an I-Mass Peel Tester made by Instrumentors, Inc., Model #3M-90, set at 180° peel and 90 inches/minute stripping speed. These release force measurements are averages and reported as "initial" in grams per inch of width.
6. At least two strips prepared in Steps 1-4 are placed in an oven maintained at 70° C. for seventy-two hours. These strips are then evaluated for aged release also using the I-Mass Peel Tester under identical settings as described in Step 5. These release force measurements are averaged and as "aged" in grams per inch of width.
The lower the force in grams per inch, the more preferable the treated paper.
From the above, it is plain that when a kraft paper is treated with a U.V.-curable silicone coating, but without the stabilizing prime coat, the release measurements are well in excess of the desired 35 grams per inch. In contrast, when this same product has been pretreated with the stabilized prime coat described above, the release measurements are well under 35 grams per inch.
A differential release sheet is one having a release value of less than 35 grams on one side, and having a release value greater than 35 grams (tight release) on the other side. Typical tight release values in the industry range from 40-300 grams.
EXAMPLE 2
A densified kraft is coated on both sides with the primer coat, as described above. One side is subsequently coated with the G.E. U.V.-cured silicone, again as described above. The second side, however, is coated with a blend of polymers. In this example, the blend comprises 60 percent GE-9320 and 40 percent GE9315. This coating can be applied using the Euclid knife over roll coater, using the same conditions as described in the previous Example, and then cured using those same conditions. This particular mixture was formulated to give a "tight," stable release value approximately four (4) times greater than that of the "easy" release value, as may be seen in Table III.
TABLE III______________________________________Differential Release Data Initial Aged______________________________________Easy Release Coated 15.8 grams/ 21.0 grams/Stabilized Prime Coat inch of width inch of widthDensified KraftTight Release Coated 60.0 grams/ 100.0 grams/Stabilized Prime Coat inch of width inch of widthDensified Kraft______________________________________
EXAMPLE 3
The cure of the U.V. silicone is dependent on the generation of a strong acid. The pH of the substrate to which the coating is applied can greatly affect the cure rate and cure completion. A specific example is a paper from Glatfelter Paper Co. (Release Liner Base II, Mfg. Code 87660). This paper has a pH of 9.3. When the U.V.-curable silicone is applied directly to the paper and processed under U.V. light, the cure is completely inhibited. This inhibition is a direct result of the high pH of the substrate, where the acid catalyst is consumed by paper instead of the polymer. When the primer coat of Examples 1 and 2 are applied to the same paper, however, the U.V.-curable silicone can be applied and cured as described in those Examples. The silicone has a stable release below the specified maximum requirement of 35 grams per inch.
TABLE IV______________________________________ Initial Aged______________________________________Silicone Coated No cure No cureGlatfelter Paper(w/o prime coater)Silicone Coated 14.6 grams/ 19.5 grams/Stabilized Prime Coat inch of width inch of widthGlatfelter Paper______________________________________
EXAMPLE 4
A prime coat-treated substrate as described in Example may be subsequently coated with a 100 percent solids, thermally-cured silicone. A suitable silicone formulation is:
______________________________________Dow Corning 7610 100 partsDow Corning 7611 3.7 partsDow Corning 7127 1.59 parts______________________________________
This formulation can be applied with the Euclid knife over roll coater at a blade pressure of 32 psi. The coated paper is then cured in a forced air oven 15 250° F. for 15 seconds. The resulting product may be tested for release, as described in Table V. The results of this test are as follows:
TABLE V______________________________________ Initial Aged______________________________________100% Silicone Treated 21.0 grams/ 33.0 grams/Stabilized Prime Coat inch of width inch of widthDensified Kraft______________________________________
EXAMPLES 5-9
In addition to the aromatic primer coat used in the above-described Examples, aliphatic primer coats have been found to provide slightly improved results. In particular, a primer coat made from a dicyclohexyl epoxy, such as 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexene carboxylate ("epoxy"), has been found suitable for the manufacture of stabilized paper substrates: ##STR6##
One suitable reactive diluent is 4-vinyl cyclohexene monoepoxide: ##STR7##
The aliphatic-based primer coat used in these Examples was manufactured in accordance with the following specifications. To the formulations listed below, there was added 0.5 parts of a surfactant and 3.0 parts of a photoinitiator (50 percent in propylene carbonate). The surfactant is Surfynol 104E and the photoinitiator is Cyracure 6990, manufactured by Union Carbide, or a similar catalytic blend. As stated above, Cyracure 6990 is a combination of 50 percent triphenyl sulfonium hexaflurophosphate and 50 percent propylene carbonate:
Example 5, 100.0 parts epoxy, 0 parts of the reactive diluent 4-vinyl cyclohexene, monoepoxide.
Example 6, 90.0 parts epoxy, 10.0 parts of this same reactive diluent.
Example 7, 80.0 parts epoxy, 20.0 parts reactive diluent.
Example 8, 70.0 parts epoxy, 30.0 parts reactive diluent.
Example 9, 60.0 parts epoxy, 40.0 parts reactive diluent.
Other reactive diluents believed to be suitable include Epodil 747, an aliphatic glycidyl ether, and Epodil 750, a diglycidyl ether of 1,4-butanediol. Both of these are available from Pacific Anchor Chemical.
After the formulations of these Examples 5-9 were blended in accordance with the instructions for the blending of the formulation of Example 1, they were tested to determine their efficacy. The primer coatings of Examples 5-9 were coated onto the paper substrates at approximately 4 pounds per ream. Then, the hydroexpansivity tests like those discussed above were done to determine the suitability of the primer coat. The aliphatic primer coat proved to result in slight improved dimensional stability, as shown in Data Columns 3 and 4 of Table VI.
The epoxy component of this stabilizing primer coat is highly reactive and can participate in radiation-cured reaction mechanisms with additional molecules of identical primer epoxy components. The epoxy component can also react with the reactive diluent and with the hydroxyl groups of the base paper to form a stabilized, highly crosslinked network.
EXAMPLES 10-14
In addition to the above aromatic primer coat/diluent combination used in Examples 1-4, another aromatic primer coat/diluent combination has been found to provide substantially improved results. In particular, a primer coat made from Araldite 6010 ("the epoxy") and the reactive diluent, 4-vinyl cyclohexene monoepoxide, has been found suitable for the manufacture of stabilized paper substrates.
The aromatic-based primer coat used in these Examples was manufactured in accordance with the following specifications. To the formulations listed below, there was added 0.5 parts of a surfactant and 3.0 parts of a photoinitiator (50 percent in propylene carbonate). The surfactant is Surfynol 104E and the photoinitiator is Cyracure 6990, manufactured by Union Carbide, or a similar catalytic blend. As stated above, Cyracure 6990 is a combination of 50 percent triphenyl sulfonium hexaflurophosphate and 50 percent propylene carbonate:
Example 10, 100.0 parts epoxy, 0 parts of the reactive diluent 4-vinyl cyclohexene monoepoxide.
Example 11, 90.0 parts epoxy, 10.0 parts of this same reactive diluent.
Example 12, 80.0 parts epoxy, 20.0 parts reactive diluent.
Example 13, 70.0 parts epoxy, 30.0 parts reactive diluent.
Example 14, 60.0 parts epoxy, 40.0 parts reactive diluent.
Other reactive diluents believed to be suitable include Epodil 747, an aliphatic glycidyl ether, and Epodil 750, a diglycidyl ether of 1,4-butanediol. Both of these are available from Pacific Anchor Chemical.
After the formulations of these Examples 10-14 were blended in accordance with the instructions for the blending of the formulation of Example 1, they were tested to determine their efficacy. The primer coatings of Examples 10-14 were coated onto paper substrates at approximately 4 pounds per ream. Then, the hydroexpansivity tests like those discussed above were done to determine the suitability of the primer coat. The aliphatic primer coat proved to result in substantially improved dimensional stability, as shown in Data Columns 1 and 2 of Table VI.
TABLE VI__________________________________________________________________________Dimensional stability data are reported as % hydroexpansivity and aretheaverage of two replicates.Trial 1 humidity range: 16.0-84.5% rhTrial 2 humidity range: 20.0-85.0% rh40 BKGF (Bleached Densified Kraft) raw stock dimensional stability:0.98% Data Column 1 Data Column 2 Data Column 3 Data Columm 4 Dimensional Dimensional Dimensional Dimensional% VCMX Stability Stability Stability StabilityMono Function VCMX in VCMX in VCMX in VCMX inDiluent* 6010/Trial 1 6010/Trial 2 6110/Trial 1 6110/Trial 2__________________________________________________________________________ 0.0% M M 0.94% 0.92%10.0% 0.75% 0.68% 0.94% 0.88%20.0% 0.76% 0.74% 0.96% 0.94%30.0% M 0.70% 0.95% 0.96%40.0% 0.78% 0.74% 1.00% 0.94%__________________________________________________________________________ *4-vinyl cyclohexene, monoepoxide M = unavailable
The epoxy component of this stabilizing primer coat is highly reactive and can participate in radiation-cured reaction mechanisms with additional molecules of identical primer epoxy components. The epoxy component can also react with the reactive diluent and with the hydroxyl groups of the base paper to form a stabilized, highly crosslinked network.
Additional Testing On Compositions of Examples 5-14
Additional tests showed the suitability and improved results obtained with the primer coats of the invention. Particularly, the tests of Table VII were performed to determine moisture vapor transmittance.
TABLE VII______________________________________Moisture Vapor Transmittance data are reported as grams weightloss/square meter/24 hours. Numbers are an average ofthree replicates.Moisture vapor transmittance of 40BKGF rawstock = 1218 g/m.sup.2 /24 hrs. Data Column 3% VCMX Data Column 1 Data Column 2 Coughlin Primer(4-vinyl Moisture Vapor Moisture Vapor Acrylic Polymercyclo- Transmittance Transmittance Coated fromhexene) VCMX in 6010 VCMX in 6110 an Emulsion______________________________________ 0.0% 119.3 414.1 987 g/m.sup.2 /24 hrs. g/m.sup.2 /24 hrs. g/m.sup.2 /24 hrs. at 0% VCMX10.0% 219.9 414.120.0% 215.2 372.030.0% 215.2 332.240.0% 374.3______________________________________
This transmittance may be loosely correlated with dimensional stability of treated kraft paper. Data Column 2 of Table VII shows that aliphatic composition of Examples 5-9 provided higher vapor transmittance than the aromatic composition of Examples 10-14 shown in Column 1. The compositions of both Examples 5-9 and 10-14, however, provide vastly superior resistance over both (1) a prior art primer, as shown in Data Column 3 of Table VII, and (2) a 40 BKGF raw (primer-free) stock, as shown immediately above the Data Columns. The data in Data Column 3 of Table VII describes the results of coating raw stock with a primer from Coughlin, U.S. Pat. No. 4,533,600.
Tensile strength also improved, as demonstrated in Table VIII.
TABLE VIII__________________________________________________________________________Tensile data are reported as pounds/width at break point. Numbers arean average of 5-9 replicates.40 BKGF raw stock tensile data (MC/CD): 43.56/23.65 Data Column 1 Data Column 2 Data Column 3 Data Column 4% VCMX MD Tensile CD Tensile MD Tensile CD Tensile(4-vinyl Strength VCMX Strength VCMX Strength VCMX Strength VCMXcyclohexene) in 6010 in 6010 in 6110 in 6110__________________________________________________________________________ 0.0% 58.18#/in. 29.06#/in. 57.11#/in. 26.79#/in.10.0% 57.03 27.67 57.38 27.5020.0% 55.13 26.84 56.67 27.2430.0% 55.78 26.81 56.69 26.8240.0% 53.76 26.04 55.27 26.45__________________________________________________________________________
As indicated directly above the columns of this Table, raw stock showed a machine direction (MD) tensile strength of 43.56 pounds per inch width at the break point, and a cross direction (CD) tensile strength of 23.65 pounds per inch. Data Columns 1 and 2 of Table VIII show that the aromatic compounds of Examples 5-9 exhibited a minimum of 53.76 (MD) and 26.04 (CD) pounds per inch width at the break point. Data Columns 3 and 4 of Table III show that the aliphatic compounds of Examples 5-9 exhibited a minimum of 55.27 (MD) and 26.45 (CD) pounds per inch width at the break point. A comparison of these Data Columns 1-4 show that the tensile strength improvements resulting from coating with the aliphatic and aromatic compounds are generally similar in magnitude.
TABLE IX__________________________________________________________________________Release data are reported as grams release force/inch of widthand are the average of two replicates.Samples aged for 72 hours at 70° C. Samples tested at a strippingspeed of 90 ipm and a peel angle of 180°. Data Data Data Data Data Column 5 Column 1 Column 2 Column 3 Column 4 Release% VCMX Si Ct. Wt. Release Si Ct. Wt. Release VCMX in(4-vinyl VCMX in VCMX in VCMX in VCMX in Coughlincyclohexene) 6010 6010 6110 6110 Type Primer__________________________________________________________________________ 0.0% 0.3264#/R 16.2 0.5444#/R 21.7 Paper g/in. g/in. delamination10.0% 0.6094 23.8 0.6288 15.6 resulted20.0% 0.5784 11.5 0.5723 14.8 because30.0% 0.5758 20.6 0.5735 20.3 release value40.0% 0.6880 14.4 0.6479 20.4 was too high at 0% VCMX.__________________________________________________________________________ (Prime coat was coated at approximatety 4 lbs./ream on each side of the paper.)
A review of Table IX shows that the release values of the U.V.-cured prime coat-treated paper was well below the 35 gram per inch standard sought by the inventors. Particularly, the aliphatic-based primer of Examples 5-9 provides release forces of between 14.8 and 21.7 grams per inch of width. The aromatic-based primer of Examples 10-14 provides release forces of between 11.5 and 23.8 grams per inch. In contrast, as indicated in Data Column 5 of Table IX, the same type paper treated with a primer of the Coughlin type delaminated during a pull test.
In conclusion, the data of Tables VIII and IX demonstrate that aliphatic primer coats (Examples 5-9) result in both enhanced tensile strength and lowered release. Thus, these aliphatic primer coats provide improvements over prior art silicone release-type primers. It appears that the aromatic components of the primer coat have a greater influence on the dimensional stability of the base paper and on the ability of the base paper to minimize moisture vapor transmission.
While the specific embodiments have been illustrated and described, numerous modifications come to mind without markedly departing from the spirit of the invention. The scope of protection is, thus, only intended to be limited by the scope of the accompanying claims.
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The invention is a method of manufacturing a substrate and, particularly, of manufacturing a release paper. The method comprises coating a release paper base with a primer coat, and curing the primer coat. The cured primer coat is then overlayed with a heat-curable or an ultraviolet-curable silicone coating which is, in turn, cured with heat or ultraviolet light. A product manufactured in accordance with this method enables a facing adhered to this release paper to be removed relatively easily from that release paper.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 09/138,926, filed Aug. 24, 1998, now abandoned.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to low molecular weight polymers formed from monomers comprising ethylene, an alpha-olefin, and optionally a non-conjugated diene, and the use of such polymers to improve the dispersion of reinforcing agents into high molecular weight polymers.
[0005] 2. Description of the Related Art
[0006] U.S. Pat. Nos. 5,391,623 and 5,480,941 are directed to the preparation of masterbatch compositions of elastomers with a high concentration of aramid fibers distributed throughout the elastomer.
[0007] U.S. Pat. No. 5,527,951 is directed to catalysts for the polymerization of ethylene or the copolymerization of ethylene with alphaolefins and (optionally) nonconjugated polyenes.
[0008] U.S. Pat. No. 5,786,504 is directed to certain catalyst promoters in ethylene polymerization processes.
BRIEF SUMMARY OF THE INVENTION
[0009] In one aspect, the present invention relates to a polymer formed from monomers comprising ethylene; CH 2 ═CHQ wherein Q is C 1 -C 8 alkyl; and optionally a non-conjugated polyene; wherein
[0010] a) ethylene is present in an amount of from about 67% to about 75% by weight;
[0011] b) the non-conjugated polyene is present in an amount of from about 0% to about 30% by weight; and
[0012] c) CH 2 ═CHQ is present in an amount of from about 15% to about 40% by weight;
[0000] said polymer having a viscosity average molecular weight of from about 4,000 to about 30,000.
[0013] In another aspect, the present invention relates to a composition which comprises the polymer described above, and a reinforcing agent.
[0014] In yet another aspect, the present invention relates to a composition which comprises:
[0015] a) a polymer formed from monomers comprising ethylene; CH 2 ═CHQ wherein Q is C 1 -C 8 alkyl; and optionally a non-conjugated polyene; wherein
i) ethylene is present in an amount of from about 67% to about 75% by weight; ii) the polyene is present in an amount of from about 0% to about 30% by weight; and iii) CH 2 ═CHQ is present in an amount of from about 15% to about 40% by weight;
said polymer having a viscosity average molecular weight of from about 4,000 to about 30,000;
[0019] b) a reinforcing agent; and
[0020] c) a high molecular weight polymer.
[0021] In yet another aspect, the present invention relates to a moulded article made from the three part composition described immediately above.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The novel low molecular weight polymers of the present invention comprise ethylene, an alphaolefin, and optionally a nonconjugated polyene. Preferred alphaolefins include propylene, butene-1, pentene-1, hexene-1,3-methylpentene-1, heptene-1 and octene-1, with propylene being most preferred. Preferred nonconjugated polyenes include dienes such as 5-ethylidene-2-norbornene, 1,4-hexadiene and dicyclopentadiene. Preferably, the polyene component is present in an amount of from about 1% to about 20% by weight, more preferably from about 3% to about 15% by weight. Preferably, the alphaolefin component is present in an amount of from about 20% to about 35% by weight, more preferably from about 22% to about 30% by weight. The polymer has a molecular weight (viscosity average) in the range of from about 4,000 to about 30,000, preferably from about 5,000 to about 10,000. Most preferably, the polymer is a solid at room temperature, and yields about 10 mm or less in a needle penetration test as described in Example 1.
[0023] The polymerization of the monomers described above may take place in the presence of a catalyst composition which comprises a) a vanadium compound; b) an organo-aluminum compound; and c) a catalyst promoter. Suitable vanadium compounds include vanadium oxytrichloride, vanadium tetrachloride, vanadium acetyl acetonate, vanadyl bis-diethylphosphate, chloro neopentyl vanadate, and the vanadium-containing catalysts described in U.S. Pat. No. 5,527,951, the contents of which are incorporated herein by reference.
[0024] The organo-aluminum co-catalyst preferably is an alkyl aluminum or an alkyl aluminum halide, with chlorides being the preferred halides. Preferred alkyl aluminum halides include ethyl aluminum sesquichloride, ethyl aluminum dichloride, diethyl aluminum chloride, and diisobutyl aluminum chloride. Ethyl aluminum sesquichloride and diethyl aluminum chloride are most preferred.
[0025] Suitable catalyst promoters include halogenated esters such as butylperchlorocrotonate (BPCC), 4,4,4-trichlorobut-2-eneoate, 2-methyl-4,4,4-trichlorobut-2-eneoate, and other compounds known in the art and described in, for example, U.S. Pat. Nos. 5,527,951 and 5,786,504, the contents of which are incorporated herein by reference, with 2-methyl-4,4,4-trichlorobut-2-eneoate (MBEY) being most preferred.
[0026] Other suitable supported and unsupported polymerization catalysts would be readily apparent to one of ordinary skill, and include metallocenes, catalytically active titanium, zirconium, hafnium, chromium, etc.
[0027] The monomers may be polymerized in the following manner. The catalyst, co-catalyst, promoter, reaction medium and co-monomers are introduced into a reaction vessel. The molar ratio of the catalyst promoter to the vanadium in the vanadium-containing compound is, preferably, in the range of between about 3:1 and about 80:1, more preferably between about 6:1 and about 64:1, and most preferably between about 12:1 and about 48:1.
[0028] The molar ratio of the cocatalyst to catalyst plus catalyst promoter is, preferably, in the range of between about 0.5:1 and about 500:1, more preferably between about 1.5:1 and about 100:1, and most preferably between about 2.5:1 and about 10:1. The catalyst concentration can typically range between about 1×10 −8 and 3×10 −1 mole of vanadium per liter of total reaction medium.
[0029] The reaction medium is an inert medium such as, e.g., pentane, hexane, heptane, octane, isooctane, decane, benzene, toluene and the like, optionally in combination with liquid alphaolefins. The polymerization reaction is typically conducted in the liquid state at a temperature in the range of between about −25° C. and about 70° C., for a time which can vary from several minutes to several hours or more depending on the specific reaction conditions and materials, typically between about 15 minutes and 3 hours.
[0030] The best reinforcement of elastomeric materials occurs when there is a uniform, non-clumped dispersion of the reinforcing agent(s) in the elastomeric material, and the low molecular weight polymers of the present invention may be used to improve the dispersion of various reinforcing fibers into such high molecular weight polymers. According to the present invention, the reinforcing fibers are dispersed with the low molecular weight polymer to form a reinforcing composition. The low melting characteristic of the preferred low molecular weight polymers allows the liquification and wetting of the reinforcing fibers with much facility. The dispersion may be accomplished by means standard in the art, such as by blending on a rubber mill. The amount of reinforcing material which may be dispersed will vary according to the desired application and the nature of the materials used. In general, it is contemplated that blends of up to about 70% by weight of reinforcing agent will be particularly useful, with about 50% being particularly preferred. The reinforcing composition may subsequently be incorporated into a high molecular weight polymer.
[0031] The high molecular weight polymers which may be reinforced according to the present invention include both natural rubber and synthetic rubber compounds. Synthetic rubber compounds include, for example, ethylene/alphaolefin/nonconjugated polyene (EPDM) rubbers, styrene/butadiene rubbers, acrylonitrile/butadiene (NBR) rubbers, polychloroprene and sulfur modified polychloroprene, polybutadiene rubbers, etc.
[0032] Suitable reinforcing agents according to the present invention include aramid fibers (various lengths, short fibers or pulp; for example as disclosed in U.S. Pat. No. 5,391,623, the contents of which are incorporated herein by reference), cotton, polyesters, fiberglass, etc.
[0033] The masterbatch reinforced high molecular weight polymers of the present invention may be processed by well known means into, e.g., various types of reinforced belts, such as v-belts, timing belts, conveyor belts and drive belts; hoses; seals; diaphragms; cables; roll covers; etc., and may contain other conventional additives such as processing aids, antioxidants, antiozonants, etc.
[0034] The following non-limiting examples are illustrative of the processes and products of the present invention.
EXAMPLE 1
[0000] Preparation of Low Molecular Weight Polymer
[0035] Into a 3 liter stainless steel stirred autoclave (Buchi, Model BEP 280) with jacketed cooling, a dip tube for feeding ethylene, a thermocouple well, pressure gauge and ports for the introduction of hydrogen, propylene, and the catalyst components, were charged 110 grams of liquid propylene and 8.9 g of 5-ethylidene-2-norbornene (ENB). The temperature was set at 60° C. by cooling the jacket with water from a circulating water bath. 25 g of ethylene were then added to the reactor. A solution of 11.1 mmole of ethyl aluminum sesquichloride in 10 ml of hexane from a pressurized bomb was then added to the Buchi followed by enough hydrogen gas to raise the pressure to 270 psig. 43 ml of a hexane solution containing 0.281 mm of vanadium oxytrichloride and 1.31 mmole of MBEY promoter were pumped in continuously over the course of 20 minutes at an inlet pressure of 400 psi. The ensuing exotherm was controlled by the jacket cooling to maintain the temperature of 60° C. The pressure was maintained at 270 psig by feeding ethylene into the Buchi at a rate of 2.4 standard liters per minute to replace the ethylene which was being polymerized. A total of 57.3 g of ethylene was fed in 20 minutes.
[0036] The contents of the Buchi were then vented to remove unreacted monomer, and transferred to a two liter agitated pressure vessel (Chemco reactor) containing 200 ml of hexane, 0.1 grams of epoxidized soybean oil and 0.1 g of octadecyl 3,5-di-t-butyl-4-hydroxyhydrocinnamate (Naugard® 76, Uniroyal Chemical Co., Inc., Middlebury, Conn.) to deactivate the catalyst. The hexane/polymer mixture was then washed twice with 400 ml of deoxygenated water, allowing to settle and decant off the aqueous layer each time. The hexane was then removed by distillation leaving a low molecular weight ethylene-propylene-ENB terpolymer with the following characteristics: Mv=8,178; 24.6% propylene; 9.1% ENB; needle penetration (see below): 4.85 mm; yield: 85 g; efficiency: 1,759 grams per gram of catalyst.
[0037] Three commercial lots of polymer were prepared substantially as described above, and their properties were determined and listed in Table 1 below.
TABLE 1 Lot 5138/6 5138/7 5138/8 Plant Data Mv 1 7190 8210 8180 % ethylene 67 71 71 % diene 11 12.6 13 GPC @ 135° C., ODCB Mw 42,000 — — Mn 14,000 — — Mw/Mn 3.0 DSC-variable temp. Tg, ° C. −46 −41 −40 Tm #1, ° C. 0 21 18 Tm #2, ° C. none 43 43 DSC @ 190° C. OIT, min 4.5 Brookfield Vis. (cps, HBT #7) 100° C. 74,000 79,000 — 60° C. 670,000 408,000 — Note: — means not tested. 1 Mv is a determination of molecular weight by a viscometric method, in which a number average molecular weight is determined by measuring the increase in viscosity of a standard viscosity oil which results when the polymer is dissolved in the oil.
The polymers are pale yellow waxy solids at room temperature.
Needle Penetration Test
[0038] Since the hardness of a polymer has some relationship to the crystallinity, molecular weight and tack of the polymer, a needle penetration test can guage the suitability of the low molecular weight polymers of the present invention. The following is an adaptation of ASTM D 1321-95, “Standard Test Method for Needle Penetration of Petroleum Waxes.”
[0039] A polymer sample is heated to approximately 100° C. in a specimen container (a glass bottle having a one inch inside diameter and a minimum depth of 1.25 inches, filled to a depth of at least 0.75 inches) for one hour or until the sample is homogeneous and free of air bubbles. The container and contents are cooled to room temperature for 2 hours.
[0040] The specimen container is placed on the test shelf of a penetrometer, and the needle is adjusted so that the tip of the needle nearly touches the surface of the specimen. The needle indicator should be in the “zero” position and the total weights of needle and plunger should equal 100±0.15 g. Lock the movable assembly into position.
[0041] By means of the fine adjustment knob, the needle tip is brought to just touch the surface of the specimen, watching the reflection of the needle tip as an aid. When in place, the needle shaft is released and held free for 5±0.1 seconds, then re-locked. The indicator shaft is gently depressed until it is stopped by the needle shaft, and the penetration is read from the indicator scale.
[0042] The needle is cleaned with hexane to remove any adhering polymer, and the test is repeated three more times, repositioning the needle to a new location each time. The mean of the four penetrations is reported to the nearest 0.1 mm.
EXAMPLE 2
[0000] Blending of Low Molecular Weight Polymer with Aramid Fibers
[0043] A Brabender internal mixer was warmed to 80° C., and the desired amount of the polymer from Example 1 was added. When the polymer melted, the desired amount of aramid fiber (KEVLAR® merge 1F561 short fiber, DuPont, Wilmington, Del.) was added to the melted polymer, the polymer and fibers were mixed for ten minutes at 100 rpm, then allowed to cool and removed. The data for runs A-E are presented below in Table 2. Up to 50% by weight of aramid fibers were blended with the low molecular weight polymer.
TABLE 2 A B C D E Low MW 150 g 150 g 150 g 150 g 140 g polymer aramid 45 g 60 g 75 g 112.5 g 140 g fiber % fiber 23% 28.6% 33% 43% 50%
EXAMPLE 3
[0000] Triblending of Low Molecular Weight Polymer, Aramid Fiber and High Molecular Weight EPDM
[0044] In this example, four different blends of a low molecular weight polymer according to the present invention, aramid fiber, and a high molecular weight EPDM rubber were made. The low molecular weight polymer was added onto a cold 8″ rubber mill. Next, the aramid fiber was added slowly, while increasing the temperature to 150-200° F. The high molecular weight EPDM rubber (Royalene® 521, Uniroyal Chemical Company, Middlebury, Conn.) was added, the mill was cooled down, and the resulting triblend was stripped off. The various compositions are described in Table 3 below.
TABLE 3 Low mw polymer Aramid fiber EPDM Blend 1 40 g 40 g 85 g Blend 2 120 g 40 g 90 g Blend 3 80 g 40 g 80 g Blend 4 80 g 40 g 80 g
EXAMPLE 4
[0045] In this example, the rate of incorporation into an EPDM rubber of aramid fibers alone, and aramid fibers mixed with a low molecular weight polymer, are compared. A triblend was prepared as described in Example 3, which contained 33% aramid fiber. As a comparison, a 33% aramid fiber/high molecular weight EPDM blend was prepared as in Example 3, except that the low molecular weight polymer was omitted. It took 35 minutes to incorporate the aramid fiber into the high molecular weight EPDM, compared to 16.5 minutes to incorporate the aramid fiber/low molecular weight polymer into the EPDM, a time saving of 18.5 minutes (53%).
EXAMPLE 5
[0046] This example demonstrates a procedure for the dispersion of aramid fiber (100 grams of 1F 538 Kevlar®) into 100 grams of Neoprene GNA with the aid of a low molecular weight polymer (100 grams of Trilene® 77) on a rubber mill according to the present invention.
Time Temperature Comments 0 76° F. Start adding Neoprene 3′ 94° F. Masticate polymer-no peptizer 6′36″ 110° F. Start adding Trilene ® 77 11′ Start adding Kevlar ® slowly 13′30″ 108° F. 15′30″ Cool, no heat added, continue adding Kevlar ® 18′ 123° F. Warms up on addition of fiber 19′ Finish adding Kevlar ® 21′ 150° F. Add heat 23′ 190° F. Turn off steam, add cold water 25′ 140° F. 27′30″ 87° F. Finished, sheet off mill.
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Disclosed are low molecular weight polymers formed from monomers comprising ethylene, an alpha-olefin, and optionally a non-conjugated diene, and the use of such polymers to improve the dispersion of reinforcing agents into high molecular weight polymers.
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RELATED APPLICATION
[0001] This application claims priority to, and the benefit of, co-pending U.S. Provisional Application No. 60/328,528, filed Oct. 10, 2001, for all subject matter common to both applications. The disclosure of said provisional application is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a method and device suitable for storing and transporting animal semen, and more particularly to a method and disposable device for storing and transporting equine semen.
BACKGROUND OF THE INVENTION
[0003] A device for transporting equine and other animal semen was introduced to the equine breeding market in 1984 with the trade name “The Equitainer” (at least a partial description of which can be found in U.S. Pat. No. 4,530,816). Since that time, horse breeding by artificial insemination using transported chilled semen has become dominant in the equine breeding sector. The technique of slowly cooling the sample en route to its destination has been an important contribution.
[0004] The Equitainer is carefully engineered to give a repeatable and reliable cooling rate and final temperature that is substantially independent of external conditions. Although the performance of the Equitainer is good, the structure is relatively bulky and not inexpensive to produce. The cost of the Equitainer implies that the container must be returned to the shipper after use. In many cases, this can be inconvenient.
[0005] The conventional Equitainer achieves a required cooling rate by placing a sample in a conductive cavity, known as the Isothermalizer, and interposing a barrier between the sample and the coolant. This configuration determines the rate at which heat can be transferred between the coolant and the sample. The volume of the sample is then adjusted using thermal ballast, to result in a desired controlled cooling rate. The sample and coolant assembly is packaged inside a large insulated cylindrical container, and dispatched to the user. There is an initial cooling rate when the start temperature is at about 37° C. of close to −0.3° C./minute. The cooling continues slowly en route, down to a minimum temperature typically 6° C., depending on exterior conditions.
[0006] It has been shown and reported in the industry that the best results are obtained for horse semen fertility when the cooling rate at 20° C. is in the vicinity of −0.1° C./min. This is to avoid a high rate of change to the cell temperature at the temperature where the lipid cell membranes are changing phase. The low temperature rate of change likely allows the proteins in the cell surface time to crystallize in an orderly fashion and avoid cell damage. The Equitainer design was based on this finding.
[0007] In addition to the Equitainer, a number of other conventional devices use a process of convection to cool the sample contained within the device. With convection, cooled air transfers heat from the sample to the coolant. The sample is normally transported in syringes ready for insemination, and a thermal barrier is introduced between the coolant and the sample to adjust cooling rate. The thermal barrier used is typically a Styrofoam sheet with one or more notches cut out. The Styrofoam sheet is placed between coolant block and sample, so that air can flow through the notches as it convects. The coolant block is normally placed above the sample. Cool air then falls through the holes in the Styrofoam and cools the sample. The sample is placed in a foamed plastic box, next to the Styrofoam thermal barrier and the coolant block.
[0008] The convection system does not independently control cooling rate and final temperature. In addition, the convection system is sensitive to orientation. This is evidenced by the fact that the cooling rate is about twice as fast when the system is upright verses when it is inverted, representing the difference between air convection cooling and air conduction cooling. To make a system in which the cooling rate is independent of orientation, convective cooling cannot be used. The failure to maintain a uniformly controlled cooling rate can have negative effects on the success rates of equine insemination.
SUMMARY OF THE INVENTION
[0009] There is a need in the art for a disposable container with similar reliable cooling rate properties as the Equitainer, but with the added constraint that the materials and components required must not only produce accurate and repeatable results, but must be simple, disposable, and inexpensive. The present invention is directed toward further solutions to address this need.
[0010] In accordance with one embodiment of the present invention, a storage and transportation container for storing and transporting a semen sample is provided. The container includes an insulated box having at least a first portion being a box protruding ridge, at least a second portion being a box recessed groove, and a floor. An insulated cover is provided having at least a first portion having a cover recessed groove and being located to receive the box protruding ridge only when the insulated cover is placed on the insulated box in a predetermined orientation. The insulated cover also has at least a second portion having a cover protruding ridge and being located to be received into the box recessed groove only when the insulated cover is placed on the insulated box in the predetermined orientation. A cooling pack is disposed on the floor of the insulated box. An insert is disposed to rest on the cooling pack inside the insulated box, such that the cooling pack is beneath the insert when the insulated box is in an upright position. The insert has at least one chamber for receiving a storage capsule holding the semen sample. The insulated cover frictionally fits on the insulated box and makes contact with the insert to hold the insert in place. The insert makes sufficient contact with the cooling pack to enable conductive cooling of the semen sample in the insert.
[0011] In accordance with various aspects of the present invention, the insulated box and the insulated cover are formed of foam plastic, such as Styrofoam, or the like. Likewise, the insert can also be made of foamed plastic, such as polyethylene, or the like. The choice of material rests on insulation properties and relative cost.
[0012] In accordance with further aspects of the present invention, the at least one chamber is sized and dimensioned to hold a storage capsule suitable for holding the semen sample. The semen sample is equine semen. The storage capsule is at least one of a syringe and a tube.
[0013] The storage capsule can be sized and dimensioned differently, and can include sizes with volume capacities of 20 ml or 50 ml. The relative size of the storage capsule will affect the number of chambers required in the insert to hold the storage capsules. Since the total amount of material to be cooled will affect the cooling rate, thermal ballast can be added to the storage capsule, if necessary, to keep the total volume in the range of 80 ml to 120 ml in one example embodiment. The thermal ballast is typically water, contained in a suitable tube, initially at substantially the same temperature as the semen sample. Smaller capsules would result in more capsules being required and thus a plurality of chambers required in the insert. A sum of the capacity of the semen sample and the thermal ballast able to be stored in the at least one chamber according to one embodiment is about 90 ml to about 110 ml, or about 80 ml to about 120 ml. With such a semen sample quantity, a cooling rate of the semen sample in the insert is about 0.1° C./min at about 20° C.
[0014] In accordance with further aspects of the present invention a method of packing a semen sample for storage or transportation includes providing an insulated box having a floor. A cooling pack is placed on the floor of the insulated box. An insert is placed on top of and substantially in contact with the cooling pack, the insert having at least one storage capsule holding the semen sample disposed within at least one chamber of the insert. An insulated cover is placed on top of and in contact with the insert, the insulated cover having a friction fit with the insulated box.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention will become better understood with reference to the following description and accompanying drawings, wherein:
[0016] [0016]FIG. 1A is a front view of a disposable container, according to one aspect of the present invention;
[0017] [0017]FIG. 1B is a side view of the disposable container of FIG. 1A;
[0018] [0018]FIG. 2 is a chart plotting measured cooling rates for upright or inverted disposable containers, according to one aspect of the present invention; and
[0019] [0019]FIG. 3 is a graphic illustration of a mathematical model of a sample tube stored in the disposable container, according to one aspect of the present invention.
DETAILED DESCRIPTION
[0020] An illustrative embodiment of the present invention relates to a disposable storage container that includes an insulating box. Inside the insulating box, a plastic foam insert is provided. The foam insert has a plurality of drilled holes or chambers provided therein for storing sample syringes or tubes. When an equine semen sample is to be transported, the sample is placed in the sample syringe or tube. A block of cooling material is also disposed within the disposable storage container to initiate cooling of the sample, and maintain a desired cooled temperature for a predetermined duration.
[0021] [0021]FIGS. 1A through 3, wherein like parts are designated by like reference numerals throughout, illustrate an example embodiment of a disposable storage container according to the present invention. Although the present invention will be described with reference to the example embodiments illustrated in the figures, it should be understood that many alternative forms can embody the present invention. One of ordinary skill in the art will additionally appreciate different ways to alter the parameters of the embodiments disclosed, such as the size, shape, or type of elements or materials, in a manner still in keeping with the spirit and scope of the present invention.
[0022] [0022]FIG. 1A illustrates a front view of a disposable storage container 10 suitable for use in storing and transporting animal semen, especially equine semen. One of ordinary skill in the art will appreciate that the disposable storage container 10 can include a number of different variations.
[0023] The disposable storage container 10 is formed of an insulated box 12 . The insulated box 12 has four walls and a floor that are insulated. The insulation can take the form of, for example, a foamed plastic, e.g., Styrofoam insulation. An insulated cover 14 fits on top of the insulating box 12 , and can also be made of foamed plastic insulation. A friction fit between the insulated cover 14 and the insulated box 12 holds the insulated cover 14 in place. However, one of ordinary skill in the art will appreciate that an additional external fastening mechanism, such as a clasp or a circumferential band, can hold the insulated cover 14 on the insulated box 12 , if desired. In addition, the insulated cover 14 can fit on the insulated box 12 using a tongue and groove configuration, or the like.
[0024] A cooling pack 16 is disposed inside the insulated box 12 . The cooling pack 16 serves as the source for cooling the contents of the insulated box 12 . The cooling pack 16 can include any number of known cooling sources, such as, for example, ice, mixtures of water with other materials, or other phase-change coolants known to one of ordinary skill in the art, and the like.
[0025] An insert 18 is disposed inside the insulated box 12 on top of, and in physical contact with, the cooling pack 16 . The insert 18 can be made of such materials as plastic, foamed polyethylene, other foamed plastic, wood, and the like. The insert 18 can otherwise be referred to as an isothermalizer, which indicates that the insert 18 helps to regulate the temperature of its contents.
[0026] Although the materials of the insulated box 12 , the insulated cover 14 , and the insert 18 can vary, it should be noted that the relative cost of the materials is an important factor in determining which material to utilize, in addition to the relative heat transfer properties. A more expensive material will result in a more expensive storage container, which may prevent or make more difficult the characteristic of being disposable. As such, different variations to the materials utilized in manufacturing the storage container must take into consideration the relative cost, to ensure that the relative cost remains sufficiently low to maintain the disposability of the container.
[0027] The insert 18 includes a plurality of chambers 20 disposed within the insert 18 . The chambers 20 are each sized and dimensioned to accommodate one or more storage capsules in the form of a syringe or tube 22 , capable of holding a semen sample. The chambers 20 can be contained within the insert 18 , or can pass through the insert 18 , creating openings at two ends of the insert 18 . There are two chambers 20 illustrated, in FIG. 1A, but one of ordinary skill will appreciate that there can be a different number of chambers, limited in part by the size of the chamber 20 and the size of the insert 18 .
[0028] The syringe or tube 22 is suitable for containing and storing a desired amount of semen sample, such as equine semen, or thermal ballast, for an extended duration. The extended duration can be several days or more. Further, the syringe or tube 22 itself can be capable of storing the semen sample much longer, with the actual storage time being limited by the duration of the cooling effect provided by the cooling pack 16 on the semen sample. The syringe or tube 22 can be made of, for example, plastic, glass, composite, metal, and the like.
[0029] After preparation, the semen sample is diluted with extender, and the extended sample is placed into the sample containers in the form of the syringe or tube 22 . These are normally two 50 ml syringes, although two 20 ml syringes and one 50 ml (thermal ballast) tube may be used in accordance with one embodiment of the present invention. The equivalent 50 ml and 20 ml Falcon-type centrifuge tubes may also be used to contain the samples. One of ordinary skill in the art will appreciate that the size and shape of the syringe can vary to include a number of different sizes and shapes. In addition, as described below, the relative quantities of semen sample and thermal ballast disposed in the syringes or tubes 22 can also vary, depending on the amount of semen sample desired to be stored and transported.
[0030] A user places the cooling pack 16 inside the insulated box 12 of the disposable storage container 10 , on the bottom or floor of the insulated box 12 . The user then loads the insert 18 on top of the cooling pack 16 , in direct contact with the cooling pack 16 . The level of contact must be sufficient to enable conductive heat transfer from the cooling pack 16 to the semen sample, or the semen sample and thermal ballast, inside the syringe or tube 22 .
[0031] To close the insulated box 12 and seal the interior, the user places the insulated cover 14 of the insulated box 12 on top of the insert 18 . The insulated cover 14 limits movement of the insert 18 , by frictionally holding the insert 18 in place. The disposable storage container 10 is thus closed and sealed in preparation for extended storage and/or transportation.
[0032] The disposable storage container 10 uses the conductive flow of heat through the insert 18 to provide a required rate of cooling in the sample. In accordance with one embodiment, the dimensions of the syringe or tube 22 , insert 18 , and cooling pack 16 are carefully designed and tested so that the required cooling rate of 0.1°/minute is obtained at a temperature of 20°. The disposable storage container 10 does not rely on convective cooling to cool the semen sample; the disposable storage container 10 relies on conductive cooling. The reliance upon conductive cooling translates to an insensitivity toward orientation of the disposable storage container 10 . The disposable storage container 10 may be turned upside-down, sideways, right-side-up, or in any other orientation during transportation, and there will be a negligible effect on the cooling rate and the final temperature inside the disposable storage container 10 at the location of the semen sample.
[0033] An example disposable storage container 10 was constructed. In the example embodiment, the sample volume was set to 100 ml. The materials were then selected to achieve an appropriate cooling rate and final temperature for the 100 ml semen sample. The insert 18 was constructed of polyethylene foam (weight 1.5 lb/cu ft). The insert 18 was about 2.0 inches thick, with a width of 4 inches and a length of 5 inches. The chambers 20 disposed in the insert 18 were arranged so that the body of the syringe or tube 22 fit snugly into the space of the chamber 20 with a friction fit. The conductivity of the foam is sufficient to provide the correct required or optimum cooling rate of 0.10±0.03° C./minute at 20° C., as well as the final temperature in the required range 5° C.-9° C., according to the desired parameters for this example.
[0034] The insulated box 12 of the disposable storage container 10 has an internal shape designed such that the coolant pack 16 fits on the base of the insulated box 12 without significant movement sideways. The walls of the insulated box 12 have a shape such that the insert 18 stays in place laterally, but can still slide down vertically into the insulated box 12 to make contact with the cooling pack 16 . The insulated box cover 14 keeps slight positive pressure on the top of the insert 18 , which in turn rests on the cooling pack 16 . Thus, all of the components are held in place.
[0035] The entire disposable storage container 10 fits into a cardboard box (not shown) for transportation. The cardboard box serves to hold the insulated cover 14 of the insulated box 12 firmly in place when in a closed position. To prevent ambiguity in the correct positioning of the insulated cover 14 on the insulated box 12 , the top of the insulated box 12 has a projecting box ridge 24 , which fits into a cover slot 26 in the insulated cover 14 (tongue and groove). On the opposite side of the insulated box 12 , the situation is reversed. A cover ridge 28 on the insulated cover 14 fits into a box groove 30 on the top of the insulated box 12 . In this way, the insulated cover 14 can only be placed on the insulated box 12 in one orientation, which locks the insulated cover 14 into place, and ensures that all of the components are properly held in place within the insulated box 12 .
[0036] Experiments were performed on the disposable storage container 10 constructed in accordance with this disclosure to determine a rate of cooling within the disposable storage container 10 at about 20° C. One parameter of the experiment was that a cooling rate of about 0.1° C./min at 20° C. should be obtained. A second parameter of the experiment was that a total of 100±10 ml of semen sample plus thermal ballast (if necessary) should be in the syringes or tubes 22 . In the example embodiment constructed, the insert 18 was designed such that the cooling rate for this volume of sample would achieve the desired 0.1° C./min at about 20° C.
[0037] The thermal ballast is placed in the insert 18 , adjacent the semen sample or samples, to provide a predetermined thermal inertia that must be cooled by the cooling pack 16 . The dimensions, locations, and materials of each of the components making up the disposable storage container 10 are designed to work with a selected thermal inertia total. If the quantity of the semen sample is less than that required for the selected thermal inertia, the thermal ballast is added to the insert to achieve the required thermal inertia. Further details concerning the application of the thermal ballast can be found in U.S. Pat. No. 4,530,816, which is hereby incorporated by reference herein.
[0038] It should be noted that for lower amounts of semen samples, substantially the same thermal behavior is obtained if a ballast tube containing water, initially at substantially the same temperature as the semen sample, is placed in the insert 18 . Thus, for two 20 ml semen samples, an additional ballast tube containing 50 ml of water would be added to insert 18 . A ballast tube is simply a storage capsule in the form of the syringe or tube 22 , filled with something other than a semen sample, such as water. The amount of thermal ballast will vary to accommodate the desired total amount of sample and ballast required for the particular storage container configuration. The ballast tube creates additional thermal energy to be transferred to the cooling pack 16 , such that the overall thermal burden placed on the cooling pack 16 is within design parameters for the particular container configuration and cooling pack 16 size.
[0039] It should also be noted that for different amounts of semen samples and/or thermal ballast, one of ordinary skill in the art will appreciate that different sizes of the components of the disposable storage container 10 will be required. More specifically, a disposable storage container suitable for storing and transporting an amount of semen sample and/or thermal ballast greater than about 100 ml to 120 ml, will require a thinner insert. In this way, the same cooling rate for the larger thermal mass of extended-semen-plus-ballast is obtained, by reducing the thermal resistance of the insert. Contrarily, a disposable storage container suitable for storing and transporting an amount of semen sample and/or thermal ballast less than about 80 mil to 100 ml, will require an insert having higher thermal impedance. The specific dimensions provided herein are based on a given parameter of 100 ml of semen sample or semen sample and thermal ballast in total.
[0040] A sample temperature was measured using a calibrated electric thermistor, located inside one of two 50 ml tubes 22 . The tubes 22 were initially loaded with water at about 40° C., and then loaded into the insert 18 . The insert 18 was then loaded into the insulated box 12 on top of the cooling pack 16 . The temperature measurements were plotted to create a cooling curve representing the starting temperature, ending temperature, and rate of cooling.
[0041] The design of the example embodiment disposable storage container 10 was tested in practice by measuring the exact cooling curves of samples loaded into the insert 18 , when the disposable storage container 10 was placed in two different orientations. In a first orientation, the disposable storage container 10 was positioned upright. In a second orientation, the disposable storage container 10 was positioned inverted or upside-down. The cooling rates, illustrated by cooling curves shown in a plot 32 in FIG. 2, were then compared. The resultant experimental cooling curve obtained with the example disposable container 10 being upright (labeled “Upright” in the figure) has a substantially identical slope to the resultant experimental cooling curve obtained with the example disposable container 10 being inverted (labeled “Inverted” in the figure). More specifically, the curves between 37° C. and 10° C. are indistinguishable. Both indicate a cooling rate close to 0.1° C. at a temperature of about 20° C. This indicates that the cooling rate for the sample in the upright position was substantially identical to the cooling rate for the sample in the upside-down position.
[0042] The use of the insert 18 enables a cooling rate independent of orientation. Inversion of the unit provides a cooling curve, which is indistinguishable from that for the upright unit over the critical transition near 20° C., as would be expected. The insert 18 , therefore, allows a properly controlled thermal regime for the sample during transportation.
[0043] It should be noted that the sample syringes or tubes 22 are in a thermal gradient, which is normal to the tube axis. A characteristic of the insert 18 is that the sample syringe or tube 22 rapidly becomes adequately isothermal, as its cooling proceeds. A mathematical model of the sample syringe or tube 22 in the insert 18 is shown in a plot 34 in FIG. 3. The external temperature is taken as 22° C. in the calculation, and the temperature of the cooling pack 16 as taken as 0° C. Finite element analysis has been used to solve the time-dependent thermal conduction differential equation.
[0044] In FIG. 3, isotherms 36 are shown for a time 105 minutes after loading the disposable storage container 10 with the sample, corresponding to a sample temperature near 22° C. The heat equation, as understood by one of ordinary skill in the art, is solved using the appropriate thermal conductivity for the polyethylene foam and for the (mainly aqueous) sample in this example. It should be noted that in the geometry chosen, with cooling in a direction perpendicular to the sample syringe or tube 22 axis, the sample itself remains almost isothermal across the syringe or tube 22 during the cooling process, despite the high thermal gradient in the insert 18 . This is due to the relatively high thermal conductivity of the sample.
[0045] The exemplified geometry for the insert 18 and for sample cooling sufficiently maintains a uniform temperature in the semen sample. The cooling rate for the semen sample is close to the ideal value for equine semen, as well as giving a final temperature between about 5° C. and 9° C.
[0046] One of ordinary skill in the art will appreciate that the present disclosure includes example embodiments for implementing the invention for the storage and transportation of equine semen. The temperature ranges provided for final temperatures and for cooling rates are representative of what is currently known to be optimal for the storage and transportation of equine semen. However, it is understood that additional experimentation may reveal different optimal temperature ranges and rates of cooling. The present invention can be modified to accommodate such different temperatures and rates of cooling, by modifying the dimensions and materials of the insulated box, the cooling pack, the insert, and the insulated cover. In addition, the characteristics of the resulting disposable storage container can be altered to accommodate optimal temperature ranges and rates of cooling for non-equine semen, such as for canine, bovine, or other semen that may require storage and transportation.
[0047] Numerous modifications and alternative embodiments of the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the best mode for carrying out the present invention. Details of the structure may vary substantially without departing from the spirit of the present invention, and exclusive use of all modifications that come within the scope of the appended claims is reserved. It is intended that the present invention be limited only to the extent required by the appended claims and the applicable rules of law.
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A container for storing and transporting semen, e.g., equine semen, along with a corresponding method of packing the container, is provided. The container is formed of an insulated box and an insulated cover. The insulated box and insulated cover each includes a collection of ridges and recesses to create a friction fit between the two that will only work with the insulated cover being placed on the insulated box in a predetermined orientation. A cooling pack is disposed on a floor of the insulated box. An insert is disposed to rest on the cooling pack inside the insulated box, such that the cooling pack is beneath the insert when the insulated box is in an upright position. The insert has at least one chamber for receiving a storage capsule holding the semen sample. The insulated cover frictionally fits on the insulated box and makes contact with the insert to hold the insert in place. The insert makes sufficient contact with the cooling pack to enable conductive cooling of the semen sample in the insert, regardless of orientation of the container. The materials forming the container are sufficiently inexpensive to consider the container disposable.
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RELATED APPLICATION
[0001] This patent arises from a continuation of U.S. application Ser. No. 13/961,633, filed Aug. 7, 2013, which is a continuation of U.S. application Ser. No. 13/446,739, filed Apr. 13, 2012, which is a continuation of U.S. application Ser. No. 12/353,928, filed Jan. 14, 2009, now U.S. Pat. No. 8,170,708, and claims priority to U.S. Provisional Application Ser. No. 61/020,941, filed on Jan. 14, 2008. The entireties of U.S. application Ser. No. 13/961,633, U.S. application Ser. No. 13/446,739, U.S. application Ser. No. 12/353,928, and U.S. Provisional Application Ser. No. 61/020,941 are hereby incorporated by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to the production of embroidery designs on embroidery sewing equipment and, more particularly, to managing the various colors of thread used to produce such designs.
BACKGROUND
[0003] Modern embroidery is commonly created on sewing equipment that pairs a sewing mechanism with a means for synchronously moving a textile beneath that sewing mechanism. More specifically, a textile is moved in forward, back, left, or right directions while the sewing mechanism embeds stitches of thread within that textile having locations dictated by the aforementioned movements. Thus, as the process progresses a pattern of stitching emerges that is designed to represent a particular image or graphic. Embroidered designs are quite common on a wide variety of garments or products such as baseball caps, sweaters, or golf shirts. Furthermore, these designs are often produced such that they contain a variety of different thread colors to best represent the aesthetics of the graphic being depicted. For example, an embroidery design depicting the image of a basketball might use orange thread stitching to depict the round circular area of the ball and then use smaller black thread stitching to depict the outline and other black lines that are present within the ball's image. Thus, two different thread colors, orange and black, are utilized to create embroidery representing the basketball design. As designs become more complex or sophisticated, designs may require an even greater number of different thread colors. In fact, many embroidery designs may require more than a dozen unique colors of thread to be produced, where each different part of the design is embroidered using a different thread color.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 : Example of a single head embroidery machine showing components where spools of thread are held on spindle stand and spindles marked 101 & 102 respectively. Other parts are marked as points of reference.
[0005] FIG. 2 : Side view of example single head embroidery machine with components labeled as in FIG. 1 .
[0006] FIG. 3 : Enlarged view of the upper thread stand and area where spools of thread are depicted as sitting on top of the thread stand spindles. Certain elements such as some of the spiral tubes, thread stand spindles, etc. are not depicted to allow a better view of components that would otherwise be obscured. In this example, although the thread stand is capable of holding 15 spools of thread, only 8 spools are shown. The numbers in parenthesis indicate the thread guide holes for which each spool's thread should initially travel (e.g. the first spool 1 travels through hole 1 , etc.).
[0007] FIG. 4 : Diagram of FIG. 3 shown as it would appear with the right most spool of thread removed and with multiple ID readers installed (see embedded ID reader 409 and power/data cables 410 ).
[0008] FIG. 5 : Depicts appearance and construction of a typical spool of thread from side and bottom view perspectives.
[0009] FIG. 6 : Summarizes the flow of information and some of the physical processes that occur during use of the thread spool sensing system.
[0010] FIG. 7 : Depicts a process for scheduling embroidery designs for production on a set of embroidery machines.
[0011] FIG. 8 : Depicts post processing steps utilized in the context of the process illustrated in FIG. 7 .
[0012] FIG. 9 : Describes and provides examples of computing color differences between sets of thread colors.
[0013] FIG. 10 : Depicts a process of re-sequencing embroidery designs which have been scheduled to occur on an embroidery machine.
DESCRIPTION
[0014] Modern embroidery equipment exists to easily produce multiple thread color designs by allowing more than one thread color to be loaded onto the equipment at a single time. In fact, many machines allow 6 or more different spools of uniquely colored thread to be placed on the equipment allowing it to automatically transition to embroidering with a different thread color at varying times during the production of a design. However, it is impractical for such embroidery equipment to hold (or have loaded) an unlimited number of thread colors and modern embroidery equipment usually does not allow more than approximately 15 unique thread colors to be loaded at a single time. This instigates an issue where from a potentially infinite palette of colors, thread manufactures have created many hundreds of unique thread colors, no more than a very limited set of those colors can be loaded onto embroidery equipment at a single time (e.g. perhaps 15 thread colors at once). Subsequently, producing designs that use a larger number of thread colors than can be loaded onto equipment is significantly more difficult or impractical. Furthermore, if one embroidery design requires a specific subset of thread colors to be loaded onto the machine, a different embroidery design may require a different subset of thread colors. While those two subsets of thread colors may overlap (i.e., both subsets may contain a black thread color for example), the differences in the subsets will require certain spools of thread to be removed from the equipment so that new spools of different colors may be loaded such that the different embroidery design may be produced.
[0015] Within many typical manufacturing environments the subset of thread colors loaded onto embroidery equipment is constantly changing to meet the requirements of the specific embroidery designs being produced. For example, if an embroidery machine can only hold two different thread colors at once and is producing a basketball design that uses orange and black colored thread, if the next design is one of a baseball design requiring white and red colored thread, both the black and orange colored threads must be removed from the machine and replaced with white and red colored threads before that baseball design may be produced.
[0016] The replacement of a thread color currently loaded onto a machine with a different new thread color is typically a manual process whereby a machine operator (i.e., a person in charge of running the equipment) must remove a spool of thread currently sitting within a holder and threaded into the mechanics of the equipment and then put a new spool of thread in its place such that it then feeds into those same mechanics. There are a variety of techniques that may be employed to facilitate this change including tying off the end of the new thread to a remnant of the old thread still contained within the mechanics of machine such that the new thread may be manually pulled through the mechanics using the old thread remnant. Regardless of the specific technique, it is a manual process involving human intervention and time. As such, human error and efficiency can become significant factors throughout this process. One such error that may occur is when the machine operator replaces a thread spool with one of an incorrect color. The machines themselves typically have no mechanism to detect what color thread has been loaded onto them. Thus, if an operator were to mistakenly load red thread onto a machine instead of black thread, for example, the embroidery design would contain red stitching where there should be black leading to output which is substantially flawed. Another drawback of human intervention is that a machine may actually need to sit idle while thread colors are changed, thereby reducing the overall efficiency of the production environment.
[0017] Described here are methods and systems designed to improve the efficiency with which thread colors are managed while also reducing the possibility of human error. The preferred embodiment employs a combination of both hardware and software based methods to achieve these goals and the description that follows begins by explaining the hardware and mechanical attributes. Referring to FIG. 1 , an embroidery machine typically holds spools of thread using some organization of spindles ( FIG. 1 , parts 101 & 102 ). FIG. 2 shows a side view of the same machine where one can more easily see how a spool of thread is placed on a thread stand spindle 202 . Once on the spindle, the thread travels through thread guide(s) 203 , a sub thread regulator 204 , a spiral tube 205 , a thread tension regulator 206 , and through other parts of the machine until ultimately it is threaded through the eye of the sewing needle, which enables the thread to penetrate the product being embroidered. The specific path that thread takes after being pulled off of the spool by the mechanics of the machine is not significantly relevant to the methods, systems, or apparatus presented here, but does provide a general context for the specification.
[0018] The methods and apparatus presented here involve the area of an embroidery machine that holds the spools of thread. FIG. 3 provides a closer view of this area of the example machine illustrated in FIGS. 1 and 2 . As shown, spools of thread 331 are placed on the thread spool stand over the spindles discussed previously. Examples of where thread flows from these spools is indicated by the dotted line thread paths 307 . Each spool typically contains a different color of thread. The example machine depicted here is capable of holding up to 15 spools whose thread eventually becomes threaded through 15 needles within another part of the machine. The needle number that thread is ultimately threaded through is commonly referred to as that thread color ‘position’ on the machine. For example, red thread may be placed on needle one while blue thread might be placed on needle seven. Here, the needle number also indicates the spindle on which the related thread spool is placed. In FIG. 3 , the spool in the furthest back left position relates to needle 1 where its thread flows through the hole labeled ( 1 ) within the thread guide. Subsequent holes are labeled ( 2 ) through ( 15 ) and lie overhead the location where a spindle and spool of thread may be placed. Hence, a direct correlation between needle numbers and numbers that may be assigned to thread spool spindles may be easily made.
[0019] Knowing what thread color is associated with which needle position is important information when considering how an embroidery design is to be produced. Specifically, the machine needs to know which needle to switch to at a given point during production to ensure use of the proper thread color at that point. If an embroidery design requires many different thread colors, the machine will have to switch to many different needle positions during the design's production. As noted previously, specifying which needles to switch to during production (or alternatively specifying which needle positions contain which colors) has typically been a manual process where a human operator typically enters this information via computer or keypads located near the equipment. This human intervention can be substantially eliminated by enabling the embroidery machine to automatically detect what thread colors corresponded to different needle positions (i.e., different thread spool spindles). As described in greater detail below, this can be accomplished by placing sensors around the thread spool spindles to allow thread spools to be automatically identified as they are placed on the machine.
[0020] Specifically in one example described herein, small radio frequency identifier (RFID) readers are embedded in a circular foam base that sits beneath each thread spool spindle. Referring to FIG. 4 , the foam pad 408 is seen with a small embedded ID reader 409 which is connected via power/data cable 410 through a hole in the foam. This cable may then easily travel through a small hole in the thread spool stand to allow its connection to a microcontroller or other interface easily mountable on the underside of the thread spool stand. Furthermore, each of the 15 thread stand spindles will have this same assembly installed beneath it in similar fashion. Thus, in this case, 15 short range RFID readers are installed corresponding to the 15 thread stand spindles. Their connection to a microcontroller or other interface enables the detection of radio frequency tags within the proximity of those readers. Specifically, an RFID tag (e.g. in the form of a small sticker) can be placed on the inside of each spool of thread that might be placed on the machine. The tag, when in the vicinity of the RFID reader, will transmit a unique identifying number to the reader that is received by a microcontroller or other interface and subsequently matched against a known list of identifying numbers to ascertain exactly which spool of thread is within the proximity of the RFID reader at a particular thread stand spindle. Of course, this presumes that thread spools have had these RFID tags previously affixed to them and that information has been recorded that relates the identifying number emitted by each tag with the particular spool's thread color to which it has been affixed. Furthermore, when the microcontroller or other interface receives unique identifying numbers, it accesses this information so that the thread color of the spool of thread placed on the spindle may be deduced.
[0021] FIG. 5 shows the appearance and construction of a typical spool of thread from side and bottom view perspectives. The thread, which often may be composed of either natural or man-made fibers, is wound around a cone-like construct typically made of some type of molded plastic. Hence, every spool of thread has two primary parts: the actual thread as well as the plastic construct around which it is wrapped. When viewed from the bottom, many hollow areas may be seen within this plastic construct including the long tube-like void at its center that allows it to be placed on a thread stand spindle. It is underneath the spool, typically within one of these hollow areas, where it is easiest to place a uniquely identifying tag, in this case, a small round shaped sticker constructed of thin PVC (polyvinylchloride). Once tags are place on the thread spools, for example, after having procured them from a thread manufacturer or distributor, each spool may be individually placed near a sensor that detects the tags identifying number and allows a user to correlate that number with the color of thread that is on the spool. These correlations are most easily stored within an electronic database after which all of the thread spools may be stored as general inventory for the manufacturing facility. When the spools are pulled from inventory and placed on an embroidery machine, the previously affixed tags enable the machine (with the modifications previously described) to deduce or determine and transmit what color thread is present on specific spindles or needles of the machine. This information subsequently allows appropriate needle position movement instructions to be sent to a machine automatically without human involvement so that related embroidery designs are produced using the correct combination of thread colors.
[0022] An embroidery design to be produced on an embroidery machine typically exists as an embroidery data file that is transmitted to the machine prior to its production. This data file typically stores a sequence of two-dimensional Cartesian coordinates (specified as pairs of x,y values) that indicate the sequence and location of needle penetration points (i.e., stitches) within the design. Also, because embroidery designs often consist of more than a single thread color, this data file usually has what are referred to as color change commands intermingled within the sequence of coordinates that indicate the precise moment in the stitching sequence when the thread color should change. Another type of useful information commonly stored within the embroidery data file is the specific sequence of thread colors that should be used to create the design. These thread colors may be represented within the file in a variety of different ways including but not limited to their related red, green, and blue color value components or specific thread manufacturer's model numbers. Regardless, the specified color sequence combined with the presence of color change commands within the sequence of coordinate positions is enough information to determine which needles or thread colors should be transitioned to at which specific points during the embroidery design's production provided that it is known which spindle or needle positions contain the specified thread colors. Thus, this again illustrates the usefulness of the system which automatically detects the thread colors placed on individual spindles versus requiring human intervention to manually specify a correlation.
[0023] FIG. 6 summarizes the flow of information and physical processes that occur during use of the thread spool sensing system. Note that microprocessor or other interface 661 represents the example hardware and software systems that may be used to act upon the digital signals that are transmitted or received here. This item 661 may typically exist in the form of a dedicated microcontroller, a general purpose Personal Computer, or a combination of two or more such devices. However, any other device capable of accepting and generating digital signals as specified via basic software instructions could be used to implement the example methods and apparatus described herein.
[0024] FIG. 6 also refers to telemetry information 667 which is data transmitted by an embroidery machine that indicates various aspects of its current state of operation. Typically, embroidery machines are capable of digitally transmitting a wide variety of data for use or monitoring at another location (for example, on the screen of a nearby personal computer). This data may include things like the number of stitches that remain to be sewn within the embroidery design currently being produced or if a sensor has detected that a thread break has occurred. In addition to these types of data, the machine may now also transmit the ID numbers of thread spools that have been placed on the machine and when a thread spool is changed (i.e., the operator replaces a thread color spool with a new one), the machine can provide notification of such changes as part of the telemetry data being continuously transmitted.
[0025] Another method developed considers that a manufacturing environment may consist of one or more embroidery machines producing a continuous stream of varied embroidery designs where the thread color requirements may be different for each design. Here, computer-implemented methods are developed to optimize such production by scheduling embroidery designs to be produced on specific machines in specific orders such that the amount of time and human intervention required to manage thread colors (e.g. replacing thread spools with other spools of different colors, etc.) is reduced. In developing such methods, there are two dominant factors considered. First, given a sequence of embroidery designs to be produced, the thread colors required by each design can be evaluated and compared to the thread colors required by the other designs. More specifically, an arbitrary ordering of embroidery designs to be produced on a particular machine may be generated. Then, the number of times any thread spool is required to be replaced (i.e., due to a design needing a different thread color that is currently not present on any spindle of the machine) is counted. This count, referred to as the spool change count, consists of the total number of replacements that would have occurred during the production of all embroidery designs in the sequence. It should be noted that if the embroidery designs where produced in a different sequence, a different spool change count could result. For example, producing all the designs whose thread colors are already present on one or more of the spindles of the machine first, before producing designs requiring different thread colors could ultimately lead to a much lower spool change count. Thus, all possible orderings of a particular set of embroidery designs could be generated where the spool change count is computed for each ordering. If the ordering chosen for actual production of the design is the one whose spool change count was lowest, this indicates fewer spools of thread will need to be changed which yields a potential reduction in the amount human operator time/labor required to change thread spools. It may also be useful to consider other metrics other than the total spool change count, to evaluate the optimality of a chosen ordering of embroidery designs. These other metrics may include the minimum, maximum, and average number of thread spools that must be changed between the productions of each embroidery design in the sequence. Incorporating the evaluation and reduction of such statistics further ensures that any significant delay between the productions of individual embroidery designs is reduced.
[0026] The second major factor to consider is that in a production environment with multiple embroidery machines, different machines may have different sets of thread colors currently loaded onto their spindles. Hence if within the set of embroidery designs to be produced, one can schedule designs to be produced on machines that already contain all (or a majority of) the thread colors needed by those designs versus scheduling them on machines that do not have all or a majority of the thread colors needed, the spool change count for the individual machines may be reduced further. Here again, all combinations of running a given set of designs on the given set of machines can be determined where the resultant minimum spool change count may then be computed as described previously for each machine. Then, the combination (i.e., a production schedule) that yields the lowest total spool change count (i.e., the spool change count when the counts for all machines are summed together), may be chosen to yield a reduction in the amount of time spent changing thread spools. Additionally, the reduction of other statistics as previously mentioned, may also be used to choose the preferred combination.
[0027] A competing factor to consider when scheduling designs to be produced among multiple embroidery machines is a situation that may occur when disproportionate amounts of production are scheduled to occur on a particular machine or subset of machines. In this case, other machines may be left dormant or running at less than their full operating capacity in terms of producing embroidery designs. Thus, even though a particular production schedule may significantly reduce the amount of time needed to change thread spools, it may increase the amount of time needed to actually produce the set of embroidery designs since all of the machines are not being fully utilized. This, in turn also can increase labor costs because a human operator typically must be present to monitor the equipment until production completes and it also has the undesirable consequence of reducing the overall throughput of the manufacturing environment. Hence, it is important to balance the need to have evenly utilized embroidery machines with the goal of reducing overall thread spool change counts.
[0028] Evenly utilizing embroidery machines in a production environment means maintaining that each machine always has an embroidery design to produce and that machines are not sitting dormant (i.e., not producing embroidery designs) while other machines have a backlog of designs waiting to be produced. Utilization can be largely predicted by understanding how much time it takes to produce a particular design on an embroidery machine. More specifically, the production time needed to produce any particular design on an embroidery machine may be approximated by factors that include the number of stitches in the design and the speed at which stitches are produced on the machine, as well as the number of trims, needle changes, jumps or other more singular events that are specified to occur during the design's production and typically require fixed or predictable time periods. For example, the amount of time required to perform a thread trim may be 5 seconds, whereas if 3 thread trims will occur during a design's production, this will effectively add an additional 15 seconds of production time. In general, a design's production time may be accurately predicted prior to it actually being produced on an embroidery machine.
[0029] Other, less significant factors that may affect the amount of time required to change thread spools or otherwise manage thread color on equipment include: the location at which a spool of thread currently resides on a machine, the likelihood that a thread color being removed will be needed again for subsequent designs in the near future (beyond the current sequence/schedule of designs), etc. These factors may also be considered when developing optimal methods for scheduling the production of a set of embroidery designs. For example, when a thread spool must be removed from a machine, it may often be feasible to do so while the machine is actually running (i.e., during the production of an embroidery design) such that the machine does not actually have to sit idle during the thread spool change process. However, when doing this, it is often easier and faster when the corresponding needle for which the thread color is being changed is not adjacent or near a needle that is currently sewing (e.g., moving up and down) on the machine. The nearby moving needle makes it more difficult for the operator to thread the new color and also increases the likelihood of bodily harm during the process. Hence, adjusting the sequence of embroidery designs to be produced can be done with a preference such that needle colors that must be changed do not lie close to needles that would be necessary or active in producing immediately preceding designs. Thus, the operator may change the thread colors on such needles while the machine is still producing one or more preceding designs. In general, a computer-implemented method can be further devised that instructs the machine operator when to change thread spools based on these factor after a preferred ordering or scheduling of the designs has been computed. This instruction of the operator may also be further based on whether or not a color to be removed from the machine would be necessary for any still yet unproduced parts of an embroidery design currently being generated or the likelihood of it being needed for future designs.
[0030] The preferred embodiment for developing a production scheduling or ordering of embroidery designs on a set of one or more embroidery machines relies on the concept of clustering. The general concept is focused on means by which similar items within a data set may be grouped or clustered together, where similarity may often be defined differently depending on the types of items contained within such a data set. This concept is applied here where data set items are references to specific embroidery designs to be produced and similarity between designs is measured by how similar their thread colors are (i.e., if they share a minimal subset of necessary thread colors they are considered more similar). FIG. 9 illustrates how one such similarity metric (referred to as color difference) may be computed. Once a similarity metric is chosen (sometimes referred to as a difference metric) a matrix may be formed that computes the similarity or difference between all pairs of items within the data set. Standard clustering algorithms may then be employed to group similar items together. Causing designs that are similar in color to be scheduled to run on the same embroidery machine should result in a grouping that necessitates fewer thread spool changes because all designs in the group are very similar in color.
[0031] FIGS. 7 and 8 describe a computer-implemented method by which designs may be scheduled (i.e., clustered) on a set of embroidery machines balanced against the factor of maintaining high utilization of all available equipment as described previously. Initialization of computer-implemented data structures begins in blocks 701 and 721 . Specifically, for each design to be scheduled, the number of unique thread colors required by that design as well as its estimated production time is computed and stored (i.e., block 701 ). Additionally, for each machine within a set of machines for which production should be scheduled, a unique sequential number is assigned to identify the machine and a production time of zero is specified to indicate that no designs have been scheduled on the machine yet; hence the machine is currently estimated to be spending 0 time producing designs. Block 722 then determines the thread spool colors that are currently residing on each machine and adds them to an ordered set of “necessary colors” for each machine. This set of “necessary colors” indicates the thread colors currently made available to the machine to produce embroidery designs (and not necessarily just the colors that are currently residing on the machine). The ordered set of “necessary colors” corresponding to each machine may change (e.g. increase or decrease) as the computer-implemented method is executed.
[0032] After block 701 , all designs are initially considered to be unscheduled which means that they have not yet been assigned to any particular machine for production. Block 702 may annotate one or more designs such that they become scheduled to run on a particular machine within the set of available embroidery machines. Annotation effectively involves marking a reference to the design with the unique number that was assigned to the machine (in Step 721 ) on which the design is scheduled to be produced. The annotation process also includes appending a reference to the design in a computer-implemented queue data structure that corresponds to the related embroidery machine. Block 702 first annotates designs that best match a machine's “necessary color” set which means the color difference (as defined in FIG. 9 ) between an embroidery design's set of unique colors and a particular machine's “necessary color” set is the lowest of all designs that could be scheduled on any particular machine. If a single design's color difference is identical when computed relative to two or more different embroidery machines (i.e., a tie exists in the best match values computed), the design is not annotated in this step.
[0033] For each design annotated, block 703 contributes any unique thread colors required by the design to the ordered set of “necessary colors” corresponding to the machine on which it was scheduled, if such colors are not already contained within the set. Additionally, block 704 adds each annotated design's estimated production time to the related machine's production time on which it has been scheduled. When designs are annotated, block 703 may effectively increase the number of items in the “necessary colors” set maintained for each machine and potentially affect best match values computed for still unassigned/un-annotated designs. Thus, if any designs were newly annotated causing a change in related machines' “necessary colors” sets, block 705 will trigger a return to block 702 of the method such that unassigned designs may attempt to be annotated based upon those machines' updated “necessary colors” sets. If no designs were newly annotated (i.e., no increases in “necessary colors” sets were realized), block 705 allows continuation to block 706 , which checks if there are any designs that have still not been annotated yet. If all designs have been annotated, block 708 is executed which subsequently continues to the post-process method described in FIG. 8 . Alternatively, if some designs are still not annotated yet, each unassigned/non-annotated design could be matched to one of several machines within the set of available machines since an identical best match value was computed for each such machine. Thus, block 707 picks one such unassigned design, and annotates it with the machine number within the set of machines whose best match values were identical and whose related production time is the shortest. This has a desirable benefit of giving a preference to scheduling designs on under-utilized machines when an equally good choice may be made in terms of thread color management constraints. After annotating a design in block 707 which potentially affects a set of “necessary colors” for the related machine, the method returns to block 703 .
[0034] FIG. 8 illustrates the post process method referenced previously in the overall scheduling method and within FIG. 7 . This method is invoked after all designs have been scheduled to occur on one or more machines within the total set of available machines. The method is used to make load-balancing adjustments such that designs scheduled to be produced on one machine may be ultimately shifted to instead occur on a different machine, such that each machine's production time is relatively equal and all machines are well utilized. To determine if such adjustments are even necessary, block 801 first compares machines' relative estimated production times to see if they are approximately equivalent (i.e., each machine would be running for approximately the same amount of time—within a specified margin). If so, the method will complete its execution as indicated in block 802 . Otherwise, block 803 evaluates all designs within the queue associated with the machine whose estimated production time is longest. More specifically, block 803 finds a referenced design that when moved to a machine with a significantly shorter production time (i.e., re-annotated and scheduled to occur there) causes the smallest increase within that different machine's “necessary colors” set. Note that this is synonymous with the color difference between the design's color set and the “necessary colors” set for the related machine being comparatively minimal. Once such a design is found, block 804 moves the reference to the design to the new machine's queue (the one with the shorter production time), re-annotating the design appropriately and adding colors to that machine's “necessary colors” set as needed as well as increasing that machine's production time by an amount equal to the estimated production time for the design. Block 805 then rolls-back the annotation of all designs that were referenced after the moved design in the longest production time machine's queue. Here, the roll back process for each design includes removal of the annotation (i.e., machine assignment), removal of the reference to the design in the machine's related queue, and removal of any entries within the “necessary colors” set that were resultant from the design's original annotation. After the roll-back step, the method returns to block 702 (as indicated in block 806 ) because there may now exist non-annotated designs within the input set of designs to be scheduled, that must be re-processed.
[0035] After the clustering methods described previously (and illustrated in FIGS. 7 and 8 ) complete, machines will each have corresponding queues that contain references to the embroidery designs that have been slated for production on them. At this point, a machine's queue contains such embroidery designs in the order in which the previously described clustering method placed them there. However, as discussed before, even the ordering in which a set of designs are scheduled to run on a single machine can have a significant impact on the spool change count or other factors relative to the cost of managing thread colors on that machine. Since the current orderings resultant from the clustering methods' application may not be optimal, a re-sequence process is now performed that is intended to address such issues.
[0036] FIG. 10 illustrates a computer-implemented re-sequence process which adjusts the order that designs are scheduled to be produced on a particular machine. This re-sequence process is executed for each machine referencing two or more designs within its related queue. The process begins with block 1001 , which moves all references to embroidery designs within the machine's queue to a new temporary list. Hence, the machine's queue is then empty with all references to the designs now residing within the temporary list. Additionally, block 1001 specifies an initial “machine color set,” which is a set of unique thread colors where the number of colors in the set is a constant number equivalent to the number of thread spindles (or needles) present on the related embroidery machine. This set of colors is initially specified to contain the thread spool colors currently residing on the embroidery machine. This “machine color set” will potentially be modified during the course of the re-sequence method.
[0037] Block 1002 computes and assigns a color difference value (using the method illustrated in FIG. 9 ) for each design referenced within the temporary list and the colors contained within the “machine color set.” The block also records the minimum color difference computed among all designs referenced within the temporary list. Block 1003 then chooses a design, among all designs that were assigned that minimum color difference within the temporary list that requires the greatest number of unique thread colors. For example, if design A uses colors red, blue and green, and design B uses just yellow and blue, but both designs have a minimum color difference of 0, design A is chosen because it contains 3 colors versus the 2 colors contained within design B. Ultimately, the chosen design is then moved out of the temporary list and back into the machine's queue of scheduled designs at the end of block 1003 .
[0038] If the design chosen in block 1003 had a minimum color difference greater than 0, this is an indication that not all colors required by the design were contained within the “machine color set”. Thus, block 1004 modifies the machine color set such that it contains all of the colors necessary to produce the chosen design. The modification here may require that one or more thread colors contained within the “machine color set” are removed such that an equal number of new thread colors may be added. For example, if the color difference value was equal to 1, this indicates that one existing color in the “machine color set” must be removed so that one new color may be added. The choice of what color should be removed is based on which existent color in the set is used the least among the designs remaining in the temporary list. For example, a color that is used by only one design within the temporary list would be removed before a color that is used by two designs within that list.
[0039] The re-sequence method then repeats and continues to execute until all designs within the temporary list have been removed and added to the machine's queue as indicated by block 1005 . The fact that the method favors designs with greater numbers of colors for earlier scheduling on the machine is a useful heuristic that in most practical circumstances helps further reduce thread spool change requirements during production. The use of such heuristics is beneficial particularly when the original number of designs referenced is large enough that the computational requirements of testing all possible orderings of embroidery designs (as discussed previously) becomes less feasible. Furthermore, the use of the color sensing apparatus described where the placement of colored thread spools on a machine's spindles are automatically detected and tracked, further facilitates many of the methods elaborated upon here and helps provide a comprehensive solution to managing embroidery thread colors in both large and small embroidery production environments.
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Systems, methods, and apparatus for embroidery thread color management are disclosed. An example method comprises determining a set of thread colors needed for a set of embroidery designs including a first embroidery design and a second embroidery design, annotating the second embroidery design, the annotating comprising appending a reference to the second embroidery design in a first queue of designs to be embroidered by a first embroidery machine, and rolling back the annotation of the second embroidery design. The rolling back comprises removing the annotation, removing the reference, and removing a thread color from the set of thread colors, the thread color resulting from the second embroidery design.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a memory device including a parallel test circuit, and more specifically, to a memory device including a parallel test circuit which overcomes a channel deficiency phenomenon of test equipment by reducing the number of input/output pads.
2. Description of the Prior Art
In general, data should exactly be read or written in a semiconductor memory device such as a dynamic RAM. For the exact read/write operation, even one defective cell should not exist on a chip. However, as the number of cells integrated in one chip increases more and more due to high integration of the semiconductor memory device, the number of defective cells may also increase in spite of improvement of the manufacture process. If the exact test is not performed on these defective cells, the reliability of the semiconductor memory device cannot be secured.
Although it is important to perform a reliable test on devices, a high speed test can also be performed on a great number of cells. Specifically, since reduction of improvement period and test time of a semiconductor memory device directly affects cost of products, the reduction of test time has been the main issue manufacture companies.
When one cell is tested to distinguish pass or fail of cells in a memory chip of a semiconductor memory device, the test of the highly integrated memory device takes much time and causes increase of cost.
As a result, a parallel test mode is used to reduce the test time.
When the same data are read after the same data are written in a plurality of cells, the parallel test determined pass or fail of the cells with an exclusive OR logic circuit. The value of the logic operation is “1” to determine pass of the cells if the same data are read, and the value of the logic operation is “0” to determine fail of the cells if the different data are read, thereby reducing the test time.
FIG. 1 is a diagram illustrating a parallel test structure of a conventional memory device. Here, a parallel test of a 4×32 DRAM is exemplified.
Referring to FIG. 1 , since the fail cells are repaired in a half bank unit HALF 0 -A, HALF 0 -B, HALF 1 -A, HALF 1 -B, HALF 2 -A, HALF 2 -B, HALF 3 -A, and HALF 3 -B, a parallel test block 1 compresses data of half banks HALF 0 -A, HALF 0 -B, HALF 1 -A, HALF 1 -B, HALF 2 -A, HALF 2 -B, HALF 3 -A, and HALF 3 -B at a parallel test mode, and outputs the compressed data to input/output pads DQ 0 , DQ 1 , DQ 2 , DQ 3 , DQ 4 , DQ 5 , DQ 6 , and DQ 7 . Here, the parallel test measures a lot of dies in one test equipment.
As a result, the large number of dies can be measured when four input/output pads DQ are used to reduce the number of channels in the test equipment than when 8 input/output pads DQ are used in the test equipment. However, since data compressed in one bank unit are outputted through four input/output pads DQ, the repair operation is required to be performed simultaneously in one bank unit, thereby reducing the efficiency of the repair operation.
SUMMARY OF THE INVENTION
It is an object of the present invention to maintain repair efficiency at a parallel test mode and to reduce the number of input/output pads DQ.
In an embodiment, a memory device including a parallel test circuit comprises a burst length regulating block, a parallel test block, an output block and a plurality of input/output pads. The burst length regulating block sets a second burst length at a test mode which is longer than a first burst length at a normal mode. The parallel test block compresses data by a repaired unit and tests the compressed data. The output block sequentially outputs data outputted from at least two or more parallel test blocks depending on the second burst length. The plurality of input/output pads externally output data outputted from the output block.
BRIEF DESCRIPTION OF THE DRAWINGS
Other aspects and advantages of the present invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:
FIG. 1 is a diagram illustrating a parallel test structure of a conventional memory device;
FIG. 2 is a diagram illustrating a parallel test structure of a memory device according to an embodiment of the present invention;
FIG. 3 is a block diagram illustrating an output unit of FIG. 2 ; and
FIG. 4 is a block diagram illustrating a burst length regulating circuit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described in detail with reference to the accompanying drawings.
FIG. 2 is a diagram illustrating a parallel test structure of a memory device according to an embodiment of the present invention.
Referring to FIG. 2 , since a repair operation is performed in a half bank unit at a parallel test mode, a parallel test block 1 compresses data of half banks HALF 0 -A, HALF 0 -B, HALF 1 -A, HALF 1 -B, HALF 2 -A, HALF 2 -B, HALF 3 -A, and HALF 3 -B, and outputs the compressed data. Here, two data outputted from one bank, that is, a pair of half banks HALF 0 -A and HALF 0 -B are sequentially outputted through one input/output pad DQ 0 . Here, an output unit 2 having a pipe latch scheme sequentially outputs two data outputted from one bank to the input/output pads DQ 0 , DQ 1 , DQ 2 , and DQ 3 .
Here, a burst length (hereinafter, referred to as “BL”) twice longer than a BL at a normal mode is required to be set at the parallel test mode.
As a result, since one bank, that is a pair of half banks, can be tested through one input/output pad DQ, the number of input/output pads DQ can be reduced without reducing the repair efficiency. Therefore, the number of dies which the test equipment can test simultaneously can be increased.
Meanwhile, if the structure according to an embodiment of the present invention is applied while the number of input/output pads DQ used at the test mode is maintained, the repair efficiency can be increased twice. That is, the repair operation can be performed in a quarter bank unit.
FIG. 3 is a block diagram illustrating the output unit 2 of FIG. 2 . Here, the output unit 2 has a pipe latch scheme.
The output unit 2 comprises two register chains 4 , two transmission switches 6 and an data output buffer 8 .
The register chain 4 comprises a plurality of registers 5 a , 5 b , and 5 c connected serially. One data HB 0 A of half banks HALF-A is inputted in one first register 5 a of the two register chains, and the other data HB 0 B of HALF-B is inputted in the other first register 5 a.
The transmission switch 6 sequentially transmits data from the final register 5 c to an data output buffer 8 . That is, data HB 0 A and HB 0 B are alternately transmitted at a rising edge of the clock signal CLK.
FIG. 4 is a block diagram illustrating a burst length regulating circuit. Here, the BL regulating circuit regulates a BL at a test mode to be twice longer than a BL used at a normal mode.
A first BL regulating unit 10 comprises an inverter IV 1 and a NOR gate NR 1 . The NOR gate NR 1 performs a NOR operation on a test mode signal TM and a signal obtained by inverting a first normal BL control signal BL 1 in the inverter IV 1 , and generates a first test BL control signal BLT 1 . Here, the first normal BL control signal BL 1 sets a BL as “1” at the normal mode.
As a result, at the normal mode, if the first normal BL control signal BL 1 is activated to a high level to set the BL as “1”, the first test BL control signal BLT 1 is activated to a high level to set the BL as “1”. Since the test mode signal TM is activated to a high level at the test mode, the first test BL control signal BLT 1 is inactivated to a low level regardless of the first normal BL control signal BL 1 .
A second BL regulating unit 12 comprises an inverter IV 2 , and NAND gates ND 1 ˜ND 3 . The first NAND gate ND 1 performs a NAND operation on a second normal BL control signal BL 2 for setting the BL as “2” at the normal mode and a signal obtained by inverting the test mode signal TM in the inverter IV 2 . The second NAND gate ND 2 performs a NAND operation on the test mode signal TM and the first normal BL control signal BL 1 . The third NAND gate ND 3 performs a NAND operation on output signals from the NAND gates ND 1 and ND 2 , and generates a second test BL control signal BLT 2 .
As a result, at the normal mode, the first test BL control signal BLT 1 is activated by the first BL regulating unit 10 to set the BL as “1” if the first normal BL control signal BL 1 is activated, and the second test BL control signal BLT 2 is activated to set the BL as “2” if the second normal BL control signal BL 2 .
At the test mode, if the first normal BL control signal BL 1 is activated, the second test BL control signal BLT 2 is activated to set the BL as “2”.
A third BL regulating unit 14 comprises an inverter IV 3 , and NAND gates ND 4 ˜ND 6 . The fourth NAND gate ND 4 performs a NAND operation on a third normal BL control signal BL 4 for setting the BL as “4” at the normal mode and a signal obtained by inverting the test mode signal TM in the inverter IV 3 . The fifth NAND gate ND 5 performs a NAND operation on the test mode signal TM and the second normal BL control signal BL 2 . The sixth NAND gate ND 6 performs a NAND operation on output signals from the NAND gates ND 4 and ND 5 , and generates a third test BL control signal BLT 4 .
As a result, at the normal mode, the second test BL control signal BLT 2 is activated by the second BL regulating unit 12 to set the BL as “2” if the second normal BL control signal BL 2 is activated, and the third test BL control signal BLT 4 is activated to set the BL as “4” if the third normal BL control signal BL 4 is activated.
At the test mode, if the second normal BL control signal BL 2 is activated, the third test BL control signal BLT 4 is activated to set the BL as “4”.
A fourth BL regulating unit 16 comprises an inverter IV 4 , and NAND gates ND 7 ˜ND 9 . The seventh NAND gate ND 7 performs a NAND operation on a fourth normal BL control signal BL 8 for setting the BL as “8” at the normal mode and a signal obtained by inverting the test mode signal TM in the inverter IV 4 . The eighth NAND gate ND 8 performs a NAND operation on the test mode signal TM and the third normal BL control signal BL 4 . The ninth NAND gate ND 9 performs a NAND operation on output signals from the NAND gates ND 7 and ND 8 , and generates a fourth test BL control signal BLT 8 .
As a result, at the normal mode, the third test BL control signal BLT 4 is activated by the third BL regulating unit 16 to set the BL as “4” if the third normal BL control signal BL 4 is activated, and the fourth test BL control signal BLT 8 is activated to set the BL as “8” if the fourth normal BL control signal BL 8 .
At the test mode, if the third normal BL control signal BL 4 is activated, the fourth test BL control signal BLT 8 is activated to set the BL as “8”.
A fifth BL regulating unit 18 comprises an inverter IV 5 , and NAND gates ND 10 ˜ND 12 . The tenth NAND gate ND 10 performs a NAND operation on a fifth normal BL control signal BL 16 for setting the BL of the normal mode as “16” and a signal obtained by inverting the test mode signal TM in the inverter IV 5 . The eleventh NAND gate ND 11 performs a NAND operation on the test mode signal TM and the fourth normal BL control signal BL 8 . The twelfth NAND gate ND 12 performs a NAND operation on output signals from the NAND gates ND 10 and ND 11 , and generates a fifth test BL control signal BLT 16 .
As a result, at the normal mode, the fourth test BL control signal BLT 2 is activated by the fourth BL regulating unit 16 to set the BL as “8” if the fourth normal BL control signal BL 8 is activated, and the fifth test BL control signal BLT 16 is activated to set the BL as “16” if the fifth normal BL control signal BL 16 .
At the test mode, if the fourth normal BL control signal BL 8 is activated, the fifth test BL control signal BLT 16 is activated to set the BL as “16”.
As discussed earlier, in a memory device including a parallel test circuit according to an embodiment of the present invention, since the number of channels in each die of the test equipment can be reduced, the test time is also reduced.
Additionally, the repair efficiency can be increased when the number of input/output pads is maintained at a parallel test mode.
While the invention is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and described in detail herein. However, it should be understood that the invention is not limited to the particular forms disclosed. Rather, the invention covers all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined in the appended claims.
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A memory device including a parallel test circuit can overcome a channel deficiency phenomenon of test equipment by reducing the number of input/output pads. The memory device including a parallel test circuit comprises a burst length regulating block, a parallel test block, an output block and a plurality of input/output pads. The burst length regulating block sets a second burst length at a test mode which is longer than a first burst length at a normal mode. The parallel test block compresses data and tests the compressed data by a repair unit. The output block sequentially outputs data outputted from at least two or more parallel test blocks depending on the second burst length. The plurality of input/output pads externally output data outputted from the output block.
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This application is based on previous application Ser. No. 60/343,081 bearing date Oct. 27, 2001 and is a continuation in part of our application Ser. No. 10/090,125 of Mar. 1, 2002 now abandoned entitled A System for Dispensing Viscous Materials.
BACKGROUND
This invention pertains generally to pressure actuated dispensers, applicators and devices for application of fluid materials, and more particularly to an apparatus which is part of a system which allows conventional dispensing devices to be adapted or modified such that a variety of materials in varying quantities may be dispensed from or applied by a single dispensing device.
Various types of dental materials are dispensed from some form of dispensing apparatus (Dragon U.S. Pat. No. 5,061,179). This may facilitate a more ergonomic action or in the case of dental composites, ease of placement. This placement may be enhanced visually by the apparatus or it may be used to overcome a drawback of the material itself. Such is the case with many of the light cured resins currently in use.
To increase strength, micron sized particles are incorporated into the resin such that when the composite is cured in the tooth, it is esthetically satisfactory and will be able to withstand the chewing forces. Today it is common to have filler content over 80%. Delivery of the material is commonly done with a hand actuated dispenser modified to magnify hand pressure as much as 5 times. Such dispensers are coupled with a cartridge filled with the appropriate material for the task. These cartridges usually are friction fit to the proximal end of the dispenser as a convenience factor. The cartridges are mostly uniform in their circumference, however their length may vary. The opening of the distal end contains a plug that when pushed along the longitudinal axis by part of the dispenser expresses the material from the proximal end of the cartridge. Such orifices may vary in size of opening and the length of the cannula that is part of the cartridge may also vary in length.
Owing to the resistance of flow by the very highly filled composites, the orifice of the cartridge can be greater than 3 mm. Multiple handheld devices that magnified the force necessary to overcome the resistance due to viscosity were patented (Kunkel, et al., U.S. Pat. No. 5,871,354). Patents on the size, shape and orifice opening of the cartridge were issued. In each case it was in overcoming the viscosity problem that drove the research. While the industry tried to market these combinations as convenience items, it noted that there was a problem of placing these materials so as not to have voids, incompletely cured resins and uncovered surfaces.
Dental composite materials are mixtures of liquid resins and suspended particles. Light wavelengths of sufficient energy to cause a reaction are introduced to allow the resin to cure producing a sufficiently strong material to withstand the chewing forces of the mouth. Many types of light sources are used but the nature of the material preclude the immediate setting throughout as with a two part chemical set resin system. The initial set starts at the area with the most intense light energy, creating a shrinkage as the material cures to the greatest mass. This occurs regardless of the intensity or wavelength of the light source.
This effect has led to open margins in the first instance which is entirely due to the chemistry of the material. In the second instance, the inability to deliver the material equally to all parts of the preparation, owing to its size, complex shape (angles, undercuts, etc), and location in the mouth are an operator shortcoming. The second instance may be attributed to the viscous nature of the material. The primary obligation of the procedure is to cover the margins such that a completely cured composite material leaves no gaps, voids or uncured material which may lead to recurrent decay.
To facilitate such coverage, reduce the total shrinkage to an acceptable level, and produce a completely cured resin, the manufacturers recommend a layering technique. Operator technique deficiency, owing to the viscous nature of the material, can incorporate voids that will alter the strength and optical properties of the cured material. To overcome the high probability of open margins, the industry introduced a flowable composite with more liquid resins and less filler. This material is placed at the interface of the tooth and retainer (should one be needed) or the floor and sides of the preparation. These flowable composites can be introduced with a cannula as small as 25 ga or smaller.
Again, these flowable composites were initially meant to close margins and reduce the overall shrinkage factor. Operator error is introduced in the use of these materials when bubbles are introduced by the manipulation of the cannula or when too much of the material is introduced into the preparation. More volatile diluents in the resins are incorporated to increase the flow (Klee, et al., U.S. Pat. No. 5,876,210, pps. 13, 14). This action reduces the strength and creates greater shrinkage. There is a decided increase in the vapor pressure that occurs when the material goes from room temperature (approximately 72° F.) to body temperature (98.6° F.), thereby creating tiny bubbles. Any area where there is oxygen present will create an oxygen inhibited layer causing uncured resin that remains uncured.
The overall intent of the manufacturers in their product and its delivery is to wet the surface of the tooth with the resin, primarily to help seal and have a homogeneous material against the tooth surface that will, when cured correctly, produce a restoration of sufficient strength to withstand the chewing forces to prevent breakage.
Patents have been issued that deal with the nature of all viscous materials, dealing with orifice openings, size and shape of the material carrier (cartridge, capsule) (Bender, U.S. Pat. No. 5,707,234), means of multiplying forces necessary to overcome the viscosity and size, shape and mechanical properties of the cartridge holder used to dispense such materials. None have been issued where the resistance to flow caused by the viscosity is overcome by applying controlled heat at the point of delivery (generating heat within the capsule itself). Such heat must be applied within a specific range to take advantage of the optimal flow given to the resin component of the mixture. Such heat range must not in any way alter the chemistry or any of the other desirable properties of the material when in a plastic state or when converted to a cured state.
This invention overcomes all the disadvantages of forcing a viscous material through a small opening by altering the plasticity of a mixture by applying controlled heat allowing a component of the mixture to become fluid.
The advantages to such a method and delivery system include: (1) reduction of voids owing to more consistent placement due to increased flow; (2) greater wetting of the surface of the tooth with the resins in a more liquid state; (3) ease of delivery (a) less force required (b) smaller delivery tips for better visualization; (4) less volatile diluents required, yielding grater strength and less shrinkage; (5) use of longer chain resins for greater strength; (6) ability to incorporate a filler content to 90% and above without compromising the flow using a standard dental hand delivery syringe; (7) the manipulation of the chemistry of the resins such that heating within controlled parameters will deliver the appropriate delta energy to initiate a self-cure; and (8) allow for a two-component system to exist in a premixed state in the same cartridge without setting or degrading prior to intended use until the appropriate delta energy is applied.
SUMMARY OF THE INVENTION
The invention provides for a delivery system where a viscous material such as dental composite is heated by an induction field or by resistance to an electric current. The system comprises at the proximate end a capsule-like cartridge that is self-heating. The capsule may be fabricated of any number of heat conducting polymers or doped polymers that are susceptible to induction fields or any material that will heat when an induction current is applied. In the second instance the capsules may have a resistance wire of the appropriate metal or any other material to allow heating of the capsule when a current is applied. In the third instance the capsule may have an induction coil embedded in its wall combined with any type of metal or other material where this becomes the heating device when current of the appropriate nature is applied. In the fourth instance a thin film or foil may be applied to either the outer surface or the inner surface of the capsule such that when a current is applied the foil or film heats and in so doing heats the capsule and the contents.
Coupled with the above described capsule is a delivery device. This hand held device whether powered manually or electrically forces a shaft to engage a piston embedded within the cartridge to move forward, dispensing the material within the cartridge at its proximal end. In the manually powered mode an electrical power source, whether a battery, capacitor discharge or AC/DC current, is used exclusively to activate the various heating methods described above. In the electrically powered mode, a linear stepper motor or other such motor with a proper configuration allows the shaft to engage the piston embedded in the cartridge and allow the material contained within the cartridge to be dispensed at its proximal end. In the electrically powered configuration the power source described above is used to power the motor as well as the energy to activate the various heating elements described above. In addition such device may have the induction coil embedded in the barrel extension of the device in such placement as to provide adequate heating of the capsule. We have found it very effective that the induction coil heat the piston, which therefore may be made in whole or in part of material such as iron which, when subjected to electromagnetic energization.
The present invention is system and carrier for the delivery of dental materials, primarily composite materials (but not limited to such materials), where the viscosity of the material is changed and other properties of the material is enhanced by the addition of a controlled heat.
The system and carrier is located at the proximal end of a hand held syringe (placement device) that provides, either by digital manipulation or a linear step motor or other type electrical motor, a force necessary to deposit a determined amount of a dental material (composite) into the tooth preparation. The placement device is electrically powered, either by battery or AC current, to activate in the first instance an induction coil that will cause the carrier of the material to heat, thereby reducing the viscosity prior to placement. In the second instance the carrier (carpule) itself is the resistance to the current thereby heating the carrier, reducing the viscosity of the material in the carrier prior to placement.
The carriers of the materials (carpules) can be of any size and shape such that it be of an advantageous nature to allow for the proper visualization. Many types of standard carpules are available to fit various handles (syringes, “guns”). Most of these carpules hold approximately ½ gram of a light-cured composite. Various materials currently on the market will allow a standard polymer material to be manufactured to meet the specifications allowing the temperature of the carpule to be raised over a carefully selected temperature.
Advantages of the heatable carpules (and or carrier of any size) is that the need for multiple types of composite materials is eliminated. One very highly filled material will suffice. The orifice openings of the carpule can be reduced, such that more accurate placement of the material can be accomplished. The properties of the resin are enhanced from both a chemical standpoint and their ability to wet the tooth surface. Strength and optical properties are enhanced by allowing a much higher filler content unencumbered by the detrimental viscosity to such materials. Adding controlled heat at the point of placement will allow different chemical composition to be manufactured such that the composite material can be manufactured where a two part resin can be incorporated into the same carrier and by adding additional energy (delta 2 ) a dual cure can be accomplished (chemical and light cure). Since the carpules may be made of a standard size, they can be used without the enhanced embodiment in the standard syringes available on the market.
Of particular importance is the necessity of having a continuous, controlled heat of the material, especially at the orifice. This is to overcome the rapid cooling of the extruded material. Composites by their nature have a low specific heat. Previous methods while using heat sources failed to recognize the nature of the material, such that over time continuous heating will alter the chemistry of the composite resin. This alteration will produce a material that becomes lumpy or produces aggregate particles that will alter the finished product. This is evidenced by altered color, strength and wear characteristics.
The advantage of the method in this application is rapid heating to a precisely controlled heat content of the material with rapid delivery such that the physical and chemical properties are not altered.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of the dispensing device and cartridge that comprises the system in accordance with the present invention.
FIG. 2 is a fragmentary enlarged top view of the anterior portion of the connection of the dispensing device with the cartridge.
FIG. 2A is a view similar to FIG. 2 , but showing an alternative embodiment.
FIG. 3 is a cross sectional view of the rear of the cartridge showing the electrical connections and the recesses for the mechanical connections of the cartridge with the proximal end of the barrel of the dispensing device.
FIG. 4 is an angular view, partly broken away, of the cartridge showing the embedded metal ribs of one of the preferred cartridges in accordance with the invention.
FIG. 5 is an angular view, partly broken away, showing the embedded resistance coil along with the electrical connection, and mechanical connection, as one embodiment of the cartridge in accordance with the invention.
FIG. 6 is a side elevational view of the cartridge.
FIG. 7 is a cross-sectional view of the cartridge.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention will now be disclosed in detail with the aid of the embodiment of FIGS. 1 through 7 .
FIG. 1 shows an ejector holder of a type especially designed to hold in an operative position a cartridge in conjunction to form a system that embodies the principles of the present invention. The holder comprises a barrel ( 1 ) having an interior bore ( 2 ) extending from a rearward end ( 3 ) toward the forward end ( 4 ) thereof for receiving a plunger ( 5 ) of the same diameter as that of the interior bore ( 2 ) for the major portion of the length of the plunger. The forward end of the plunger has a smaller diameter extension ( 6 ).
The rearward end ( 3 ) of the barrel ( 1 ) extends through the handle member ( 8 ). The barrel ( 1 ) has a flange ( 7 ) that is located in a recess of the handle ( 8 ) that is perpendicular to the barrel ( 1 ). The barrel is then free to rotate within this recess ( 14 ). Connected to the flange ( 7 ) of the barrel ( 1 ) is an electrical connection ( 26 ) such that when the barrel ( 1 ) is rotated the electrical connection is not compromised. The proximal end of the barrel ends in forward bulkhead ( 15 ) that allows the forward end of the plunger ( 2 ) to pass through. The bulkhead is of such thickness as to allow for an electrical connection to electrical leads ( 21 ) running longitudinally from the electrical connection ( 50 ) at the proximal end of the barrel to the distal flange ( 7 ) with the associated electrical connection ( 26 ). The proximal end of the barrel ( 1 ) has forward extensions such as to engage recesses ( 61 ) located in the distal face of the cartridge ( 32 ) as shown in FIGS. 3 and 5 , in such a configuration that these mated extensions and recesses ( 61 ) when rotated in the proper direction will give a positive seat between the anterior portion of the bulkhead ( 15 ) and the flat portion of the distal end of the cartridge ( 28 ).
The cartridge ( 32 ) has an electrical connection ( 50 ) which mates with a concomitant connection in the bulkhead ( 15 ) of barrel ( 1 ) as shown in FIG. 2 . The cartridge ( 32 ) has an embedded coil ( 60 ) as shown in FIGS. 1 and 2 . The cartridge ( 32 ) mates with the barrel ( 1 ) at its proximal end which contains a bulkhead ( 15 ) allowing for a strong connection of the combined member to become a part of a rotating, electrically conductive component attached to a handle ( 8 ).
The handle ( 8 ) is pivotally connected to an operating lever ( 12 ) through a pivot pin ( 10 ) located at the upper end of the handle ( 9 ) and the operating lever ( 12 ) that is offset laterally to facilitate the operation of the lever ( 12 ) with respect to the outer end of the plunger ( 8 ) which terminates in a button ( 11 ) engaged by the inner surface ( 12 ) of the operating lever.
A coiled spring ( 28 ) surrounds the distal portion of the plunger between the forward handle ( 8 ) and the button ( 11 ) for purposes of extracting the plunger ( 5 ) when the operating lever ( 9 ) is released, following ejection of material from the cartridge ( 32 ).
The handle ( 8 ) contains an appropriate electrical source ( 13 ) such as a battery or capacitor discharge device and/or connection to an electrical outlet through a connecting cable. The handle ( 8 ) contains an on/off switch ( 22 ) connected to the electrical source ( 13 ) in conjunction with a temperature controller device ( 23 ) through a feedback thermocouple contained within or on the surface of the cartridge ( 60 ) ( 55 ).
The cartridge ( 32 ) which in conjunction with the dispensing device comprises the system is located at the proximal end of the barrel ( 1 ). The cartridge ( 32 ) is preferably formed by molding from a rigid synthetic resin or plastic material by means of a suitable mold. The intermediate body portion of the capsule ( 63 ) as shown in FIG. 5 for connection to the barrel ( 1 ) projections and also has electrical connections ( 50 ) that mate with similar connections ( 59 ) in the connecting face of the barrel ( 1 ). The cartridge is of sufficient thickness ( 62 ) to allow for an appropriate placement and configuration of a wire ( 60 ) that may be a coil but not limited to such configuration that when an electrical current is passed through creates a rise in temperature through resistance in one method and induction in the second method. The capsule ( 32 ) has a thermocouple device ( 55 ) to allow for a feedback mechanism to control the temperature of the material in the cartridge ( 70 ). Horizontal metal ribs ( 55 ) located in a longitudinal direction within the cartridge walls beneath the induction coil ( 60 ) become hot when subjected to the proper current and also act as a thermocouple ( 55 ) in a form of the invention. In another form of the invention, the barrel ( 1 ) is extended to cover the cartridge ( 32 ) which contains only the horizontal metal ribs ( 55 ) and no induction coil ( 60 ). The induction coil ( 60 ) is located in the barrel ( 1 ) as shown in FIG. 2A at the extended end and the electrical connection is with a direct wire ( 21 ) to the distal portion of the barrel ( 1 ) and connected to an on/off switch connected to the temperature feedback mechanism.
The body of the cartridge ( 63 ) extends forward in a uniform manner to a hemispherical closed end with an opening into an angularly placed discharge nipple ( 40 ), the opening of which is preferably a very fine dimension of small diameter. To effect the ejection of material from the cartridge ( 32 ) such as dental filling material, cement, or other viscous material and the like, for example, the cartridge ( 32 ) includes a piston ( 31 ) as shown in FIG. 2 , and the inner end thereof also is hemispherical and complementary to the interior of the closed end of the cartridge. Without restriction thereto, the outer end of the piston may be flat for encasement, for example in FIG. 2 where the proximal end of plunger ( 5 ) is moved forward by actuation of the operating lever ( 9 ).
Removal of the cartridge ( 32 ) from the proximal end of the barrel is accomplished by turning in the appropriate direction allowing the connecting tangs on the proximal end of the barrel ( 15 ) to disengage from the female connection ( 61 ) in the distal end of the cartridge ( 28 ).
From the foregoing, it will be seen that the proximal end of the barrel ( 15 ) is especially adapted to receive the particular type cartridge ( 32 ) to be used therewith, which is a subject of the system in this application. This does not limit the connecting mechanism to the one previously described but only to demonstrate the necessity of having a positive connection to allow for a secure tight seal and positive electrical conductivity. The connection is very simple, highly effective design to permit a sure and effective adaptation and release.
The cartridge ( 32 ) comprising part of the method and the system of the invention not only is capable of serving as receptacle for material to be discharged when filled for example, from storage supply, but, even more importantly, the cartridge can be filled at a factory with predetermined quantities of material, by automatic machinery, and sealed therein by application of the piston ( 31 ) which, under the circumstance, serves as a closure for the cartridge. The above described design particularly facilitates such operations. Further, during filling, air in the cartridge in advance of the material can be discharged through the nipple ( 44 ) until filled and then the open end of the nipple may be suitably and inexpensively closed by suitable seal means, such as a small piece of sheet material having pressure sensitive cement on one side and placing said piece across the nipple in any suitable manner.
In accordance with the invention, a further improved feature for the cartridge comprises providing a preferably cup-shaped cap ( 45 ) which is of a suitable shape either to frictionally engage the tip portion of the nipple ( 44 ) or either the cap or nipple, or both to secure the cap releasably upon the tip of the nipple in sealed manner. Cap ( 45 ) has an outer flange position adjacent to the opening of the cap. In closed position, the inner surface of the cap ( 45 ) is retained by the nipple with a force sufficient to slightly bend the wall of the cap. This creates enough friction to allow for a secure closure and also allows for easy removal prior to its intended use.
Moreover, the cap ( 45 ) serves an important additional feature in that, in addition to sealing the contents of the cartridge in conjunction with the piston ( 31 ), the cap may be color coded to any number of purposes, weight or quantity of the material therein, setting time, and otherwise.
Also the body of the cartridge as well as the cap ( 45 ) and piston ( 31 ) may all be molded from a similar plastic material which is colored suitably to render the items opaque or otherwise impervious to the transmission of ambient light which, if the contents are subject to being set by such light, prevents premature setting thereof.
In an alternate, and preferred, embodiment the wire 60 defines an induction coil and the piston 31 is formed at least in part of material such as iron which, when subjected to a varying electromagnetic field, will become heated and transfer heat to the cartridge contents.
The foregoing description illustrates preferred embodiments of the invention. However, concepts employed may, based upon such description, be employed in other embodiments without departing from the scope of the invention. Accordingly, the following claims are intended to protect the invention broadly, as well as in the specific forms shown herein.
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A cartridge-type system having a fluid containment in the cartridge which comprises a fluid containing body which is adapted to be attached to a delivery device, the body of the cartridge including preferably electrically energizable heating means, preferably energized through a delivery device, for heating the contents of the cartridge and thus enhancing their deliverability.
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BACKGROUND
1. Field of Invention
The present invention relates to threaded oilfield tubulars. The present invention is directed to a tool for applying torque and rotation to an add-on pipe segment to make up or break out a threaded pipe connection or to rotate a pipe string. More specifically, the present invention is directed to a tool having one or more elastomeric sprags oriented on the tool for engaging and rotating an add-on pipe segment in a first rotational direction, but not in the opposite rotational direction. Additional sprags may be disposed on a separate portion of the tool for selectively providing for the capacity to rotate an add-on pipe segment in the opposite direction.
2. Description of the Related Art
Conventional power tongs are machines used on a rig to grip the exterior surface of an add-on pipe segment and rotate the add-on pipe segment about its axis to threadably make-up a connection between the add-on pipe segment and an aligned pipe string. The power tong generally has a throat through which the add-on pipe segment may be introduced between gripping jaws of the power tong. The gripping jaws are pivotally securable to a gripping jaw retainer that supports the jaws in position to grip, rotate and torque the add-on pipe segment by powered rotation of a surrounding ring gear. The ring gear may be rotatable using hydraulically-powered pinion gears to make up the threaded connection. After the threaded connection is torqued, a conventional power tong must generally be moved back away from well center for subsequent well operations. Conventional power tongs may be movably disposed on a track or in a groove that provides for automated advancement to and retraction from well center.
A power tong may cooperate with an elevator that kicks out from well center to secure to and position an add-on pipe segment for being joined to the pipe string. Elevators may be suspended from a vertically movable top drive or a block using a pair of elongate bails. After an add-on pipe segment is joined to the proximal end of the pipe string, the elevator may be used to support the pipe string within the borehole so that the spider may disengage and the lengthened pipe string may be further installed in the borehole by lowering the elevator and the pipe string through the disengaged spider. This process may be repeated until the pipe string reaches a desired length.
Conventional power tongs are generally large machines that consume a large portion of space on the rig floor, and some rigs may need to be retrofitted to accommodate conventional power tongs that operate on tracks or in grooves on the rig floor. Conventional power tongs may obstruct the view on the rig floor and often cause unwanted marks on the exterior of the add-on pipe segment and/or the pipe string. Conventional power tongs may present an obstruction on rigs equipped with elevators that kick out from well center to support and position add-on pipe segments at well center for being joined into the pipe string.
Other power tongs may comprise tools that internally grip the add-on pipe segment. Internally gripping power tongs, which may include casing running tools, often employ complex mechanisms for deployment of pipe gripping jaws. Actively deployable gripping jaws may deploy by operation of cams, cylinders or axially movable mandrels. These mechanisms result in additional cost, weight and maintenance, and often require a source of external power for deployment and retraction of gripping jaws to engage and release an add-on pipe segment, respectively.
What is needed is a method of rotating and torquing an add-on pipe segment to make up a threaded connection to a pipe string that utilizes substantially less rig floor space than a conventional power tong. What is needed is a power tong that can rotate and torque an add-on pipe segment using a top drive. What is needed is a power tong that can internally or externally engage and apply torque to an add-on pipe segment for making up or breaking out a threaded connection, thereby eliminating the cost, weight and maintenance of more complex actuated gripping jaws, and avoiding the need for coupling the tool to a source of power for engaging or retracting the tool. What is needed is a power tong that cooperates with elevators that kick out from well center to secure to and position add-on pipe segments at well center for being joined into the pipe string. What is needed is a tool for gripping and rotating an add-on pipe segment that does not mark or scar the pipe wall, and that does not cause damage to the threads that form the connection upon insertion of the tool into the bore of the add-on pipe segment.
SUMMARY OF THE PRESENT INVENTION
The present invention satisfies some or all of the above-referenced needs and others. The present invention is directed to a sprag tool for gripping and applying torque and rotation to an add-on pipe segment upon powered rotation of the sprag tool about its axis in a first direction.
The sprag tool of the present invention may provide a ratchet-like function that is achieved by strategically shaping the sprags that are disposed on the sprag tool. Each sprag may be shaped to grip the wall of the add-on pipe segment when the sprag is moved relative to the wall in a first direction, but to slip along the wall of the add-on pipe segment when the sprag is moved relative to the wall in a second direction. In one embodiment of the present invention, a sprag tool comprises a plurality of sprags formed using an elastomeric material and having a base, a top portion, an interrupted side and a substantially uninterrupted side. The sprag is generally securable to a sprag support at its base so that the top portion extends generally radially outwardly from the surface of the sprag support. The interrupted side of the sprag may comprise a gap, a recess, a hole, a notch or void, or a plurality of these features, to permit the sprag to compliantly lean, fold or collapse in response to the application of a generally lateral force near the top portion of the sprag and in the direction of the generally interrupted side.
The opposite side of the sprag is substantially uninterrupted so that the sprag deforms to a generally compressed and non-compliant configuration in response to the application of a generally lateral force near the top portion of the sprag and in the direction of the substantially uninterrupted side of the sprag by movement of the sprag support and the sprag relative to the contacted wall of the add-on pipe segment. The generally non-compliant mode of deformation of the sprag results in substantial compression of the sprag between the sprag support at its base and the wall of the add-on pipe segment at its top portion, and the compression of the sprag between these two surfaces causes the sprag to be forcibly urged against the wall of the add-on pipe segment, thereby substantially increasing the frictional grip of the elastomeric sprag on the wall of the add-on pipe segment.
Consequently, a sprag tool comprising an arrangement of angularly distributed sprags disposed on the exterior of a generally cylindrical sprag support that is inserted into the interior bore of an add-on pipe segment will not grip or turn the add-on pipe segment with much torque when the sprag tool is rotated on its axis in a direction that causes the sprags to engage the interior wall of the add-on pipe segment and the resulting force on the top portion of each sprag causes it to lean, fold or collapse toward its interrupted side. However, the same sprag tool will frictionally grip the interior bore of the add-on pipe segment, and rotate and torque the add-on pipe segment, when the sprag tool is rotated on its axis in the reverse direction that causes the sprags to engage the interior wall of the add-on pipe segment in a manner that produces a lateral force applied near the top portion of each sprag that causes the sprag to deform toward the substantially uninterrupted side and to assume a generally compressed configuration between the sprag support and the wall of the add-on pipe segment. The relatively great force applied to the interior wall of the add-on pipe segment as a result of the compression of the sprag between the sprag support and the wall of the add-on pipe segment enhances frictional contact that is multiplied by the number of sprags in the arrangement that engage and contact the interior bore of the add-on pipe segment.
Similarly, the sprag tool of the present invention may easily be adapted for gripping and rotating an add-on pipe segment by contacting the exterior wall. A sprag tool comprising an arrangement of angularly distributed sprags disposed on the interior bore of a generally cylindrical sprag support that is receivable over the end of a relatively smaller diameter add-on pipe segment will not grip or turn the add-on pipe segment with much torque when the sprag tool is rotated on its axis in a direction that causes each sprag to lean, fold or collapse toward its interrupted side. However, the same externally-gripping sprag tool will frictionally grip the exterior wall of an add-on pipe segment, and it will rotate and torque the add-on pipe segment, if the resulting lateral force on each sprag causes the sprag to deform toward the substantially uninterrupted side and to deform to the generally compressed configuration. The great force applied by each sprag to the exterior wall of the add-on pipe segment as a result of the compression of the sprag provides enhanced frictional contact that is multiplied by the number of sprags in the arrangement that contact the exterior bore of the add-on pipe segment.
One embodiment of the sprag tool of the present invention comprises sprags secured to the sprag support using adhesives. Another embodiment of the sprag tool of the present invention comprises sprags formed with a fastener that is releasably securable to a sprag support so that the sprags may be releasably installed on the sprag support. Yet another embodiment of the present invention comprises a sprag support having a plurality of radially outwardly protruding or inwardly protruding sprag stems, clips or retainers for securing sprags to the sprag support. In one embodiment, the sprags are installed on the sprag stems, clips or retainers when they are formed. In yet another embodiment the sprags are installed on the sprag support by being fitted into holes, apertures, grooves or channels within the sprag support. In yet another embodiment, a plurality of sprags may be coupled one to others to form a band or ring that is securable to a sprag support using fasteners, clamps or other known structures for securing a ring or band onto or within a generally cylindrical structure.
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of a preferred embodiment of the invention, as illustrated in the accompanying drawings wherein like reference numbers represent like parts of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of the sprag tool of the present invention rotatably supported above a rig floor by a top drive assembly and generally aligned with the bore of an add-on pipe segment supported by an elevator and positioned to be threadably coupled to a pipe string.
FIG. 2 is an enlarged perspective view of the sprag tool of FIG. 1 comprising two arrangements of sprags, each arrangement comprising a generally angularly distributed plurality of sprags supported on the exterior surface of a generally cylindrical sprag support.
FIG. 3 is an elevation view of a top drive assembly for supporting the sprag tool of FIGS. 1 and 2 in a position generally aligned with the bore of an add-on pipe segment suspended from the top drive assembly using an elevator supported by a pair of bails. The lower end of add-on pipe segment is received into and bears against the proximal end of a pipe string that is supported from the rig by a spider.
FIG. 4 is the elevation view of FIG. 3 after the lower portion of the sprag tool comprising the first arrangement of sprags is lowered and inserted into the bore of the add-on pipe segment at its upper end as the elevator slid downwardly along at least a portion of the length of the add-on pipe segment, and after the sprag tool is rotated about its axis to partially make-up the threaded connection between the add-on pipe segment and the pipe string.
FIG. 5 is the elevation view of FIG. 4 after the second portion of the sprag tool comprising the second arrangement of sprags is inserted into the bore of the add-on pipe segment.
FIG. 6 is a top cross-sectional view of the sprag tool of FIG. 2 showing the arrangement of relaxed sprags supported on the sprag support before insertion of the sprag tool into the bore of the add-on pipe segment.
FIG. 6A is an enlarged view of one embodiment of a sprag 12 in its generally relaxed configuration.
FIG. 7A is a cross-sectional view of FIG. 6 as the sprag tool is inserted into the bore of the add-on pipe segment and rotated by the top drive in the direction of the arrow 60 . The sprags are shown deformed toward the complaint configuration to slide along the interior wall of the add-on pipe segment upon rotation of the sprag tool.
FIG. 7B is the cross-section view of FIG. 7A as the sprag tool is rotated by the top drive in the direction of the arrow 62 . The sprags are shown deformed toward their non-compliant configuration to grip the interior wall of the add-on pipe segment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a perspective view of one embodiment of the sprag tool 10 of the present invention rotatably supported above a rig floor 4 by a top drive assembly 17 and generally aligned with the bore of an add-on pipe segment 22 supported by an elevator 70 and positioned to be threadably coupled to a pipe string 80 . The add-on pipe segment 22 is supported from the top drive assembly 17 using a collar ring 9 and a pair of bails 68 . The add-on pipe segment 22 comprises an upper end 22 A having an internally threaded sleeve and a lower end 22 B having external threads for being received and threadably coupled to the proximal end 80 A of the pipe string 80 . The pipe string 80 is supported from the rig using a spider 25 having a set of slips 26 that cooperate to grip and suspend the pipe string within a borehole (not shown).
FIG. 2 is an enlarged perspective view of the sprag tool shown in FIG. 1 comprising an upper arrangement 21 and a lower arrangement 11 of sprags, each arrangement comprising a generally angularly distributed plurality of sprags 12 supported on the exterior surface of a generally cylindrical sprag support 13 . The lower arrangement 11 is positioned on the sprag support 13 a sufficient distance below the upper arrangement 21 so that the lower arrangement can be inserted into the bore of the add-on pipe segment 22 without engaging the upper arrangement 21 with the add-on pipe segment 22 . A stop plate 88 may be included to limit the extent to which the sprag tool 10 can be inserted into the bore of the add-on pipe segment 22 .
In the embodiment shown in FIG. 2 , each sprag 12 is shown extending radially outwardly from the generally cylindrical sprag support 13 , and each sprag 12 is comprised of an elastomeric material, such as rubber or polyurethane. The sprags 12 are resilient and may be deformable in multiple modes without excessive failure. The sprag tool 10 shown in FIG. 2 is adapted for being inserted within the bore of pipe having a diameter that is substantially larger than the diameter of the sprag support 13 .
The shape of each elastomeric sprag 12 provides for its ratchet-type function. For example, the lower arrangement 11 comprises a generally angularly distributed plurality of sprags 12 , when inserted into the bore of the add-on pipe segment 22 along with the sprag support 13 will conform to the annulus between the interior wall of the add-on pipe segment 22 and the sprag support 13 . As will be discussed in more detail below, the sprags 12 are shaped such that they will permit rotation of the sprag tool 10 within the bore of the add-on pipe segment 22 in a first direction, but not in the second, opposite direction.
This sprag tool may have outwardly protruding sprags arranged on and secured to the exterior surface of a sprag support like those shown in the appended drawings, or it may comprise inwardly protruding sprags arranged on and secured to the interior surface of a larger pipe, such as a 24-inch pipe, to engage and grip the outside of a smaller pipe, such as a 20-inch pipe.
FIG. 3 is an elevation view of a top drive assembly 17 for supporting the sprag tool 10 of FIGS. 1 and 2 in a position generally aligned with the bore of an add-on pipe segment 22 suspended from the top drive assembly 17 using an elevator 70 supported by a pair of bails 68 . The lower end 22 B of the add-on pipe segment 22 is received into and bears against the proximal end 80 A of the pipe string 80 that is supported from the rig by the spider 25 . The elevator 70 is of the type that engages and supports the shoulder formed between the lower end of the sleeve 22 A and the pipe segment 22 and is adapted for sliding along at least a portion of the length of the pipe segment 22 when the add-on pipe segment 22 is supported to unload the elevator 70 , as in FIG. 3 . Lowering of the top drive assembly 17 , including the collar ring 9 , the bails 68 and the elevator 70 from its position shown in FIG. 3 will slide the elevator 70 downwardly along at least a portion of the length of the add-on pipe segment 22 and insert the sprag tool 10 into the bore of the add-on pipe segment 22 .
FIG. 4 is the elevation view of FIG. 3 after the traveling block 8 are used to lower the top drive assembly 17 , including the collar ring 9 , bails 68 and the elevator 70 , to partially insert the sprag tool 10 of the present invention into the aligned bore of the add-on pipe segment 22 and slide the elevator 70 along at least a portion of the length of the add-on pipe segment 22 from its upper end 22 A. FIG. 4 shows that the lower arrangement 11 is inserted into the bore of the add-on pipe segment 22 through its upper end 22 A, and both the upper arrangement 21 and the stop plate 88 remain above the bore of the add-on pipe segment 22 . The sprag tool 10 has also been rotated after insertion into the bore of the add-on pipe segment 22 to threadably make up the connection between the lower end 22 B of the add-on pipe segment 22 and the upper end 22 A of the pipe string 80 to lengthen the pipe string 80 . The lengthened pipe string 80 can be lifted by raising the traveling block 8 , withdrawing the sprag tool 10 from the bore of the add-on pipe segment 22 , and reengaging the elevator 70 with the shoulder between the proximal end 22 A of the add-on pipe segment 22 , then by continuing to raise the traveling block 8 to lift the lengthened pipe string 80 and unload the spider 25 so that the lengthened pipe string 80 can be lowered further into the borehole (not shown) to position the upper end 22 A of the add-on pipe segment 22 for joining an additional add-on pipe segment 22 .
FIG. 5 is the elevation view of FIG. 4 after a greater portion of the sprag tool 10 comprising both the lower arrangement 11 and the upper arrangement 21 of sprags is inserted into the bore of the add-on pipe segment 22 . The insertion of the greater portion of the sprag tool 10 comprising both the lower arrangement 11 and the upper arrangement 21 of sprags 12 into the bore of the add-on pipe segment 22 enables rotation of the add-on pipe segment 22 about its axis in either direction if the sprags 12 that comprise the upper arrangement 21 are reversed from their orientation within the lower arrangement 11 . In the event of a need to break out a threaded connection between the add-on pipe segment 22 and the pipe string 80 , simply lowering the traveling block 8 and the sprag support 13 further into the bore of the add-on pipe segment 22 until the upper arrangement 21 of sprags 12 enters the bore, and rotating the sprag support 13 in the reverse direction from that which causes the lower arrangement 11 of sprags 12 to grip, will cause the upper arrangement 21 of sprags 12 to grip the interior wall of the add-on pipe segment 22 and rotate the add-on pipe segment to break out the threaded connection. While the lower arrangement 11 is predisposed to slip within the bore of the add-on pipe segment upon rotation in a first direction, the upper arrangement 21 of sprags 12 is reversed from the lower arrangement 11 , and will grip and rotate the add-on pipe segment 22 whereas slipping would have otherwise been permitted by the lower arrangement 11 . Accordingly, a sprag tool 10 such as that shown in FIG. 5 having two or more spaced-apart arrangements of sprags—one arrangement reversed relative to the other—enables easy switching of modes from make up to break out.
FIG. 6 is a top cross-sectional view of the sprag tool 10 of FIG. 2 revealing the shape and profile of the lower arrangement 11 of relaxed sprags 12 supported on the sprag support 13 prior to insertion of the sprag tool 10 into the bore of the add-on pipe segment 22 . The sprags 12 are arranged in a ring that is generally shaped like a ripping blade for a circular saw. FIG. 6A is an enlarged view of one embodiment of a sprag 12 that may be used on the sprag tool of FIG. 6 . The sprag 12 in FIG. 6A is shown in a relaxed configuration. As shown in FIG. 6A , each sprag 12 generally comprises a base 12 A, a top portion 12 B, an interrupted side 12 C and a substantially uninterrupted side 12 D. The sprag 12 is secured at its base 12 A to the sprag support 13 . The base 12 A is secured to the sprag support 13 and the top portion 12 B extends generally radially away from the base 12 A. The interrupted side 12 C comprises a large recess, gap or void portion in the sprag 12 that allows the sprag 12 to lean, fold or collapse in response to a force applied laterally to the sprag 12 near the top portion 12 B and generally along the direction of the arrow 50 . The substantially uninterrupted side 12 D of the sprag 12 is generally opposite the interrupted side 12 C and is structured to resist leaning, folding or collapsing in response to a force applied laterally to the sprag 12 near the top portion 12 B and generally along the direction of the arrow 52 .
The two distinct modes of deformation of the sprag 12 described in relation to FIG. 6A are illustrated in FIGS. 7A and 7B . FIG. 7A is a cross-sectional view of the lower arrangement 11 of deformed sprags 12 ′ shown in FIG. 6 after the sprag tool 10 inserted into the bore of the add-on pipe segment 22 and the sprag support 13 is rotated by the top drive assembly 17 in the direction of the arrow 60 . The deformed sprags 12 ′ are shown to be compliantly deformed, each by a force applied by the interior wall 22 C of the add-on pipe segment 22 and in the direction shown by the arrow 50 in FIG. 6A . The leaned, folded or collapsed sprag 12 ′ slides along the interior wall 22 C of the add-on pipe segment 22 during rotation of the sprag support 13 in the direction of arrow 60 . Each deformed sprag 12 ′ imparts minimal friction to the interior wall 22 C because there is little force imparted by each deformed sprag 12 ′ to the interior wall 22 C. The resulting rotational torque applied by the leaning, folded or collapsed sprags 12 ′ to the add-on pipe segment 22 is illustrated by the direction and length of arrows 64 .
It should be noted that there are a variety of sprag shapes that may provide the ratchet-like function of the sprag tool. The shape of the sprag, in additional to its elastomeric properties, provides for its ratchet-like function in the present invention. One embodiment of a sprag used on a tool of the present invention comprises a base for being secured to a sprag support, a top of the sprag generally opposite the base for contacting the wall of an add-on pipe segment, and two sides generally intermediate the base and the top of the sprag. The sprag is generally flexible to enable it to be placed into an annular space between the sprag support and the wall of an add-on pipe segment.
One side of the sprag is generally interrupted to allow the sprag to lean, fold or generally collapse when a generally lateral force is applied by movement of sprag support relative to the contacted wall of the add-on pipe segment, near the top of the sprag, and in the direction toward the generally interrupted side of the sprag. The leaning, folding or collapsing of each sprag in response to the lateral force applied as a result of movement of the sprag tool relative to the wall of the add-on pipe segment results in relatively little force applied by the sprag to the wall of the add-on pipe segment and, as a result, little frictional resistance to sliding movement of the wall of the add-on pipe segment relative to the sprag. It should be appreciated that the frictional force applied by the sprag to resist relative movement of the wall of the add-on pipe segment is a function of the force applied by the sprag to the wall, the area of contact between the sprag and the wall, and the coefficient of friction between the sprag material and the wall.
FIG. 7B is the cross-section view of the lower arrangement 11 of deformed sprags 12 ″ shown in FIG. 6 after the sprag tool 10 inserted into the bore of the add-on pipe segment 22 and the sprag support 13 is rotated by the top drive assembly 17 in the direction of the arrow 62 . The deformed sprags 12 ″ are shown to be deformed to a generally non-compliant configuration, each by a force applied by the interior wall 22 C of the add-on pipe segment 22 and in the direction shown by the arrow 52 in FIG. 6A . The generally collapse-resistant sprag 12 ″ bends to a configuration that compresses between the interior wall 22 C of the add-on pipe segment 22 during rotation of the sprag support 13 in the direction of arrow 62 . Each non-compliant and compressibly deformed sprag 12 ″ imparts substantial friction to the interior wall 22 C because there is a great force imparted by each compressibly deformed sprag 12 ″ to the interior wall 22 C. The resulting rotational torque applied by the sprags 12 ″ to the add-on pipe segment 22 is illustrated by the direction and length of arrows 66 .
The embodiment of the sprag tool 10 shown in the appended drawings is rotatably suspended from a rotatable quill of a top drive assembly 17 , and positionable above and alignable with a pipe string 80 suspended in a borehole (not shown) using a spider 25 . It should be understood that any tool that provides for supporting and rotating the sprag tool 10 may be substituted without loss of function.
It should be understood that the capacity of a sprag tool to impart torque to an add-on pipe segment may vary according to the number, size and shape of the sprags. Also, additional torquing capacity may be achieved by including multiple rows or rings of sprags within an arrangement. For example, an arrangement of sprags resembling those shown in the lower arrangement 11 in FIG. 2 that were secured on the exterior surface of a 16-inch cylindrical support produced 4,200 ft-lbs of torque on a 20-inch add-on pipe segment when the sprag tool was inserted into the bore of the add-on pipe segment and rotated using a simulated top drive. This amount of torque may be readily doubled by securing two adjacent rows or rings of sprags into a single arrangement. In this manner, unless the add-on pipe segment is somehow obstructed or is extremely short, almost any reasonable torque may be attained using a sprag tool of the present invention.
The terms “comprising,” “including,” and “having,” as used in the claims and specification herein, indicate an open group that includes other elements or features not specified. The term “consisting essentially of,” as used in the claims and specification herein, indicates a partially open group that includes other elements not specified, so long as those other elements or features do not materially alter the basic and novel characteristics of the claimed invention. The terms “a,” “an” and the singular forms of words include the plural form of the same words, and the terms mean that one or more of something is provided. The terms “at least one” and “one or more” are used interchangeably.
The term “one” or “single” shall be used to indicate that one and only one of something is intended. Similarly, other specific integer values, such as “two,” are used when a specific number of things is intended. The terms “preferably,” “preferred,” “prefer,” “optionally,” “may,” and similar terms are used to indicate that an item, condition or step being referred to is an optional (not required) feature of the invention.
It should be understood from the foregoing description that various modifications and changes may be made in the preferred embodiments of the present invention without departing from its true spirit. The foregoing description is provided for the purpose of illustration only and should not be construed in a limiting sense. Only the language of the following claims should limit the scope of this invention.
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A pipe torquing sprag tool comprises one or more elastomeric sprags supported on a sprag support in an arrangement lying generally in a plane that is generally perpendicular to the axis of the rotatable sprag support. Each sprag has a solid, uninterrupted side and an interrupted side, and each sprag reacts to a lateral force in the general direction tangential to the surface of the sprag support and applied near the top of the sprag to bend the elastomeric sprag either toward the interrupted side to at least partially lean, fold or collapse, or towards the substantially uninterrupted side for being deformed to a generally compressed and non-compliant configuration for gripping. The sprag tool of the present invention may comprise a sprag support for positioning an external arrangement of sprags for being inserted into the bore of an add-on pipe segment. Alternately, the sprag tool of the present invention may comprise a sprag support for positioning an internal arrangement of sprags for being received over the end of an add-on pipe segment.
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TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
This invention relates to gas turbine engines, and more specifically to the reduction of axial stress in disk hubs of gas turbine aircraft engines. The invention is disclosed and explained in this application with specific reference to high pressure turbine (“HPT”) disk hubs of gas turbine aircraft engines. Severe thermal gradients at the hub of HPT disks during takeoff can lead to high compressive axial stresses at the center of the hub surface. This high axial stress can lead to calculated life values well below engine program requirements. Prior art solutions have included large reductions in thermal gradients and/or the disk rim loading, or a large increase in hub size. These solutions negatively impact engine performance.
More particularly, current practices to reduce axial stress include adjusting the disk rim load, hub size, or idle hub flow to get adequate life from the disk hub. The approach of adjusting the disk rim load is indirect. The weight of the blades is reduced in order to reduce the hoop stress in the disk to the point that it meets life requirements even with the high axial hub stress. This approach has negative life and performance implications for the blade. Adjusting the hub size is indirect as well. This practice also reduces the hoop stress so that the disk will accommodate the large axial stress with acceptable life. This approach has negative weight and thermal performance impacts for the disk. Increasing the engine idle hub flow directly reduces the axial stress on the hub by warming the disk prior to takeoff. This, in turn, reduces the thermal gradient that causes the high axial stress. However, the high hub flow has negative system performance implications.
The invention disclosed and claimed in this application addresses this problem in a novel manner and thereby reduces axial stress on the HPT disk hub without disadvantageous tradeoffs incurred with prior art solutions.
SUMMARY OF THE INVENTION
According to one aspect of the invention, geometric features are introduced into the disk hub to mitigate high axial stress in HPT disk hubs.
According to another aspect of the invention, a chamfer is formed into the inner diameter of the disk hub
According to another aspect of the invention, radial grooves are formed in the hub surface.
According to yet another aspect of the invention, hub material is removed along a line parallel to an axial stress isoline.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial vertical cross-sectional view of a HPT disk hub with indicated axial thermal gradients according to a prior art HPT disk hub design;
FIG. 2 is a fragmentary cross-section, taken along a longitudinal axis, of the HPT section of a gas turbine engine;
FIG. 3 is a partial vertical cross-sectional view of a HPT disk hub with indicated axial thermal gradients according to a HPT disk hub design in accordance with one aspect of the invention;
FIG. 4 is a partial vertical cross-sectional view of a HPT disk hub in accordance with another aspect of the invention;
FIG. 5 is a partial vertical cross-sectional view of a HPT disk hub in accordance with one aspect of the invention; and
FIG. 6 is a partial vertical cross-sectional view of a HPT disk hub in accordance with one aspect of the invention;
DETAILED DESCRIPTION
A typical prior art disk hub is shown in FIG. 1 at reference numeral 1 , and includes a hub surface 2 . Stress gradient lines 7 - 3 indicate progressively higher stresses towards the hub surface 2 . This occurs as the material at the hub surface 2 increases in temperature and thermally expands. The interior material of the disk hub 1 is cooler, as indicated by a relatively cool interior area 8 of reduced stress that restrains the thermal expansion of the hotter material closer to the surface 2 of the hub 1 . The stress peaks in the center, as shown, and falls away at the opposing ends due to the axial free surfaces that permit the expansion. As described below, reducing the distance from the center of the hub to a free axial surface has been shown to reduce the magnitude of the central axial stress.
FIG. 2 illustrates a portion of a HPT section 10 of an aircraft high bypass ratio gas turbine engine. The HPT section 10 includes first and second stage disks 14 , 16 , having respective webs 18 , 20 extending outwardly from respective hubs 21 , 24 . The first stage disk hub 21 includes a hub surface and a chamfer 23 , as described in further detail below. Dovetail slots 26 , 28 are formed on the outer ends of the webs 18 , 20 , respectively.
The first stage disk 14 includes a forward shaft 30 that is integral with the web 18 . Hub 21 of the first stage disk 14 includes a rearwardly-extending aft shaft 42 that is press-fitted into engagement with a bearing 44 . The shaft 42 includes a plurality of openings 46 that allow cooling air to enter the interstage volume 48 . An interstage seal 50 is positioned between the first stage disk 14 and the second stage disk 16 , and includes an outer shell 52 and a central disk 54 having a hub 56 . Shell 52 is generally cylindrical with forward and aft-extending curved arms 58 and 60 that extend from a mid-portion 62 that supports seal teeth 64 and attach to the respective disks 14 , 16 .
Referring now to FIG. 3 , the surface 22 of the disk hub 21 is provided with a radially-displaced chamfer 23 on the forward end of the hub surface 22 . This places a free surface, i.e., a “corner”, of the chamfer 23 immediately below the coolest portion of the hub 21 , thereby forcing the axial stress to be the greatest at an off-center position, thereby decreasing its magnitude. This is shown in FIG. 3 , where the area of greatest stress, indicated at “X” is shifted to a forwardly off-center position.
Optimum shape, angle, size and dimensions of the chamfer are determined empirically by implementing a design change and then reviewing the effect of the change through computer analysis to observe the resulting stresses, rather than by a purely analytical method. The design process is adapted to balance the decrease in axial stress with an accompanying increase in hoop stress caused by lowering the cross-sectional area of the disk hub 21 .
In a preferred version, the chamfer 23 intersects the non-chamfered portion of the hub surface 22 at the same axial location as the center of maximum axial tensile stress. The chamfer 23 is preferably planar, as shown, with radiused fore and aft transitions and may be between about 0 and 50 degrees.
Prior art disk hubs in a specific General Electric gas turbine engine were rated at 11,000 cold start cycles. Incorporation of the chamfer as shown and described above into a computer simulation resulted in an improvement to 15,300 cold start cycles, enabling the engine to meet program life requirements.
Similar improvements may be obtained with a variety of techniques. As is shown in FIG. 4 , a disk 70 includes an integrally-formed web 72 and a disk hub 74 with a hub surface 76 . The disk 70 includes an integrally-formed forward shaft 78 and a rearwardly-extending aft shaft 80 . The hub surface 76 is provided with radial grooves 82 and 84 , the shape of which is defined by the nine indicated variables. Thermostructural DOE is used to determine the appropriate design space to achieve minimum stress in the hub 74 . Average hoop stress, burst margin and selected rim stress are other variables that must be taken into account. The grooves 82 and 84 effectively cut the axial stress path at the hub surface 76 . Somewhat less material is removed from the hub 74 for a given amount of stress reduction in comparison with the chamfered hub surface 22 shown in FIG. 3 , thereby minimizing the increase in disk hoop stress resulting from the reduction in disk cross-sectional area.
Another alternative is shown in FIG. 5 , where a disk 90 includes an integrally-formed web 92 and a disk hub 94 with a hub surface 96 . The disk 90 includes an integrally-formed forward shaft 98 and a rearwardly-extending aft shaft 100 . The hub surface 96 is provided with a concave annular recess, the shape of which is defined by variable A, R 1 and R 2 . Thermostructural DOE is used to determine the appropriate design space to achieve minimum stress in the hub 94 . While the impact on the disk temperature may be moderate, this design may significantly reduce axial stress by decreasing the thermal gradient within the hub 94 .
Referring now to FIG. 6 , a further modified design is illustrated. A disk 110 includes an integrally-formed web 112 and a disk hub 114 with a hub surface 116 . The disk 110 includes an integrally-formed forward shaft 118 and a rearwardly-extending aft shaft 120 . The hub surface 116 is provided with a radially-extending annular convex ring, the shape of which is defined by variables essentially as with FIG. 5 . Thermostructural DOE is used to determine the appropriate design space to achieve minimum stress in the hub 114 . While the impact on the disk temperature may be moderate, this design may significantly reduce axial stress by increasing the distance over which the thermal gradient is formed within the hub 114 . This design illustrates the principle that any surface other than a planar axial cylindrical surface will achieve a reduction in peak axial stress. The objective is to reduce peak axial stress while minimizing compensating variations in other undesirable conditions. For example, cylindrical grooves in the hub surface would reduce peak axial stress, but would also introduce very high stress points at the sharp corners that would be highly detrimental to the operational life of the disk. As is evident from the foregoing, the radially-displaced portion of the disk hub surface may be planar, e.g., FIGS. 2 and 3 , or non-planar, e.g., FIGS. 4 - 6 —the principal determining factor being the results achieved by DOE studies and the effect of the radially-displaced portion of the disk hub surface on axial stress, hoop stress, burst margin and rim stress.
A disk hub with reduced axial stress, and methods of reducing axial stress in a disk hub are disclosed above. Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of the preferred aspect of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation—the invention being defined by the claims.
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A gas turbine engine disk that includes a centrally disposed disk hub having an integrally-formed, radially outwardly extending web terminating at an outer end. The disk hub has a radially-displaced annular hub surface exposed to high pressure, high temperature discharge gases during engine operation. The radially-displaced annular hub surface acts as an axial free surface mitigating the formation undesirable axial stress in the disk hub.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an automatic exposure device for use in an image: forming device such as an electronic copying machine.
2. Description of the Prior Art
A conventional automatic exposure device for use in a copying machine is arranged so as to detect the amount of light reflected from an original document to be copied by a light sensor and to control the power of a light source for illuminating the original document based on the light signal obtained by the light sensor. In case where detection indicates that the original document is dark, power supplied to the light source is increased, alternatively, when detection indicates that the original document is bright, the power supplied to the light source is decreased, in order to assure an optimum exposure to the original document corresponding to the density of the picture of the original document to prevent a fogging of the copied picture. In the automatic exposure control device mentioned above, although the power to the light source is increased if it is detected that the original document is dark, the light source emits excessive light without an upper power limit. The problem that results with the aforementioned process is that if an original with slight lines near very dark characters is copied, the lines and/or characters disappear in the copied picture. To solve this problem, therefore, an upper limit of the supplied power level for the light source is set. In the conventional automatic exposure control devices, the upper limit of the power level supplied to the light source is fixed.
However, there may occur a case that the starting up time of the light value emitted from the light source differs greatly depending on the kinds of the light source and the temperature of the atmosphere of the light source. For example, when a fluorescent lamp is used as the light source, the starting up time of the light from the lamp is delayed greatly if the atmosphere temperature is low compared with the lamp driven in a normal room temperature and there may occur such a case that the amount of the light reflected from the original document can not reach a sufficient light level even if a full power is supplied to the lamp. If the power to the light source is limited to the upper limiting level under the condition mentioned above, the amount of the light reflected from the original document becomes insufficient, resulting in making a copy that is foggy.
SUMMARY OF THE INVENTION
An essential object of the present invention is to provide an automatic exposure control device which is able to prevent lack of light for exposure even if the amount of light from the light source is starting up by changing the upper light limit level corresponding to the degree of the starting up state.
According to the automatic exposure control device of the present invention, the degree of the starting up of the light from a light source is detected based on the output value of the light sensor at a predetermined period after application of the power to the light source. The detection of the degree of the starting of the light source can be conducted in such a manner that the light source is turned on with full power before a portion lighted by the light from the light source reaches the leading end of the original document, and the the degree of the starting light is detected based on the output level of the sensor just before the lighted portion comes to the end of the original document. If the amount of the light during the starting up period is not sufficient, the output level of the sensor is low, on the other hand, if the light amount of the light has fully starting up, the output level of the sensor is high. With the detection of the starting up condition of the light, the level of the upper limit of the power supplied to the light source is changed corresponding to the output level of the sensor. The lower the degree of the starting up of the light source, the higher the upper power limit is set. If the degree of starting up of the light source is sufficient, the level of the upper power limit is set relatively low. By the arrangement mentioned above, when the degree of the starting up of the light amount of the light source is low, it becomes possible to supply a sufficient power to the light source. If the degree of the starting up of the light amount of the light source is sufficient, the power to the light source is limited so that an excessive power supply can be prevented.
BRIEF EXPLANATION OF THE DRAWINGS
FIG. 1 is a block diagram showing an embodiment of the automatic exposure control device according to the present invention,
FIG. 2 is a schematic diagram showing an operation of a PWM generation circuit used in the device shown in FIG. 1,
FIG. 3 is a schematic diagram showing a detailed circuit of a limiter switching circuit and a high level limiter switching circuit, and
FIG. 4 is graphs showing change of the upper limit of the power supply.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, fluorescent lamp 1 used for illuminating an original document platform 2 of a copying machine. It is noted that in general the fluorescent lamps have a property that the rising of the amount of light emitted from the lamp is delayed greatly in low temperature compared with the starting time of the light amount in normal temperature. The light emitted from the fluorescent lamp 1 and projected to the original platform 2 is detected by an automatic exposure sensor 3 (referred to as AE sensor hereinafter) in terms of the light amount and the voltage proportional to the amount of the received light is amplified to a suitable level by an amplifier 4. The output of the amplifier 4 is supplied to a inverted amplifier 11 and a limiter switching circuit 10. The output signal inverted and amplified by the inverted amplifier 11 is supplied to a PWM generator 7 in which pulse width modulated (PWM) signal is generated by comparison with the signal from the inverted amplifier with a triangular signal fed from a triangular wave generator 6. FIG. 2 shows a specific operation of the PWM generator 7. In the arrangement shown in FIG. 2, the circuit comprising IC 21 formed by a comparator having its + input terminal applied the triangular wave from the triangular wave generator 6 and - input terminal applied with the output signal of the inverted amplifier 11. The level of the output signal of the inverted amplifier 11 is in inverse proportional to the amount of light incident to the AE sensor 2 as shown. That is, the greater the reflection light amount, the lower (the brighter) the level of the AE sensor, on the other hand, the smaller the reflection light amount, the higher the level of the AE sensor (the darker). The IC 21 compares the output level of the inverted amplifier 11 with the triangular wave signal and generates the PWM wave signals from the output terminal. The PWM wave signals are fed to an inverter 8 in which control the high frequency drive time of the fluorescent lamp 1 corresponding to the pulse width. That is, if the amount of the reflection light from the original document is low, the on period of the inverter 8 is made long so as to increase the power supplied to the fluorescent lamp 1 thereby resulting in making the fluorescent lamp 1 bright. On the other hand, the amount of the reflection light from the original document is high, the on period of the inverter 8 is decreased to make the fluorescent lamp 1 dark.
A full power generator 5 is connected to the input terminal of the inverter 8, the full power generator 5 supplies a full power supply signal to the inverter 8 in a period beginning from pressing of a copy button (not shown) to reception of a signal S1 from the LSI of the control unit (not shown). The inverter 8 supplies the full power to the fluorescent lamp 1 so long as the inverter receives the signal S1 independent of the PWM wave signal. It is noted that the signal S1 raises just before the period of time during which, after the copy button is pressed, the position of the emitting light by the fluorescent lamp 1 reaches the leading end of the original document (the time defined by the copy magnification) lapses.
When the signal S1 raises, the output from the full power generator 5 disappears and the inverter 8 controls the light of the fluorescent lamp 1 based on the PWM wave signal. As shown in FIG. 1, there is located a white reflection region made of a white plate in front of the original leading end position on the original platform 2 and the AE sensor 3 receives the reflection light from the white reflection region p until the signal S1 has fully raised up. As mentioned below, the output of the AE sensor 3 when the signal S1 has started up relates to the degree of the light amount of the starting up of the light of the fluorescent lamp 1, whereby the upper limit level of the power supplied to the fluorescent lamp 1 is set based on the output of the AE sensor 3.
The circuit arrangement for setting the upper limit of the power supplied to the fluorescent lamp 1 is formed by a limiter switching circuit 10 and a HIGH level limiter generator 9.
The limiter switching circuit 10 receives the output of the amplifier 4 and the signal S1 to determine the upper limit level (deferred to as HIGH level limiter) of the power supplied to the fluorescent lamp 1. The HIGH level limiter generator 9 generates the HIGH level limiter upon receipt of the output of the limiter switching circuit 10 and inputs the HIGH level limiter in the input terminal of the PWM generator 7. The output of the inverted amplifier 11 and the HIGH level limiter are fed to the same input terminal of the PWM generator 7, therefore, the upper level of the output of the inverted amplifier 11 is limited by the HIGH level limiter.
FIG. 3 shows a specific diagram of the limiter switching circuit 10 and the HIGH level limiter generator 9.
The limiter switching circuit 10 comprises IC 31 to IC 33 and the HIGH level limiter generator 9 comprises dividing resistors R6 to R8 and IC 34.
The output of the amplifier 4 is fed to the + input terminal of the IC3 as the voltage V 0 . A standard voltage V 1 which is divided by the resistors R1 and R2 is applied to the - input terminal of the IC 31. The standard voltage V1 is set to a level for discriminating whether or not the amount of the reflection light is raised sufficiently at the time of the raising of the signal S1, showing that the amount of the reflection light has fully raised with V0>V1, and the amount of the reflection light has not raised with V0>V1. The IC 31 generates "H" (high level) for V0>V1 and generates "L" (low level) for V0<V1. The IC32 is used for locking the output of the IC 31. Since the signal S1 is input to the - input terminal of the IC 32, at the start point of the automatic exposure control operation (AE operation) by the application of the signal S1, in other word, when the output of the IC 31 is "H" at the period when the illuminating point of the fluorescent lamp 1 reaches just before the leading end of the original document, the output of the IC 32 becomes "L", whereby "H" output of the IC 31 is maintained. If the output of the IC 31 is "L" at the time of application of the signal S1, since the - input terminal of the IC 32 becomes "L", and the output of the IC 32 becomes "H", whereby the output "L" of the IC 31 is maintained. In the latter case, when the signal S1 rises, the voltage V0 corresponding to the light reflected from the white reflection region P disposed just before the leading end of the original document is lower than the standard voltage V1, the light amount reflected from the white region of the original document during the AE operation is lower than the amount of the light reflected from the white reflection region P, the relation V0<V1 can be maintained, whereby the output of the IC 31 is maintained at "L".
The IC 33 generates the signal "L" when the output of the IC 31 is "H" corresponding to the output of the IC 31 which is fixed after the signal S1 is raised, and when the output of the IC 31 is "L", the IC 33 generates the signal "H".
The IC 34 composing a part of the HIGH level limiter circuit 9 is formed by a voltage follower to output the input signal applied to the + input terminal directly to the output terminal. When the output of the IC 33 is "H", the IC 34 generates the voltage V L1 determined by the dividing ratio determined by the resistors R6, R7 and R8, on the other hand, when the output of the IC 33 is "L", the IC 34 generates the voltage V L2 decided by the dividing ratio determined by the resistors R6 and R7. It is noted that V L1 is greater than V L2 that is V L1 >V L2 .
Summing up the above operations, if the amount of the light of the fluorescent lamp has sufficiently started up, the operation is described as V0>V1 results in V3>V3 and V3>V2 results in the output of the IC 33 to be "L", which results in V L2 .
If the amount of the light of the fluorescent lamp has not fully started up, the operation is described as V0<V1 results in V3<V2 and V3<V2 results in the output of the IC 33 to be "H", which results in V L1 , wherein V V1 >V L2 .
In the present embodiment, there are set two steps of the HIGH level limiters based on the output of the AE sensor 3 upon turning on of the fluorescent lamp 1 and upon raising of the signal S1. The voltage of the HIGH level limiter is fed to the - input terminal of the IC 21 of the PWM generator 7 with the output signal of the inverted amplifier 11. Therefore, the signal of the inverted amplifier 11 is so controlled not as to be higher than the voltage V L2 under such a condition that the light amount of the fluorescent lamp 1 has sufficiently started up, on the other hand, the signal of the inverted amplifier 11 is so controlled not as to be higher than the voltage V L1 if the light amount of the fluorescent has not sufficiently started up.
In other word, if the light amount of the fluorescent lamp 1 has not sufficiently started up or the fluorescent lamp is dark, the HIGH level limiter is set to the brighter level, on the other hand if the light amount of the fluorescent lamp 1 has sufficiently started up, the HIGH level level limiter is set to the darker level. By the control mentioned above, it can be avoided that the HIGH level limiter is set excessively low in case where the light amount of the fluorescent lamp has not sufficiently started up, on the other hand, it can be avoided that the HIGH level limiter is set excessively high in case where the light amount of the fluorescent lamp has sufficiently started up. Accordingly, even if the amount of light of the fluorescent lamp has not sufficiently started, there can be obtained a copy without fog. On the other hand, even if the light amount of the fluorescent lamp 1 has sufficiently started, there can be obtained a good copy preventing from making such a copy that characters and lines around a heavily dark portion are made thin or disappear.
FIG. 4 is a graphs showing optimum voltage range at the - input terminal of the IC 21. The level (1) shows a critical boundary for preventing from making such a copy that the characters or lines near the heavily dark portion of the original document becomes thin or disappear. The level (2) shows a critical boundary for preventing from making fogged copy. The dotted line (3) shows the HIGH level limiters V L1 and V L2 . In the region A in which the light amount of the fluorescent lamp has not sufficiently started, the higher HIGH level limiter V L1 is set. If the lower HIGH level limiter V L2 is set in the range A, the upper power supply limit is set lower than the critical boundary line (2), and therefore, the copy may be fogged. In the region B, in which the amount of light of the fluorescent lamp 1 has sufficiently started, the HIGH level limiter V L2 of lower level is set. If the HIGH level limiter V L1 of the higher level is set, the upper power supply limit exceeds the critical boundary (1) which makes the characters near the heavily dark portion of the original document becomes thin.
In the embodiment mentioned above, a full power is supplied to the fluorescent lamp 1 before the signal S1 starts up so as to accelerate start up of the lamp to the sufficient light amount.
In the embodiment mentioned above, there are two steps of the HIGH level limiters, there may be provided more than two steps of the HIGH limiters.
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An automatic exposure control device for use in a copying machine in which a light source for illuminating the light to an original document is controlled based on the signal representing the light amount of the original document sensed by a light senses. There are two kinds of HIGH level limiter for limiting the upper limit of the power supplied to the light source. The HIGH level limiters are selected depending on whether the amount of light of the light source has been raised sufficiently or not, whereby over exposure copy or foggy copy can be prevented.
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FIELD OF THE INVENTION
The field of invention relates to the semiconductor chip arts; and, more specifically, to the embodiment of design techniques that may result in increased yield and/or other benefits during manufacture.
BACKGROUND OF THE INVENTION
Integrated circuit (IC) manufacturers produce dice containing circuits on typically circular substrates referred to as semiconductor wafers. Each individual die may be of rectangular or square shape and a wafer may contain hundreds of them. The unsingulated dice on a wafer, (i.e. each unsingulated die), must ordinarily be tested to determine good from bad before the dice are singulated in order to manage cost and yield.
The use of photolithography with etching is well-known and commonplace in semiconductor wafer fabrication. A single photo-mask may be used with a stepper to create multiple (more or less) identical reticles—clusters of circuits that often contain more than one substantially identical unsingulated die. Thus a set of masks (often one per layer) for a reticle may include a plurality of circuit images, including images of application circuit components and elements. Each die will typically contain one or more application circuits composed of many circuit elements (such as gates, channels, lines etc.)
Because a typical circuit cluster, sometimes termed a “reticle”, includes more than one unsingulated die it is often advantageous to expose a partial (i.e. incomplete) reticle, such as at the wafer edge. This applies even though it is known that only some (at most) of the dice etched will ultimately be usable in products. A significant problem arises wherein systemic defects within a reticle but outside a particular unsingulated die impede the testing of that otherwise good unsingulated die.
Thus, there is a need for improved defect isolation in regards to semiconductor die fabrication. Benefits may include increased average yield for a fabrication process and/or improved reliability of the finished product (such as by eliminating marginal dice that might otherwise have passed testing).
Although embodiments of the invention were developed to address and remedy a particular class of wafer defects, the benefits of the invention may be expected to find a wider usage and utility and may extend far beyond solving the problem that originally motivated the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements and in which:
FIG. 1A shows a plan view of a semiconductor wafer according to an embodiment of the invention.
FIGS. 1B and 1C show close-up views of part of the semiconductor wafer of FIG. 1A .
FIGS. 2A and 2B show a symbolic representation of complete and incomplete dice within a single reticle of a semiconductor wafer.
FIG. 3 shows a further close-up view of another part of the semiconductor wafer of FIG. 1A .
FIG. 4A shows a plan view of a semiconductor wafer manifesting a manufacturing issue or problem.
FIG. 4B shows a graph of after-etching notional polysilicon line width for the semiconductor wafer of FIG. 4A .
FIG. 5A represents a prior art CMOS microcircuit embodied near the edge of a wafer such as the wafer of FIG. 4A .
FIG. 5B represents the microcircuit structure of FIG. 5A , further showing from where components have been removed due to the effect described in conjunction with FIG. 4B .
FIG. 5C represents the microcircuit structure of FIG. 5B without the removed components, which therefore causes a short circuit.
FIG. 6 shows a plan view of a part of a semiconductor wafer according to an embodiment of the invention.
FIG. 7A represents a CMOS microcircuit embodied on a wafer according to an embodiment of the invention.
FIG. 7B represents the microcircuit structure of FIG. 7A , further showing from where components have been removed due to the effect described in conjunction with FIG. 4B according to an embodiment of the invention.
FIG. 7C represents the microcircuit structure of FIG. 7B without the removed components, but which does not causes the short circuit of FIG. 5C according to an embodiment of the invention.
FIG. 7D represents a microcircuit structure according to another embodiment of the invention.
FIG. 8 is a flowchart of a method for manufacturing a semiconductor wafer according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1A shows a plan view of a semiconductor wafer 100 having a circular edge 144 . Semiconductor wafer 100 may typically contain a number of complete reticles 120 , 121 as well as a number of partial reticles 110 , 111 and 112 .
FIG. 1B shows a close-up view of part of the semiconductor wafer 100 of FIG. 1A bounded by edge 144 . As shown, semiconductor wafer 100 may contain one more complete reticles 120 , and at least one partial reticle 112 . Partial reticle 112 is shown as containing a number of complete die 210 , 222 a partial die 221 and a marginally complete die 125 . Also shown are two power rails (V DD and GND) in the form of conductive traces and a set of probe pads 290 . On-wafer test circuits 170 , 171 , 175 are also shown. In the exemplary reticle shown, each test circuit is associated with, and energizes precisely one unsingulated die. For example, test circuit 177 energizes and drives unsingulated die 211 during testing by impressing signals on conductive traces 179 . Test circuits, such as 175 , will typically be discarded as scrap material during die singulation (not shown).
Still referring to FIG. 1B , as shown, V DD and GND connect probe pads 290 to on-wafer test circuits 170 , 171 , 175 . Also (not shown) will be other similar conductive traces that also couple probe pads 290 to on-wafer test circuits 170 , 171 , 175 .
FIG. 1C shows a further close-up view of part of the semiconductor wafer of FIGS. 1A and 1B . As shown, on-wafer test circuit 177 is coupled to unsingulated die 211 (shown only in part in FIG. 1C ) by conductive traces 179 . Conductive traces 179 may include a ground rail 199 , a fixed voltage power supply rail 198 and various other traces 191 including signal traces 197 , such as may be driven by control circuitry 196 . In embodiments of the invention, the traces 179 may be tailored to be purposefully narrowed (for purposes described below) at any of several points, off-die or on-die. Traces 197 may carry either inputs or outputs, such as clock, data, enable, etc. FIG. 1C includes examples of on-die narrowed traces (or narrowed regions) 194 and off-die narrowings 195 .
Thus, pulling together the features of FIGS. 1A , 1 B, 1 C, under the control of an automated test system (not shown) that may impress programmed signals via probe pads 290 , on-wafer test circuits may be used to generate on-wafer test sequences for a purpose of distinguishing good dice from bad prior to singulation. These on-wafer test sequences may generate various strobe signals and also constant or quasi-constant voltages at voltage nodes that are connected to conductive traces 179 including grounds, power rails and enable inputs.
FIGS. 2A and 2B show a symbolic representation of complete dice 210 and incomplete dice 221 within a single reticle of a semiconductor wafer. FIG. 2A shows a full reticle 120 . FIG. 2B shows a partial reticle 112 . Scribe lines 220 are shown and serve to guide dividing a reticle into singulated dice. In FIG. 2B , the pecked line 244 indicates the curved edge of the wafer which also forms part of the boundary of the partial reticle 112 and of the incomplete dice 221 . Dice 121 , though complete, are proximate to the edge of the wafer and so being can raise issues as discussed infra.
FIG. 3 shows a further close-up view of another part of the semiconductor wafer of FIG. 1A . Good unsingulated dice 210 are shown. Scribe lines 350 may be used in the singulation process. Also shown are two test circuits 320 . These on-wafer but off-die test circuits 320 may be used to test the unsingulated dice 210 , but since the scribe lines 350 run through the test circuits 320 , the test circuits necessarily do not survive the singulation process and are discarded. Nor are these on-wafer test circuits 320 needed after die singulation.
FIG. 4A shows a plan view of a sample semiconductor wafer 400 manifesting a manufacturing issue or problem. An annular outer area 447 of the wafer adjoining the edge of the wafer 444 may be vulnerable to polysilicon over-etching due to a number of reasons, some of which may be photo-resist non-uniformity, photolithography inaccuracy, and so on. A large central portion 446 of the wafer bounded by a circle 445 is unaffected by the problem of polysilicon over-etching.
It is commonplace in the art to use polysilicon lines to create microcircuit conductive traces and other circuit elements, such as field-effect transistor (FET) gates, especially in Metal-Oxide semiconductor (MOS) technologies. The process typically involves etching a deposited polysilicon layer using photolithography with a mask and photo-sensitive etch resist. For whatever reasons, polysilicon lines near the edge of a wafer may be vulnerable to over-etching. Over-etching a polysilicon line will typically result in reduced width, and/or part or all of the line may disappear altogether.
FIG. 4B shows a graph of after-etching polysilicon line width (y-axis) across a diameter (x-axis) of the semiconductor wafer 400 of FIG. 4A . As shown in FIG. 4B , over the entire central portion of the wafer the resultant polysilicon line width holds a substantially consistent value meeting specifications. But towards the edge of the wafer 444 , polysilicon line width is progressively reduced.
FIG. 5A represents a prior art Complementary MOS (CMOS) microcircuit 500 embodied on a wafer substrate, such as on the wafer of FIG. 4A . Such microcircuits may be used for many purposes including forming parts of tag circuits for RFID (Radio Frequency Identification Device) tags. As shown, V DD and GND are the conventional power rails formed as metallization. The microcircuit depicted in FIG. 5 may be a CMOS inverter. Signal IN port 560 and OUT port 570 may be formed as metallization. Complementary channel regions 540 operate gates formed as polysilicon lines 510 to provide the two FETs that formed the heart of the inverter circuit.
FIG. 5B represents a microcircuit structure 550 similar to that 500 of FIG. 5A but formed near the edge of the wafer, further showing by pecked lines where components have been removed due to the effect described in conjunction with FIG. 4B . A defect illustrated by FIG. 5B is the result of polysilicon over-etching. Contrasting FIG. 5B with FIG. 5A it may be seen that the polysilicon line 580 is of reduced width due the over-etching and the FET gates 581 are missing altogether. Not only will this defect prevent the microcircuit from operating correctly but it will also conduct excessive current “SHORT” between the two power rails V DD and GND. This is, more or less, a short circuit condition that may cause other circuits that rely on the same V DD and GND rails to malfunction also.
Referring to both FIG. 1B and FIG. 5B , suppose that defective (short-circuited) microcircuit 550 is part of test circuit 175 or unsingulated die 222 . In these circumstances, there is a significant risk that, since test circuit 175 energizes die 222 then the combination of test circuit 175 and die 222 will short the power rails V DD and GND together. If such a short-circuit happens then none of the good dice 170 on the partial reticle 112 may be testable prior to singulation and the entire partial reticle 112 may therefore be lost-even though it contains good dice 170 . The need for defect isolation to improve manufacturing yield is self-apparent.
FIG. 5C represents the microcircuit structure of FIG. 5B without the removed components, which therefore causes a short circuit of microcircuit 550 A between the power rails V DD and GND as shown.
FIG. 6 shows a plan view of a part of a semiconductor wafer according to an embodiment of the invention. In an embodiment, a circular boundary 645 may divide the wafer 600 into an overetched annular portion 647 and a non-over-etched central portion 646 .
An isolated defective microcircuit structure 621 may be embodied on a wafer 600 having an edge 644 according to an embodiment of the invention. Over-etched polysilicon lines may be formed. However, the specialized conductive trace(s) 611 are also over-etched to the point of having more or less vanished; this results in an open-circuit at 611 which may function to isolate the defective circuit 621 from the V DD rail. Conductive trace(s) 612 (which may optionally be of the same specialized form) are not overetched, and so the good microcircuit structure 622 may be successfully tested since it is isolated from the short associated with defective microcircuit structure 621 .
FIG. 7A represents a CMOS microcircuit 700 embodied on a wafer according to an embodiment of the invention. Contrasting FIG. 7A with FIG. 5A , the most obvious difference is the presence, in FIG. 7A , of additional polysilicon conductive traces 770 and 771 each with narrowed regions. The conductive traces with narrowed regions 770 and 771 are each connected to a power supply rail and may each function, in a working microcircuit, to energize the circuit by conducting current to or from a power supply voltage rail or ground. In a non-working circuit they may function as disconnect links to isolate the microcircuit from V DD and/or ground. Other embodiments of the invention may include a different number of conductors tailored to become disconnect links under certain conditions (for example just one).
The specialized conductive traces in microcircuits according to embodiments of the invention may serve a similar function to fuses in macro circuits. A purpose of specialized conductive traces is to isolate malfunctioning circuits. The conductive traces 770 , 771 of the circuits of FIG. 7A are tailored, by design, to be at least as vulnerable to over-etching as the microcircuit that they are intended to isolate. For example if, in the circuit of FIG. 7A , the polysilicon line 510 embodying FET gates were to be over-etched then either or both of the specialized conductive traces 770 , 771 would in all likelihood become open-circuit also. Thus, taken as a whole, if the circuit were malformed it would more likely be open-circuit than short-circuit. Although the microcircuit is non-functional either way (short-circuit or open-circuit), failure open-circuit would tend to isolate the defect and so improve average yield as described above. In contrast, failure short-circuit would tend to interfere with the operation of neighboring microcircuits merely sharing the same power rails and thus fail to isolate the defect.
Disconnect links may loosely be termed “fuses” by analogy with similarly purposed components in circuits which rely on fusion to create circuit disconnects. Although conductor fusion is not a particular feature of the present invention the absence of conductor fusion is not a requirement.
In order to embody the invention various approaches may be used to ensure that the specialized conductive traces do indeed disconnect whenever the protected application circuit is over etched. For example, the specialized conductive trace may be formed as a polysilicon line of width or thickness that has been tailored to be purposefully more narrowed in either width or thickness (or both) as compared with conductors in other parts of the circuit thus increasing the relative vulnerability to over-etching of the specialized conductive trace. The line width, embodied such as through photolithography may thus be tailored to have a sufficiently narrowed width that results in this desired greater vulnerability to over-etching.
Alternatively, since over-etching tends to occur near the edges of a wafer, and referring again to FIG. 4B , it will readily be apparent that a gradient of over-etching may occur across a reticle. This can render it advantageous to provide two specialized conductive traces (as in FIG. 7A ), rather than merely one. If both a first and second specialized conductive trace is provided and one of them is on each side of the polysilicon circuit element being protected, then there is an improved chance that at least one conductive traces will be more vulnerable to over-etching than the circuit element it protects. The circuit layout, embodied such as through photolithography may thus be tailored to have a layout that results in this desired greater vulnerability to over-etching for the disconnect link(s).
There is also an issue as to whether the narrowed conductive traces (used as disconnect links) should be placed on the die or off the unsingulated die (but still on the wafer, typically in a test circuit that is discarded in a later manufacturing stage). The circuit of FIG. 7A could apply to either on-die or off-die placement.
For on-die placement, a die may typically comprise an application circuit that includes power rails (conductors), an active circuit and one or more disconnect links. Again typically the disconnect link(s) would be connected between the active circuit and the power rail(s), thus so as to be able to isolate the active circuit from one or more power rails should the manufacture be defective (typically by over-etching). Advantages of on-die placement may include a closer proximity between the disconnect link and the active circuit being protected. Disadvantages may include increased area in the completed die and the possible need to revise a microcircuit that is already proven reliable. It is well known in the art that there is no such thing as a circuit revision that is free of risk.
FIG. 7B represents the microcircuit structure of FIG. 7A , further showing from where components have been removed due to the effect described in conjunction with FIG. 4B according to an embodiment of the invention. In microcircuit structure 750 , disconnect links 780 , 781 are substantially absent due to over-etching and gates 783 , 784 are entirely absent.
FIG. 7C represents the microcircuit structure of FIG. 7B without the removed components, but which does not causes the short circuit of FIG. 5C according to an embodiment of the invention. Although microcircuit 750 A is defective and thereby non-functional is does not interfere with the testing of other dice (especially those on the same reticle).
FIG. 7D represents a microcircuit structure 750 D according to another embodiment of the invention. In this embodiment specialized conductive traces 790 are narrowed by etching to produce a significant resistance rather than an open circuit. As shown the specialized traces 790 have narrowed regions that may act as an equivalent current limiting resistor. Advantageously, the current may be sufficiently limited that testing of other microcircuits on the same reticle is not impacted by the performance of microcircuit 750 D.
It will be apparent to those of ordinary skill in the art that various alternative but substantially equivalent topologies and placements are possible without changing the theory of operation of embodiments of the invention. For example, a disconnect link may be placed in series with a power source feeding the unsingulated die. Typically that power source may be a test circuit and the disconnect link may be created in series with the test circuit, or indeed may be embodied as a part of the test circuit itself.
FIG. 8 is a flowchart of a method 800 for manufacturing a semiconductor wafer according to an embodiment of the invention. In box 810 the method starts. In box 820 a polysilicon layer is formed at (on) a surface of the wafer by methods well-known in the art. In box 830 , the polysilicon layer is etched to embody circuit elements such as may be rendered in a photomask. In embodiments of the invention these may typically include circuit elements of one or more application circuits and one or more conductive traces purposefully tailored to be narrowed, thinned and/or placed in judicious locations for high vulnerability to etching.
In optional box 840 , each die is tested and in optional box 850 the wafer is singulated into dice. In box 890 the method ends.
In the foregoing specification, the invention has been described with reference to specific exemplary embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention as set forth in the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.
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Microcircuits may include polysilicon features that are vulnerable to defects due to undesirable phenomena during manufacturing processes such as, inter alia, over-etching. The same phenomena that may cause defects can be exploited to automatically isolate the affected circuit and thus limit the harm caused by defects or incipient defects.
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TECHNICAL FIELD
[0001] The present invention relates to the field of VLSI lithography, and more particularly to lithographic overlay.
BACKGROUND ART
[0002] As the demand for products with finer and finer features increases, alignment and overlay is becoming more difficult and product failure due to misalignment is becoming more prevalent. Even when the alignment metrology is perfect and the measured misalignment of an alignment mark near a chip is very small, distortion in the projected image of the mask due to mask writing errors and lens aberrations and in the wafer due to internal strains from prior processing steps can ultimately limit the alignment accuracy.
[0003] There are numerous sources of potential distortion in a mask pattern or in its projected image (if it is a photomask) relative to an existing pattern on a silicon wafer. Some of these sources and their properties are described below.
[0004] The electron beam (e-beam) tool used for mask patterning may make mistakes during the write step. Fortunately, in a typical projection lithography tool, the mask pattern is four times larger than the wafer pattern and small, discrete errors, such as a missing micron of chrome, can be corrected by ion implantation. However, long-range errors, such as an entire segment of a mask being displaced (by 0.25 microns for example) cannot be corrected and, if out of tolerance, the mask must be discarded. Mask writing errors vary from mask to mask, and thus each mask must be inspected. To significantly reduce mask writing errors below current levels would greatly increase mask costs. Further, the processing of a photomask may introduce strains (mask strain) in its fused-silica substrate and, hence, lead to pattern distortions.
[0005] Wavefront errors in the projection lens also may distort the projected image. This is called lens distortion. Distortion often limits the maximum field size a lens can project. In many cases the image is best near the optic axis and deteriorates at increasing radii. In scanning systems, some of the lens distortion tends to be averaged out, but at the price of a fuzzy line edge. If the same lens is used to make both the wafer pattern and the projected image of the mask, the lens distortions will be almost identical and will not lead to significant overlay errors. However, if different lenses are used for the two lithographic levels, lens distortion can be a significant problem.
[0006] Further, the silicon wafer may be distorted in x and y (affecting alignment) and z (affecting focus) during processing steps such as, heating, cooling, and the removal or addition of material under stress. These distortions vary greatly from wafer to wafer in different lots and even to some extent from wafer to wafer within the same lot. U.S. Pat. No. 5,094,536 to MacDonald et al. discloses a system where a wafer chuck is distorted in the z direction. In MacDonald et al., vertical distortions in the wafer (distortions out of the plane of the wafer surface) are corrected using piezoelectric actuators to increase the depth of focus. Other techniques, such as grinding the wafer to achieve a high degree of smoothness and pulling the wafer flat with a vacuum chuck, have also been used to reduce out-of-plane distortions. A wafer with significant out-of-plane distortions may be covered with a smooth, flat organic layer which is then covered with the photoresist—since the resist is on a flat surface, the projected image will be in focus over the whole wafer. It is noted that out-of-plane distortions may introduce some lateral distortions because the wafer is stretched when pushed out of plane.
[0007] Still further, the translation and rotation stages are not perfect and can position the wafer in slightly the wrong place. In a scanning system, the mask position is also subject to stage error.
[0008] In every level but the first, the projected image of the mask is aligned to a previous lithographic level on the wafer. Each chip on a particular level is subject to all of the errors, described above, produced during the printing of that level. Since the mask errors at two different levels can be drastically different, the error between the projected image (the current level) and the wafer pattern (a previous level with a different mask) can be significant.
[0009] Distortions can also be created by a chuck that is not holding the wafer (or mask) properly, by temperature effects, or by other environmental factors.
[0010] In practice, many distortions are found to vary continuously, some across the whole wafer and some only across a chip. Still others vary discontinuously from chip to chip. To compensate for such distortions, sufficient misalignment information must be acquired to make an accurate distortion map of the mask/wafer system.
[0011] A case where a projected image of the mask and the existing pattern on the wafer are squares of equal size is a good example. If the two squares do not overlap, they can be brought into alignment simply by moving the mask or the wafer stage. If, however, distortion is present and one of the squares is actually a parallelogram or a square of a different size, the two shapes cannot be made to overlap by stage motions alone because their shapes are not congruent. While it is possible to bring part of the patterns into alignment, it is impossible to achieve alignment over the entire image field.
[0012] The same overlay problems exist in other types of lithography in which there is no projection lens and hence, no projected image. In these types of lithography, the mask itself is aligned with the pattern on the wafer. An example is nano imprinting, a sub-50 nm lithography technique, in which the resist pattern is directly stamped on the wafer. Optical contact printing, proximity printing, and x-ray proximity printing are all lensless lithographic techniques that may suffer the same overlay problems.
SUMMARY OF THE INVENTION
[0013] The present invention provides a holder that can deform a mask or wafer in such a way that much of the image of the mask has a distortion almost identical to the distortion of the pattern on the wafer, and thus the mask image overlays the pattern on the wafer with little misalignment in the exposure field.
[0014] Here, the term image is used in the broad sense—a copy of an original mask pattern. The image could be an image of a mask projected by a lens as in photolithography or it could be a copy of a mask generated by a contact printing method. It is noted that the distortion itself need not be cancelled. The mask is distorted such that the image projected on the wafer has substantially the same distortion as the wafer pattern, thus, the distortion differences between the projected image and the wafer pattern are reduced. As set forth above, the image of the mask may refer to nano imprinting masks (also called molds) or to the projected image produced by a lithography technique, such as photolithography or extreme ultraviolet (EUV) lithography.
[0015] The present invention also provides a process for determining misalignment due to errors from a plurality of sources between the image of a mask and an existing pattern on a wafer, determining deformation values to substantially cancel the misalignment, and deforming the mask and/or the wafer in accordance with the deformation values to substantially realign the projected image of the mask and the existing pattern on the wafer.
[0016] The present invention also provides a lithographic system including a sub-system for determining misalignment due to errors from a plurality of sources between the image of a mask and an existing pattern on a wafer, a computer or other processor for determining deformation values to substantially cancel the misalignment, and a holder for deforming the mask and/or the wafer in accordance with the deformation values to substantially realign the projected image of the mask and the existing pattern on the wafer.
[0017] The present invention corrects overlay errors between the image of the mask on a wafer and a previously existing pattern on the wafer by laterally distorting (i.e., causing in-plane distortions parallel to a surface) the mask or the wafer.
[0018] The present invention can correct for in-plane distortions, such as lateral swelling or shrinking due to localized processing (e.g., metal deposited at high temperature can cause shrinkage when cooled to room temperature) or image distortions due to errors in the mask or projection lens.
[0019] The various embodiments of the present invention are particularly beneficial if the distortion is such that some or all alignment marks can not be brought into registration simultaneously by conventional x-y translations and rotations.
[0020] The adaptive mask holder or adaptive wafer chuck of the present invention use actuators that apply forces and thus deform the mask or wafer in the x-y plane to achieve alignment. Since the mask must remain transparent, actuators apply force to the edges of a mask. Since the wafer is opaque, lateral forces can be applied anywhere on a wafer. In EUV lithography the mask is opaque to EUV radiation (it is a reflective mask) and thus the actuators can be applied to both the edges and the back of the mask.
[0021] There are many types of actuators. Piezoelectric, electrostrictive, or magnetostrictive actuators are preferred because of their speed. However, there are other types driven by thermal expansion, motorized micrometers, etc. that are also usable in the present invention
[0022] It is also noted that the term “optical” refers to all electromagnetic radiation including optical, ultraviolet (UV), deep UV, extreme UV (EUV), and x-ray radiation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1( a ) illustrates a holder for a fused-silica photomask showing the location of piezoelectric actuators and stress uniformizing buffer blocks when undistorted.
[0024] [0024]FIG. 1( b ) illustrates producing a trapezoidal distortion in the horizontal direction.
[0025] [0025]FIG. 1( c ) illustrates an alternate arrangement including actuators and holding pins.
[0026] [0026]FIG. 1( d ) illustrates a cross section of a patterned nano-imprinting mold pressed against a patterned wafer.
[0027] [0027]FIG. 1( e ) illustrates the mold of FIG. 1( d ) being compressed by an actuator to bring both gratings into alignment.
[0028] [0028]FIG. 2( a ) illustrates a vector map of the x and y-offsets on a typical wafer.
[0029] [0029]FIG. 2( b ) illustrates one exposure field representing an average of the five measured fields.
[0030] [0030]FIG. 2( c ) illustrates numerical values for the x and y-offsets of the average exposure field at the upper left (UL), upper right (UR) and lower right (LR) alignment mark locations.
[0031] [0031]FIG. 3( a ) illustrates an adaptive mask holder for a 5″×5″×0.090″ thick fused-silica mask showing the forces required to produce x and y surface displacements that reproduce the x and y offset data shown in FIG. 2( c ).
[0032] [0032]FIG. 3( b ) illustrates a plot of the in-plane surface displacements (in inches) for a mask with the loads computed using a finite-element linear-stress analysis code.
[0033] [0033]FIG. 4 illustrates a block diagram of a through-the-lens alignment metrology system for a step-and-scan projection lithography tool.
[0034] [0034]FIG. 5 illustrates a block diagram of a near-real-time latent-image (or around-the-lens) alignment metrology system for a step-and-scan projection lithography tool.
[0035] [0035]FIG. 6( a ) illustrates a holder for a 6″ silicon wafer comprised of a number of square segments, each with a cross sectional area of 0.5 in 2 , with a vacuum port to hold the wafer and with two piezoelectric actuators per side.
[0036] [0036]FIG. 6( b ) illustrates a plot of the in-plane surface displacements (in inches) for a 6″×0.025″ thick silicon wafer, computed using finite-element linear-stress-analysis (FEA), loaded to reproduce the x and y offset data provided in FIG. 2( c ).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] The present invention is generally directed to an adaptive mask holder that uses actuators to apply force to one or more sides of a mask to produce a controlled deformation of the mask that cancels misalignment due to the distortion that is observed between the projected image of the mask and an existing pattern on a wafer.
[0038] The present invention is applicable to photolithography. The present invention is also applicable to other lithography types, for example, deep UV and EUV projection lithography and to nano-imprinting techniques. There is no lens in nano-imprinting—the mold, which applies a pattern directly to the wafer, is deformed to match the distortions in the pattern printed on the wafer. The present invention is also useful for overlay and metrology applications.
[0039] As described herein, a tool is defined as a machine that uses a mask for some purpose. In VLSI lithography, an image of the mask is recorded on the wafer—thus an EUV scanner step and scan projection camera including for example, a EUV source and condenser, mask, holder, lens, wafer holder, alignment system and wafer transport system is a tool that projects a 13.6 nm EUV image on a wafer coated with radiation sensitive resist.
[0040] In metrology, the pattern on the mask is often used as a standard against which other patterns are compared. The metrology tool provides the optics, lasers, transport stages, etc. which make such comparisons possible. For example, in an optical comparator a test piece is compared to a standard. For example, a VLSI mask may be inspected by comparing it optically against a known perfect mask and differences between the two are defects in the work piece.
[0041] Most inspection tools often inspect a mask for long range errors by determining the x-y coordinates of a number of points in the mask. This may be done with a laser interferferometer controlled stage transport system that has a well-calibrated stage positioning. Long range errors can also be detected with an optical comparator that compares images. Long range errors include whole segments of the pattern being displaced from their ideal coordinates. The pattern itself may be perfect (i.e. have no short range errors) but is positioned in the wrong place. In metrology, long range location of features must be know with precision.
[0042] As described herein the term mask is used as a generic term for the physical plate upon which a pattern is printed. The term vehicle is considered synonyms with the term mask. The mask pattern is the original source of the pattern used in the work. The ultimate source of the pattern is usually the software an e-beam writer sues to create the mask. In lithography the mask pattern is transferred to the wafer by projection, stamping (imprinting), contact printing, etc.
[0043] In metrology, the mask is often a used as a standard and observed directly. The mask may be used to calibrate a tool, such as distortion I a projection lens. There are several types of masks. Long range errors can be corrected by pre-distorting the mask, as described below.
[0044] In a holographic device, an image is reconstructed on a resist to write a pattern or on a photocell to read a memory. In a holographic system, long range errors add noise and false bits to the reconstructed image. By predistorting the mask containing the holographic pattern so the pattern is closer to the theoretical ideal, the reconstructed image will have much lower noise.
[0045] A plate (i.e. mask) used as a reference in metrology typically has features separated by very precise distances. Long range errors in these separations due, for instance to writing errors, can be corrected by predistorting the mask by placing the mask in a holder capable of introducing precise distortions. The mask can then be used in the distorted state while held in the special holder, or by making a replica of the distorted (but accurate) mask by contact printing, imprinting, etc.
[0046] Long range errors are defined as a continuous slowly varying displacement of features over the face of the wafer or mask. The distorted region may be a significant fraction of the whole pattern. Long range errors may be caused by thermal effects, release of built in strains during processing, aberrations in projection lenses, or failure in the tools used to generate the patterns. Long range errors are often found by comparing the measured distance between features to the ideal distances between the features. These displacements can be categorized as strains in the material, e.g. the distance between the features ideal 1 cm apart is actually 1.00001 cm apart, corresponds to a strain of 10 parts per million (10-5). If the mask is being used in a sub-tenth micron lithography, the error would be larger than the line width. If the mask is being used in a quarter micron lithography this may be tolerable, but in a tenth micron lithography it would be fatal.
[0047] Long range errors in the image projected on the wafer may include masks errors and projection lens errors. Long range errors in the existing pattern on the wafer may include projection errors from masks of previous levels and projection lens errors from lenses used in previous lithographic levels plus wafer errors due to wafer processing and the transport system of the camera.
[0048] In VLSI processing, the projected image of the mask should overlay the existing images on the wafer as perfectly as possible. For economic reasons, as many good VLSI chips per hour as possible should be produced. This means a certain percentage of failure is tolerable if the throughput of product is high.
[0049] The first steps to produce overlay is to adjust an x and y position of the wafer, via a trasport system, to bring the alignment marks into registration. As alignment requirements get more severe, overlay is often improved by always using the same lens for all lithographic levels. This means the distortion in both the wafer and the projected image due to the projection lens will always be the same, and there are no overlay errors due to the projection lens. This gives some improvement in alignment, or allows one to use cheaper lenses.
[0050] The next step is to measure the distortions in the projected image and then use this invention to predistort the mask such that a perfect image is projected on the wafer. Note that distorting the mask alone can compensate for distortion in both the mask and the projection lens. All the lithographic levels, including the first, were printed with a perfect projected image, overlay will be improved. Note also that the same lens need not be used for all levels—the predistortion in the mask can be changed to accommodate the specific lens errors from different lenses.
[0051] If the pre-existing pattern on the wafer is already distorted, it is common that each chip has its own distortion, but there is often an average distortion that is similar for most of the chips. By studying the distortion of a few chips, say five or seven, an average distortion is found. The mask is then distorted so that projected image has this average distortion, that in general provides a better overlay than would a perfect projected image. In this strategy, the average distortions of the chips for a particular level are matched and overlay is improved.
[0052] However, the component of chip distortions that deviate from the average and also long range distortions that extend over several chips are not addressed. The distortion of each chip is either measured, or, by measuring a number of chips, the distortions of intermediate chips is calculated by extrapolation. In all cases the distortions in each chip may be different from each other, and for each shot (exposure of a chip) in the step and repeat or step and scan camera, the mask is distorted to compensate for mask and projection lens distortions (as above) plus the known distortions in the chip pattern on the wafer. In a step and repeat camera, the whole mask is distorted by the holder. In a step and scan camera only the part of the mask actually being projected at a particular moment need be distorted, but since the mask scans at high speed, the holder causing the distortions must be fast.
[0053] Mask errors are defined as errors in the actual pattern recorded on the mask plate. These are often errors printed into the resist by incorrect e-beam writing and errors that occur when the e-beam resist pattern is developed and transferred to a film on the mask plate.
[0054] Projection errors are defined as errors introduced to the image of the mask by the lens used to project an image of the mask onto a substrate, usually a photoresist coated wafer.
[0055] Wafer errors are defined as errors in the pre-existing pattern on the wafer due to previous lithographic levels. This may include effects of wafer distortion due to processing, projection errors in previous lithographic levels, and errors in the transport stages used to move the wafer.
[0056] An exemplary adaptive mask holder 10 , with two actuators 12 on each side, is shown in FIGS. 1 ( a )- 1 ( b ). The adaptive mask holder 10 may include a frame 14 to hold the mask 16 . To ensure that the stresses applied to the mask 16 are substantially uniform, the force from an actuator 12 may be applied to a small area of a hard stiff buffer block 18 in such a way that the contact point 20 between the actuator 12 and the buffer block 18 can pivot. Using actuators 12 in tension as well as compression enables a wide variety of mask deformations, such as changing the size of a square mask, deforming a square mask into a rectangular mask, a parallelogram mask, or a trapezoidal mask (illustrated in FIG. 1( b )), or rotating the mask in either direction. In general, the kinds of deformations that can be produced with an adaptive mask holder 10 of the type shown in FIG. 1 can change continuously and monotonically, i.e., the surface displacements may continuously increase or decrease across the mask 16 .
[0057] An arbitrary mask deformation can be more easily obtained when many actuators are used. In FIGS. 1 ( a ) and 1 ( b ) each actuator 12 is opposed by another actuator 12 . However in FIG. 1( c ) the force opposing the actuator 12 is a fixed stud or pin 13 . Using a stud or pin 13 instead of another actuator 12 may complicate the calculations that determine the deformations that should be applied to the mask 16 , but there may be an economic advantage in cost and in reliability.
[0058] [0058]FIG. 1( d ) illustrates a cross section of a patterned nano-imprinting mold pressed against a patterned wafer. FIG. 1( d ) illustrates a wafer 15 , a patterned oxide layer 17 , a liquid polymer 19 , and a fused silica mold 21 . The gratings 23 on the left are aligned but the gratings 25 on the right are missaligned. FIG. 1( e ) illustrates the mold of FIG. 1( d ) compressed by an actuator 12 to bring both gratings 23 , 25 into alignment.
[0059] It is noted that the arrangements in FIG. 1 are only exemplary. For example, the mask 16 of FIG. 1( a ) need not be square and there may be more or less than two actuators 12 and/or blocks 18 per side.
[0060] In cases where a mask 16 can only be squeezed from its edges, not all deformations are possible. For example, the induced deformations cannot have a strong compression in the center of the mask 16 and tension on the periphery. To achieve such a strain pattern in a mask, forces should be applied to the mask center, not just to the mask edges. A photomask is used in transmission, so no actuators 12 can be applied to the center. Because EUV masks are used in reflection, not transmission, actuators 12 may be applied to the back of an EUV mask as well as to the edges. Furthermore, a more complex strain pattern could also be produced in a silicon wafer by placing actuators on the back of the wafer. The actuators would deform the wafer such that displacements are produced in the plane of the wafer surface. Distorting the wafer can produce alignment of all lithographic systems, even those that require transparent masks. However an adaptive wafer holder has many actuators, making it much more expensive, and there is difficulty in attaching the actuators to the wafer using vacuum chucks, but the maximum force that can be applied to the wafer is limited.
[0061] In practice, actuators 12 that compress a mask 16 can be easily employed. In order for actuators 12 to apply tension, the actuators 12 could be bonded to the fused-silica mask substrate, but may inhibit rapid mask changes, cause local strains as the adhesive cures, increase particulate production and increase mask costs. Gripping the mask at the edges with a clamp also has very undesirable side effects. Thus, in its neutral state the mask 16 should be compressed. If the required deformation calls for tension, the compression can be reduced, but should not be reduced to the point where the actuator 12 is no longer in contact with the mask 16 . The residual strains due to distortion are usually less than ten parts per million, which corresponds to 0.2 microns across a 20 mm chip. Thus, it is possible to insert a mask 16 into the adaptive mask holder 10 by pulling the actuators 12 back mechanically or by applying a voltage that would make the actuators 12 shrink so that the mask 16 , in is neutral state is compressed from all sides by, for example, 20 parts per million. In this case, a projection lens could be adjusted to give an extra 20 parts per million magnification so that the final image projected on the wafer has the proper size.
[0062] As described above, it is not feasible to measure the misalignment at all points in a mask/wafer system. Alignment measurements can only be made at those locations that have alignment marks. Since alignment measurements take time, and time spent on tasks other than printing reduces throughput, the time spent making alignment measurements should be reduced. One way of reducing the number of measurements necessary is to measure a few sites and compute the distortion at other sites by interpolation. Accurate interpolation requires that the general pattern of both intra-field and inter-field (or whole-wafer) distortion be known. For example, the distortion introduced by a projection lens in most cases is available from the lens manufacturer. Further, the distortion remains unchanged unless the lens suffers some trauma and its effect will be identical for every chip on the wafer.
[0063] Similarly, mask-writing and mask-strain errors will occur in every chip that uses a particular mask, but these can be accurately measured in advance. The voltages applied to the adaptive mask holder 10 when printing the previous level can be recorded, so the major part of the intra-field distortion on the wafer should be known. Similarly, the long-range distortions in the wafer's previous level should also be known. The distortion added during the processing of the previous level is the difference between the measured misalignment and the misalignment computed from the distortions just described. If this difference is small, then the computation of the distortions at unmeasured sites by interpolation will be fairly accurate.
[0064] In current practice, the lead wafer in a lot is exposed and the resulting overlay errors between the mask and wafer patterns are measured offline (at, typically, three sites per exposure field and five exposure fields per wafer) with an overlay metrology tool such as the Bio-Rad Model Q200. The three measurements at each chip give information about the distortion within a chip. The information from the five separate chips allows an alignment system computer to calculate the overall or long range distortion in the wafer. Alignment marks 22 and vectors 24 of the x and y offsets of a typical device wafer recorded with an overlay metrology tool are shown in FIG. 2( a ). The map of FIG. 2( a ) was produced with a Bio-Rad Model Q200 Overlay Metrology Tool showing five exposure fields. The map of FIG. 2( a ) shows that there are long-range distortions that vary continuously over the whole area of the wafer (as indicated by the left/right asymmetry evident in the center row of exposures) as well as errors localized to the individual chips. Long range distortions may be caused by stresses in the patterning layers, thermal gradients over the wafer during processing, systematic errors in the x-y stages, differences in speed between the mask and wafer in a scanner, etc. A vector map 26 of the average x and y offsets for all five fields are shown in FIG. 2( b ). The vector map 26 shows that each site within a single exposure field can be quite different and that a single x-y wafer displacement can not bring all three sites into alignment simultaneously. Although the above describes three sites per exposure field and five exposure fields per wafer, the number of readings per chip as well as the number of chips may vary.
[0065] The deformations required to cancel the measured misalignments at three sites in an exposure field can be computed analytically by solving six simultaneous equations involving the six known displacements, e.g., the x and y misalignments at the three alignment mark sites shown in FIG. 2( b ), and the six unknown orthogonal strains (magnification, shear and trapezoidal distortion in the x and y directions). Once the strains required for alignment are known, the proper voltages can be applied to the piezoelectric actuators 12 in the adaptive mask holder 10 to create the known strains and bring the mask 16 and wafer into alignment simultaneously at all three alignment marks 22 .
[0066] Another exemplary analytical solution to the problem of determining the required strains uses finite-element linear-stress-analysis (FEA) to simulate the behavior of the mask substrate when subjected to externally applied forces, i.e. the actuators. FEA computations on a 5′×5×0.090′ thick fused-silica mask (exemplary elastic modulus=1.04×10 7 lb/in 2 , exemplary Poisson's ratio=0.17) loaded on its edges with the forces shown in FIG. 3( a ) have been carried out. A plot of the in-plane surface displacements from a simulation that exactly reproduced the measured x and y offsets at the three sites shown in FIG. 2( b ) is shown in FIG. 3( b ). Not surprisingly, the results from the analytical solution to the six simultaneous equations and those from the FEA simulation are quite similar. The only differences are in areas of the mask 16 near the piezoelectric actuators 12 (lying outside of the patterned area) and are a result of the overly simplistic boundary conditions assumed in the analytical solution.
[0067] It is also noted that the two techniques described above could be used together. For example, the simultaneous equations can be solved and the results used as a starting condition for the FEA, which is usually faster if the starting conditions are close to the desired solution.
[0068] The above analysis was conducted using known misalignment measurements at three sites in the chip. If not all chips are measured individually, then the misalignment can be extrapolated from measurements on surrounding chips.
[0069] In order to reduce the misalignment, the first step is to measure the misalignment at a number of alignment mark locations, use that information to re-position the wafer, and deform the mask to compensate for image and wafer distortion, before the exposure is made. When employing such a strategy, a new set of voltages is applied to the piezoelectric actuators 12 before each chip is exposed. Piezoelectric actuators 12 may be subject to hysteresis when the voltages are changed and to drift when a constant voltage is applied. In order to improve accuracy and predictability, the piezoelectric actuators 12 may be equipped with auxiliary devices, such as strain gauges.
[0070] If alignment measurements could be made in real time, i.e. during exposure or so shortly before exposure that the piezoelectric actuators did not have time to drift, the piezoelectric actuators 12 would be less expensive and the whole alignment system would have a faster response time. To accomplish this, a through-the-lens alignment metrology system may be employed, as illustrated in FIG. 4, to monitor the misalignment just before and just after a point on the mask is exposed. Two or more alignment tools may be used simultaneously to obtain sufficient data. In this case, all of the alignment marks on the wafer could be utilized without increasing the measurement time.
[0071] As illustrated, the through-the-lens alignment metrology system 300 of FIG. 4 includes a compound projection lens 104 , a wafer 108 , and the mask 16 . It is noted that the compound projection lens 104 may be a complex lens made up of several optical elements, including lenses and is not limited to the exemplary dual lens arrangement illustrated in FIG. 4. The through-the-lens alignment metrology system 300 may also include alignment optics 306 . It is noted that the alignment optics 306 may include a beam splitter 308 . It is also noted that the arrows on the mask 16 and the wafer 108 of FIG. 4 indicate the use of a scanner, in which the mask 16 and/or wafer 108 are moving in opposite directions during exposure.
[0072] The through-the-lens alignment metrology 300 provides more accurate alignment because all of the misalignment data comes from direct measurements not from extrapolations. A real-time through-the-lens alignment system 300 should be faster (alignment measurements can be made during exposure), more accurate (no interpolated alignment data is used) and cheaper (no need to correct for hysteresis and drift in the piezoelectric actuators 12 ).
[0073] If light at the actinic wavelength is used for alignment, there will be no chromatic aberration in the projection lens 104 and an alignment mark 22 on the mask 16 will be in focus at the wafer 108 . However, in this case, there is danger that the alignment light will expose the resist. This problem can be reduced if the alignment light is turned on only when alignment marks 22 pass beneath the alignment optics (in a scanning system) or if the intensity of the alignment light is small compared to the exposure light. If the alignment light is not at the actinic wavelength, but the projection lens 104 is almost achromatic (as is the case with the catadioptric lens present in a SVG Lithography Microscan Tool), compensating optics can be employed to achromatize the alignment system 300 . Alternatively, the alignment system 300 may employ a light path that goes around the projection lens 104 . In this case, the alignment light can be at any wavelength.
[0074] It is noted that the beam splitters 308 should not extend into the lithographic image field and therefore cast a destructive shadow on the wafer 108 . The lithographic field is the region that has the highest resolution, for example, 0.18 microns in a projector. The alignment marks 22 are usually made of coarser lines, for example, 0.3 microns, and can thus be used in the region of the lens adjacent to the lithographic image field which still has adequately high resolution for these coarser features.
[0075] The mask-to-wafer alignment system 300 may also include a computer 302 and photodiodes 304 . A through-the-lens alignment metrology system 300 , such as the one illustrated in FIG. 4, may also be used to monitor the misalignment between the mask image and the wafer in near real time, just before and just after a slit-shaped region on the mask is exposed. In practice, there may be several alignment marks 22 in the direction of the rectangular or in some cases arc-shaped region being exposed. The results of the alignment measurements are fed to the computer 302 which calculates the voltages to apply to the actuators 12 in the adaptive mask holder 10 that deforms the mask 16 so that it compensates for the wafer distortion and brings all of the alignment marks 22 in the exposed area into substantial registration simultaneously. Since only roughly 15% of the mask area is being imaged at any instant, the alignment accuracy in such a system 300 is better than in one that employs a step-and-repeat strategy because fewer compromises need to be made in the alignment. Since it takes tens of milliseconds for a point on the mask to cross the region being scanned, and a time constant of the actuator 12 system may be in the millisecond range, there is time to make fine adjustments to the voltages on the actuators 12 on the fly.
[0076] An alternative near-real-time alignment metrology system 200 that exploits the fact that actinic light produces a change in the index of refraction of a photoresist on the wafer 108 is shown in FIG. 5. The near-real-time alignment metrology system 200 may include a pre-exposure alignment metrology system, a post-exposure alignment metrology system 204 , the adaptive mask holder 10 , a projection lens 208 , and a computer 210 . The pre-exposure alignment metrology system may include pre-exposure element 202 that reads the position of the mask 16 relative to the projection lens 208 and pre-exposure element 203 that reads the position of the wafer 108 relative to the projection lens 208 . Using this information a computer moves the mask 16 and/or wafer 108 into position for accurate alignment. The post-exposure alignment system 204 measures how accurately the image was projected, and thereby recalibrates the mask-wafer pre-exposure alignment system. The alignment metrology system 200 of FIG. 5 does not go through the projection lens 208 , and is therefore termed an around-the-lens metrology system. The pre-exposure alignment metrology system 202 at the mask 16 (and/or wafer 108 ) feeds information to the adaptive mask holder 10 to correct the mask region that is about to be exposed. A post-exposure alignment metrology system 204 that can see the latent image on the wafer 108 measures the actual alignment immediately after the exposure and produces information that is used to fine tune the alignment. Such a near-real-time alignment metrology system 200 that is both fast and accurate increases throughput, and checks every exposure field so that interpolation is not needed and thus, would be more accurate than any off-line system.
[0077] The embodiments above teach deforming the mask 16 with an adaptive mask holder 10 . This need not be the case; the wafer 108 could be deformed as well as the mask 16 . An adaptive wafer holder 400 , comprised of a number of square segments 402 each with a cross sectional area of 0.5 in 2 and with a vacuum port to hold the wafer 108 , is shown in FIG. 6( a ). Two piezoelectric actuators 12 per side allow each segment to be distorted in a variety of ways, from simple x and y displacements to complex changes in shape (magnification, shear, rotation, etc.). A finite-element linear-stress-analysis was used to simulate the behavior of a wafer 108 (exemplary elastic modulus=2.36×10 7 lb/in 2 , exemplary Poisson's ratio=0.22) on the adaptive wafer holder 400 . Simulation shows that the most uniform distribution of surface displacements on the wafer 108 was created by applying forces to all segments except those directly under the exposure site.
[0078] A plot of the in-plane surface displacements from a simulation that exactly reproduced the measured x and y offsets at the three sites shown in FIG. 2( b ) is shown in FIG. 6( b ). Even with a frictional coefficient of 1.0, the forces in some segments 402 were close to the maximum vacuum hold-down force (14.696 lb/in 2 ×0.5 in 2 ). As a result, larger wafer distortions may be accommodated with an adaptive mask-holder 10 than with an adaptive wafer-holder 400 .
[0079] The adaptive mask holder 10 shown in FIG. 1 uses actuators 12 to apply force to one or more sides of a mask 16 to produce a controlled deformation of the mask 16 that cancels misalignment due to the distortion that is observed between the projected image of the mask 16 and an existing pattern on a wafer 108 .
[0080] The distortion in the wafer 108 is measured by taking readings from a number of alignment marks 22 on the wafer 108 . These alignment values are provided to a computer that calculates the forces that must be applied to the mask 16 to cancel the error. Several strategies to minimize the time required to take the readings have been discussed above.
[0081] If real-time (or, through-the-lens) alignment is used, i.e. alignment measurements are made during exposure, all of the alignment marks on the wafer are used and one would expect better results than with systems that measure fewer marks and rely on interpolation between marks for much of the input data. Such a system of near-real-time measurements is expected to be especially valuable for commercial scanners.
[0082] It is noted that the mask 16 described above may be a photomask. It is further noted that the wafer 108 may be made of silicon. Further, the actuators described above may be piezoelectric actuators, electrostrictive actuators, magnetostrictive actuators, bimetallic actuators, thermal actuators or any other actuator known to those of ordinary skill or later developed could also be utilized. Still further, although the present invention may be used with features of any size, the present invention is particularly effective for features smaller than 100 nm. Still further, although the present invention is applicable to lithography systems, such as optical systems with optical elements, such as lenses, between the mask and the wafer, UV, deep UV, EUV, x-ray, and other lithography systems, the present invention is also applicable to imprint lithography systems, such as nano imprinting. Imprint lithography systems generally involve a mold and a wafer coated with an energy curable polymer. The polymer is cast by being placed in contact with the mold. The polymer is then cured and the mold removed. The pattern in the polymer is then transferred into the underlying substrate.
[0083] It is further noted that the adaptable mask holder of the present invention also works in an arrangement where a lead wafer is sent through a lithographic system, overlay is measured at a number of sites and interpolation is used to calculate the deformations required at the sites that are not directly measured.
[0084] As industry demands force the various lithographic systems to produce circuits with ever finer patterns and the overlay requirements become more stringent, lithographic methods of aligning the pattern of the mask with the pattern of the wafer may produce more errors and the yield (the percentage of products that actually operate) will decrease. This may lead to the popularization of imprinting techniques, such as nano imprinting.
[0085] It should be noted that the present invention may be used in a wide variety of different constructions encompassing many alternatives, modifications, and variations which are apparent to those with ordinary skill in the art. Accordingly, the present invention is intended to embrace all such alternatives, modifications, and variations as falling within the spirit and scope of the appended claims. We claim:
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A deformable holder, system, and process where long range errors (any of lithography, metrology, or overlay errors) between the image of a mask and an existing pattern on a wafer from a number of potential sources are corrected. The long range errors are determined using either a through-the-lens alignment metrology system or an around-the-lens metrology system. Deformation values are determined to compensate for the longe range errors. The deformation values are determined by either solving simultaneous equations or by finite-element linear-stress-analysis (FEA). The mask or wafer is then distorted, in-plane, by an amount related to the determined deformation values using an actuator such an a piezoelectric ceramic to push or pull the mask or wafer to substantially realign the projected image of the mask and the existing pattern on the wafer.
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BACKGROUND
[0001] Some information management processes, e.g. document, e.g. invoice approval processes, need to be automated to enhance the efficiency of the process. The automation is based on the content of the document as well as knowledge about how to interpret the content.
[0002] The process automation in prior art systems has been implemented using some complex rule-based logic. The rules must typically be maintained by an administrator who may not be aware about all the small details that should have an effect on the rules. The complexity of the rules increases the amount of code executed by the computer as well as maintenance work required from administrators. The rules are typically able to handle majority of the transactions, but there are almost always some exceptional transactions that cannot be handled by the rules without making the rules and/or their maintenance process complex. Such transactions require manual processing. There may also be transactions, that do pass the rules of the automatic approval process, but the rules have been outdated because the rules administrator may not have all the information available required to maintain the rules. In such cases, there needs to be a feedback loop from manual approval process to the rules to keep the rules up-to-date using information obtained in the manual process.
[0003] There is a need to find a solution that facilitates efficient manual processing of documents which have not been successfully automatically processed e.g. by a rule-based solution. Advantageously, such solution should also improve the ability of the system to utilize the most recent knowledge about the various aspects of the document in the decision making process regarding the document.
BRIEF DESCRIPTION OF THE INVENTION
[0004] An aspect of the present invention is a computer executable method for facilitating a decision making process for a first document comprising a plurality of data components, each data component comprising at least one data field. The method may be characterized in that it comprises computer executed steps for identifying from the first document at least one data component for which a confidence rate is calculateable, for each identified data component, selecting a plurality of second documents that are associable with the first document based at least in part on the data content of the identified data component of the first document, for each identified data component of the first document, calculating a confidence rate utilizing e.g. the respective data components of the plurality of second documents, and initiating a decision making process for the first document wherein the process utilizes at least one of the calculated confidence rates.
[0005] In an embodiment, the method may further comprises calculating a decision confidence rate for the entire document from the calculated component confidence rates.
[0006] In an embodiment, the step of initiating the decision making process may comprise rendering the calculated decision confidence rate of the entire document on a display device. The step of initiating the decision making process may also comprise executing an automatic decision for the document based on the value of the calculated decision confidence rate.
[0007] The method may further comprise the step of rendering at least one of the calculated component confidence rates on the display device of a terminal computer. Yet further, the method may further comprise the step of rendering at least one user interface control on the display device of the terminal computer for the purpose of detecting at least one user input event regarding at least one component confidence rate of the document.
[0008] The display device may be a touch sensitive display device.
[0009] The method may further comprise the step of storing in the memory of the computer the at least one user input event related to at least one calculated component confidence rate of the document. The user input event may comprise e.g. a new value for the component confidence rate or an process action associable with the component confidence rate.
[0010] The method may further comprise the step of storing the reached decision regarding the document and creating or updating, based on the decision and the content data of at least one document, at least one rule to automate the decision making process for future documents.
[0011] Any of the steps of the method disclosed herein may be executable by at least one computer comprising memory and at least one processor.
[0012] Another aspect of the invention is a non-transitory computer-readable storage medium having instructions stored thereon that, when executed by at least one processor, cause the at least one processor to function as a decision making system adapted to facilitate a decision making process regarding at least one document, the functioning comprising the steps of the method of an embodiment of the invention disclosed herein.
[0013] An aspect of the invention is a computer arrangement comprising any or any combination of the following computer implemented functional components:
statistics maintenance module for accumulating statistics about a plurality of data components of at least one document type, automatic document processing unit for processing incoming documents e.g. using rules and providing input data for the statistics data maintenance module, statistics data storage for storing statistic data related to the data components of the documents, rules repository for storing rules usable by the incoming document processing unit, decision data storage for storing the decision and optionally also opinion data related to the processed documents and/or their components, rule maintenance module for maintaining rule data from the data of the statistic data storage, and terminal device comprising an input device and an output device for providing user interface for manual decision and component characterization data.
[0021] Another aspect of the present invention is an arrangement comprising at least one computer, e.g. a terminal device and/or a server computer. The arrangement is adapted to comprise computer means for performing the steps of any of the methods disclosed herein.
DRAWINGS
[0022] Some preferred embodiments of the invention are described below with references to accompanied figures, where:
[0023] FIG. 1 depicts an exemplary computer and networking arrangement usable in an embodiment of the present invention,
[0024] FIG. 2 presents a diagram of some functional and data elements of the present invention,
[0025] FIG. 3A shows a method according to an embodiment,
[0026] FIG. 3B shows a method according to an embodiment,
[0027] FIG. 4A shows a user interface according to an embodiment,
[0028] FIG. 4B shows a user interface according to an embodiment,
[0029] FIG. 4C shows a user interface according to an embodiment, and
[0030] FIG. 5 shows a high-level conceptual diagram of a computer device usable in various embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] FIG. 1 depicts an arrangement 100 for a preferred embodiment of the present invention. The arrangement comprises a terminal device 101 having a display device 102 . The terminal device may be e.g. a mobile terminal and the display device of the terminal may be e.g. a touch-sensitive display. Also other kinds of terminal devices, e.g. personal computers, are applicable. The terminal device 101 is communicatively connected 121 , 122 to a server computer 110 via a data communication network 120 , e.g. a TCP/IP network. The server computer 110 comprises a data storage 111 adapted to store the data required by the method of an embodiment of the present invention. The data advantageously comprises documents, e.g. invoices that need to undergo an approval process, which for some documents may comprise a manual process. A schematic diagram of the components of a server or terminal computer is shown in more detail in FIG. 5 and discussed in the related detailed description.
[0032] FIG. 2 shows some functional and data components of a preferred computer-implemented embodiment of the present invention. The method is adapted to reach a decision regarding a document 200 . The decision may be e.g. approval or rejection of an invoice or a purchase order or a purchase requisition. In a preferred embodiment, the processing is mostly automatic processing 204 , which may utilize e.g. rules 201 as a means to reach the decision. The automatic processing is implemented using application program logic ( 512 in FIG. 5 ) executable e.g. by the processor ( 502 in FIG. 5 ) of the computer 110 ( 500 in FIG. 5 ) of the system of an embodiment of the present invention.
[0033] The rules 201 are advantageously adapted to reach the decision based on the data of the document and on some additional data associable with the document. The additional data may comprise the calculated component confidence rates of an embodiment of the present invention. For example, a rule may stipulate that an invoice may be approved automatically, if its total amount is less than the amount of a related approved purchase requisition plus some tolerance. An invoice that fails the automatic approval must be approved manually. The rule may be expressed e.g. in pseudo-code e.g. as follows:
[0000]
IF
invoice.total_amount <= requisition.amount *
(1+tolerance_percentage)
THEN
APPROVE
ELSE
SEND_TO_MANUAL_APPROVAL .
[0034] Those documents 200 , whose decisions cannot be reached automatically, are processed using statistics-aided processing module 206 of the arrangement. The statistics-aided processing module 206 utilizes statistics data 203 in its decision making process which advantageously has at least one step requiring manual input. Both the automatic processing 204 and statistics-aided processing 206 modules produce decisions 205 . The decision data 205 may be used to update the statistics data 203 via statistics data maintenance module 207 . Both the automatic processing 204 and statistics-aided processing 206 are advantageously adapted to produce new statistics data 203 or update existing statistics data via the statistics data maintenance module 207 . In an embodiment, statistics data may be utilized by a rule maintenance module 202 , which is adapted to maintain the rules 201 of the automatic processing 204 . For example, a sender of an invoice, whose invoices' approval rate in the manual approval process falls below a certain level, may be marked by the statistics data maintenance module of an embodiment of the present invention as a blacklisted sender in the statistics data. Now, the approval rule of the automatic approval process may be amended by the rule maintenance module 202 to use statistics data as follows:
[0000]
IF
invoice.total_amount <= requisition.amount *
(1+tolerance_percentage) AND
invoice.sender NOT IN statistics.blacklist[ ]
THEN
APPROVE
ELSE
SEND_TO_MANUAL_APPROVAL .
[0035] The rule maintenance module is especially useful in embodiments, where the analysis methods performed by the statistics data maintenance module 207 on the statistics data 203 continually evolve and new findings are thus made from the data. Whenever new findings are made that should have effect on the rule-based automatic processing, the rules 201 may be amended by the rule maintenance module 202 . In the shown example, such evolution is the introduction of statistics-based blacklist.
[0036] FIG. 3 a illustrates the computer executable process 300 of obtaining a statistics-aided decision for a document according to an embodiment of the present invention. The process begins with the step of selecting 301 a document to be processed. This step may comprise reading the data of the document from a storage device 111 into the memory of a computer (e.g. 110 or 101 in FIG. 1 ). Next, in step 302 , the content data of the selected document is analyzed by some computer executable application logic ( 512 in FIG. 5 ) to identify and select a plurality of data fields for components of the decision confidence rate of the document. For example, if the document is an invoice, the data fields of a component may comprise e.g. the fields related to the sender (e.g. id, name and address) of the invoice or data fields (e.g. id, name, unit count, unit price, total price) of a single line item of the invoice. Next, at least one confidence rate is calculated for at least one component 303 using the program logic of an application program ( 512 in FIG. 5 ). The calculation utilizes data of a plurality of second documents. For example, confidence rate of the sender information of the invoice may be calculated by analyzing a plurality of earlier invoices that has the same or at least partially similar sender information. The analyzed data of the component may comprise the decision data of those documents and/or user input data related to the documents. For example, in case of an invoice document, the approval/rejection information of the invoices may be utilized in the calculation. If all earlier invoices from the sender have been approved, the confidence rate of the sender information may be e.g. 100%. Further, if an invoice from the set of earlier invoices comprises user entered information related to the sender of the invoice, such data may be also taken into account when calculating the confidence rate of the component. For example, as part of the approval process of an earlier invoice, a user may have suggested blacklisting the supplier. Such input may lower significantly the confidence rate of the supplier, i.e. the sender of the invoice. In step 304 , the calculated component confidence rates of the document are stored for later possible use. As another example, a confidence rate for a line item may be calculated by an application program ( 512 in FIG. 5 ) e.g. by calculating a median value for e.g. unit count and unit price from previous invoices having the same item and calculating deviation of the current document's corresponding data from the median. The bigger the deviation to the upside, the smaller the confidence rate for the item could be. Selecting the suitable exact computer executable algorithm for such calculations is obvious for a person skilled in the art.
[0037] In a preferred embodiment, the decision for the document is first attempted to be concluded using at least one decision making rule. The evaluation of the document using the rules is performed in step 305 . In an embodiment, the calculated component confidence rates may be utilized by the rules. If the final decision may be reached automatically 306 , e.g. an invoice may be automatically approved, the execution of the method ends and the status of the document is set to “Approved”. If, however, automatic decision making fails, the document is assigned to a computer-aided manual decision making process. In step 307 , a confidence rate for the entire document is calculated by an application program ( 512 in FIG. 5 ) utilizing the component confidence rates in step 303 . For example, a suitably weighted average of the component confidence rates may be used as the calculation algorithm. Next, in step 308 , the document is rendered, using computer executable instructions, on the display device 102 of terminal device 101 of a user whose task is to manually approve/reject the invoice. In addition to the document data, at least one calculated confidence rate is rendered on the display device by an application program ( 512 in FIG. 5 ). In a preferred embodiment, the display device is a touch-sensitive display device arranged to send signals to the computer processor ( 502 in FIG. 5 ) upon detection of touches or gestures on the display device. In step 309 , a user-entered decision and possibly some other user input is obtained from the user interface. The input data, including the decision data, may be indicated by the user via a touch or gesture of the display device. The display device communicates the decision further to the processor ( 502 in FIG. 5 ) which executes suitable instructions of an application program ( 512 in FIG. 5 ) utilizing services of the operating system ( 511 in FIG. 5 ). The application program may also take some further actions, e.g. by storing the decision data and optionally some other user input data into the persistent memory of the system, e.g. into the data storage 111 ( 503 in FIG. 5 ). In a preferred embodiment, the stored data is utilized in the processing of future documents and/or in the maintenance work of the decision making rules of the system.
[0038] FIG. 3 b shows in greater detail the method of obtaining user input of step 309 , e.g. adjusting 320 a component confidence rate of the document, usable in a preferred embodiment of the present invention. In step 321 , the overall confidence rate of the document is calculated and rendered on a touch screen display by a computer executed application program ( 512 in FIG. 5 ). The overall (document level) confidence rate may be e.g. a percentage rate between 0-100 or it may be a binary recommendation value (e.g. “approve” vs. “reject”) or a value from any other suitable scale. In step 322 , the processor ( 501 in FIG. 5 ) of the terminal computer 101 ( 500 in FIG. 5 ) receives a signal from the touch screen display 102 ( 504 and 505 in FIG. 5 ). The signal indicates a request to show components of the calculated confidence rate. In step 323 , the application logic ( 512 in FIG. 5 ) instructs the display device to render at least one component confidence rate on the display device, preferably as an overlay of the document image. Next the touch screen device detects a touch which indicates a request to modify value of a component confidence rate. In a preferred embodiment, the processor executing the application logic receives a signal 324 which is translated by the instructions of the application program ( 512 in FIG. 5 ) into the modification request. In response to the request, the application program instructs the processor to render a UI control for manual adjustment of the value of the component confidence rate 325 . Once the control has been rendered, the user may touch the rendered control which makes the display device to send a signal to the processor 326 . The signal is then translated into an instruction to adjust the component confidence rate of the document 327 .
[0039] FIG. 4 a shows an exemplary implementation of a user interface for statistics-aided processing of a document. The terminal device 400 ( 101 in FIG. 1 , 500 in FIG. 5 ) comprises a display device, which in a preferred embodiment is a touch-sensitive device and is thus capable of acting both as an input and an output device ( 504 and 505 in FIG. 5 ). The display device 401 is adapted to display a document 402 . In a preferred embodiment of the present invention, the display device is also adapted to display an area that indicates a first decision alternative, e.g. document rejection 403 , and a second decision alternative, e.g. document approval 405 , as well as a statistical document-level confidence rate 404 for the second decision alternative.
[0040] FIG. 4 b depicts the example of FIG. 4 a after the user of the terminal device 400 has touched 410 the area illustrating the statistical confidence rate 404 . In the shown embodiment, the confidence rate of the entire document is split into components 411 - 416 . The components characterize the calculated confidence level of components of the invoice to recommend the second decision alternative, e.g. document approval 405 . In the exemplary case of an invoice, the confidence level of a component may be calculated e.g. for the sender 411 , due date 413 , reference number 414 , unit price of the line item 415 , the product/service of the line item 412 or additional payment terms (e.g. dynamic discounting) 416 . To calculate the component level confidence rates, any suitable algorithm may be used. The algorithm may vary from one component to another. In a preferred embodiment, the component confidence rate is calculated using the data of the shown document and the data of a plurality of second documents. The decision data associable with the documents may also be used in the calculation. For example, the confidence rate of the sender component 411 may be calculated from the approval rate of the invoices received earlier from the same sender. E.g. 90% confidence may indicate, that 90% of the invoices received from the sender have been approved without disputes.
[0041] In a preferred embodiment, the confidence rate of a component of the document may be manually adjusted by the user making the approval/rejection decision. FIG. 4 c shows an example, where user touches 420 the component confidence rate 415 of the unit price line item of an invoice line item. The calculated confidence rate in the shown example is 40%, which may e.g. indicate to the user, that the item unit price has significantly risen recently (i.e. the current unit price deviates significantly from the mean unit prices of the same item of the previous invoices). For that reason, the attention of the users is drawn to the component. Now the user may use the user interface control 421 rendered by the application program ( 512 in FIG. 5 ) to manually adjust the confidence rate higher or lower from the value calculated by the algorithm of the application program ( 512 in FIG. 5 ). For example, the user may set the confidence rate 415 to zero and touch the “Reject” button 403 rendered on the screen. This indicates, that the new unit price was not acceptable to the receiver of the invoice and that some additional action should be taken, e.g. the invoice should be disputed because of the sudden rise of the unit price. Alternatively, the user may adjust the confidence rate 415 higher and touch the “Approve” button 405 . This indicates that the price increase is an acceptable one and the new price is the new approved price for the product/service of the line item. The user's input may be utilized in subsequent invoices having the same line item. For example, the calculated confidence rate of the component may remain at the user-defined level until the invoices have been approved or the unit price has been corrected. This way, component-level information about potential issues in the documents may be conveniently communicated within the organization utilizing the decision-making process related to the documents.
[0042] FIG. 5 shows a schematic illustration of one embodiment of a computer system, e.g. a server computer or a terminal computer that can perform the methods of the embodiments described herein. It should be noted that FIG. 5 is meant only to provide a generalized illustration of various components, any or all of which may be utilized as appropriate. FIG. 5 , therefore, broadly illustrates how individual system elements may be implemented in a relatively separated or relatively more integrated manner.
[0043] The computer system 500 is shown comprising hardware elements that can be electrically coupled via a bus 501 (or may otherwise be in communication, as appropriate). The hardware elements can include one or more processors 502 , communication subsystems 506 , e.g. network connection equipment, one or more input devices 504 , which can include without limitation a touch-sensitive device, mouse, a keyboard and/or the like; and one or more output devices 505 , which can include without limitation a display device, a printer and/or the like. The computer system 500 may further include (and/or be in communication with) one or more storage devices 503 . The computer system 500 also may comprise software elements, shown as being located within the working memory 510 , including an operating system 511 and/or other code, such as one or more application programs 512 , which may comprise computer programs of the described embodiments, and/or may be designed to implement methods of the described embodiments of a computer-method of the embodiments as described herein.
[0044] At least some embodiments include a program storage device readable by a machine, tangibly embodying a program of instructions executable by the machine to perform a computer-method of an embodiment of the present invention.
[0045] Although specific embodiments have been described and illustrated, the embodiments are not to be limited to the specific forms or arrangements of parts so described and illustrated.
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The invention concerns a computer executable method for facilitating a decision making process for a first document comprising a plurality of data components, each data component comprising at least one data field. The method is characterized in that it comprises computer executed steps of identifying from the first document at least one component for which a confidence rate is calculateable, for each identified data component, selecting a plurality of second documents that are associable with the first document based at least in part on the data content of the identified data component of the first document, for each identified data component of the first document, calculating a confidence rate utilizing the respective data components of the plurality of second documents, and initiating the decision making process for the first document wherein the process utilizes at least one of the calculated confidence rates.
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FIELD OF INVENTION
This invention relates in general to poultry processing equipment, and relates in particular to apparatus for peeling the pocket lining from poultry gizzards.
BACKGROUND OF THE INVENTION
The edible portions of gizzards from chicken and other poultry carcasses are harvested in several steps. These steps in processing the gizzard include removing the viscera from the gizzard, after which the gizzard is split and opened for washing and removal of the pocket lining from the split gizard.
Gizzard peeling machines usually employ a pair of peeling rolls mounted in side-by-side relation with each other. These peeling rolls have helical teeth along their lengths, with the teeth of the rolls being mutually spaced apart sufficiently to define an elongate space for receiving a gizzard placed on the rotating rolls. This space is too small to permit passage therethrough of the gizzard itself. The counter-rotating action of the toothed peeling rolls removes the pocket lining and draws that lining downwardly through the space until the peeled gizzard rests on the rolls. The gizzard thus becomes properly aligned along a longitudinal axis parallel to the rolls, and the helical teeth on the rotating rolls draws the gizzard longitudinally along that path. The gizzard then is removed from the peeler rolls for further processing.
Because the proper operation of such gizzard peeling apparatus requires a firm engagement of the gizzard with the toothed peeling rolls, some peeler machines use tampers which urge the gizzards inwardly toward the nip of the peeling rolls. These tampers preferably move back and forth relative to the longitudinal gizzard-receiving space defined by the nip between the rolls, the tampers thus alternately moving away from the rolls to accommodate incoming gizzards and moving toward the rolls to tamp those gizzards firmly against the helical teeth on the rotating rolls.
The preferred way of driving the tampers in prior-art peeler apparatus is to mechanically link the tamper to at least one of the rotating peeling rolls at the so-called free or undriven end of that roll. This seemed like a relatively inexpensive and effective way of utilizing the motion of the driven peeling rolls to operate the tamper. However, disadvantages to this driving arrangement have become evident. A principal disadvantage of the tamper drive arrangement in the prior art is that the mechanical load imparted to the peeling rolls damages the bushings of the rolls. This damage may arise from the nonuniform or periodic nature of the radial load imparted to the rotating rolls by driving the oscillating tamper into and out of tamping engagement with a gizzard on the rolls. The problem of damage to the support bushings of the peeling rolls has worsened as the preferred length of these rolls has increased for better performance. The rolls themselves are driven from the end opposite to the location of the tamper, so that a common drive mechanism coupled both to the tamper and the corresponding end of the drive rolls heretofore was considered not feasible without major redesign and reconstruction of the gizzard peeler apparatus.
SUMMARY OF THE INVENTION
The foregoing and other disadvantages associated with the prior art are overcome by the present invention, in which a tamper associated with at least one pair of peeling rolls is driven apart from the rolls themselves. The tamper moves back and forth on a path toward the gizzard receiving space between a pair of peeling rolls, and a separate drive imparts oscillating or reciprocating motion to the tamper. The rolls thus are not subjected to the intermittent or periodic loading heretofore encountered with roll-driven tampers of the prior art, whenever the tamper pressed against a gizzard on the rolls.
Stated somewhat more particularly, the tamper associated with the present invention is mounted for oscillating movement above a pair of laterally-aligned peeling rolls. A movable support holds the tamper for movement along a predetermined path relative to the rolls, and the position of the tamper may optionally be variable to insure proper alignment of the tamper. The drive mechanism for the tamper is directly connected to a drive motor, and in turn oscillates the tamper support on the path leading to contact with gizzards on the rolls. This drive mechanism preferably includes a shaft driven for rotation, and a tamper moving arm eccentrically attached to the shaft so as to convert rotary movement of the shaft into oscillating movement of the tamper.
Accordingly, it is an embodiment of the present invention to provide an improved gizzard peeler apparatus.
It is another object of the present invention to provide a gizzard peeler apparatus wherein the tamper is driven independently of the peeling rolls.
It is a further object of the present invention to provide a gizzard peeler apparatus in which the peeling rolls do not drive the tamper.
Other objects and advantages of the present invention will become more readily apparent from the following description of a preferred embodiment.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a pictorial view showing a gizzard peeling apparatus according to a preferred embodiment of the present invention.
FIG. 2 is an end elevation view taken from the right side of FIG. 1.
DESCRIPTION OF PREFERRED EMBODIMENT
A gizzard peeler apparatus embodying the present invention is indicated generally at 10 in FIG. 1. The gizzard peeler apparatus 10 includes a first pair of peeling rolls 11 and a second pair of such rolls 12 laterally alongside the first pair of rolls, although it should be understood that the present invention is as well applicable to gizzard peeler apparatus having only a single pair of peeling rolls. An infeed chute (not shown) is positioned at one end 14 of the paired viscera removal rolls 11 and 12, and this one end is hereafter known as the infeed end of the rolls. The infeed chute has a downward pitch leading to the viscera removal rolls, and thus comprises part of a conveyor for supplying gizzards to the peeler apparatus 10 from the gizzard splitting and opening machines, as is known to those skilled in the art. A gizzard removal trough 15 is located alongside the paired peeling rolls, longitudinally spaced from the infeed end 14 of the rolls. The gizzard removal chute 15 is pitched downwardly to convey gizzards away from the apparatus 10 after the pocket lining is removed, in the manner known to those skilled in the art.
The infeed end 14 of each peeling roll pair 11 and 12 is mounted in the bearing blocks 20, permitting free rotation of each roll. Each pair of viscera removal rolls 11 and 12 is powered from the end opposite the infeed end 14 in a manner known to those skilled in the art. The bearing blocks 20 mounting the infeed ends of each pair 11 and 12 of peeling rolls are adjustably mounted on the base 23 of the apparatus 10 so that the longitudinal axes of those rolls can be slightly divergent at the infeed end. This adjustability permits the nip between the peeling rolls of each pair 11 and 12 to decrease in width, as seen in the direction toward the discharge ends of the rolls. The peeling rolls of each pair 11, 12 may actually contact each other at the gizzard removal end remote from the infeed end 14, so that only one roll of each pair need be power-driven; the helical teeth of each driven roll thus engages the helical teeth on the mating paired roll, causing the rolls of each pair of counter-rotate at the same speed.
A tamper 25 is positioned above the nip between the first pair of viscera removal rolls 11. Another tamper 26, best seen in FIG. 2, is positioned above the nip between the second pair of viscera removal rolls 12. The tampers 25 and 26 each comprise a flat sheet having a lower edge 27 parallel with the nip of the corresponding pair of peeling rolls, and vertically spaced in close proximity to the nip. Each tamper 25 and 26 preferably is fabricated from a relatively soft nonmetallic material such as nylon or the like, so that the steel toothed peeling rolls 10 and 11 are not damaged by inadvertent contact with a tamper.
A mounting bracket 30 is attached to the back side of the tamper 25 near the upper end of the tamper. Affixed to the upper edge of the mounting bracket 30 is an axle rod 31, which also is secured to the plate 32 extending outwardly from the back side of the tamper at approximately a horizontal attitude. One or more elongated adjustment apertures 33 are formed in the plate 32, and the plate is secured to the oscillating bracket 34 by bolts 35 or the like extending through the apertures in the plate 32 and through similar apertures in the second plate 36 stacked atop the first such plate.
The second tamper 26 also has a mounting bracket 40 attached near the upper end of the tamper. Secured to the mounting bracket 40 is one end 41 of a Z-shaped rod 42, whose other end 43 is secured to the second plate 36 mounted atop the oscillating bracket 34. The second plate 36 is slotted to permit adjusting the rod 42, and thus the lateral position of the tamper 26, relative to the nip between the second pair of peeling rolls 12. The tampers 25 and 26 thus are independently adjustable in the lateral direction relative to their corresponding rolls 11 and 12.
The oscillating bracket 34 is substantially L-shaped, with one leg of the oscillating bracket being substantially vertical and attached to the frame of the gizzard peeler apparatus 10 along a pivotable connection 46. The other leg 47 of the oscillating bracket 34 extends substantially horizontally in the direction of the first tamper 25, and provides a mounting surface on which the plates 32 and 36 are stacked and attached as previously described.
An adjustable connecting rod 50 is pivotably attached at one end of the axle rod 31 associated with the tamper 25. The other end of the connecting rod 50 is rotatably attached to the eccentric shaft 51 carried by the collar 52 secured to the tamper drive shaft 53. The tamper drive shaft 53, in turn, extends through a pair of ball bearing blocks 54 and engages a chain-driven sprocket 55. This sprocket engages the sprocket chain 56 driven by a motor 57 through a speed reducer, which also is coupled to the drive for the peeling rolls 11 and 12 in the disclosed embodiment, as schematically illustrated by the chain-driven sprocket 58 on the shaft extending to a peeler roll.
The operation of the apparatus should now be apparent. As gizzards with attached viscera arrive at the infeed end 14, these gizzards come to rest on the nip 21 between either the first or second pair of peeling rolls 11 and 12. The lateral width of each nip at the infeed end of each pair of peeling rolls is sufficiently narrow to accommodate the gizzards, and the helical teeth on the rolls peels the pocket lining from the gizzards in the manner known to the art. The gizzards, which were split and washed before arriving at the peeler apparatus 10, tend to become aligned with the longitudinal direction of the nip, and are drawn away from the infeed end of the rolls by the helical teeth.
While incoming gizzards thus become positioned on the peeling rolls, the tamper drive shaft 53 continuously rotates and imparts an oscillating motion to the connecting rod 50. This oscillating motion in turn causes the bracket 34 to oscillate about the pivotable connection 46, an action which alternately moves the tampers 25 and 26 toward and away from the respective nips between the peeling rolls 11 and 12. This oscillating movement of the tampers 25 and 26 periodically moves the lower edge 27 of each tamper blade downwardly and at close proximity with the nips, moving the lower edges into contact with a gizzard in the nip beneath a particular tamper. This contact between the tamper and a gizzard presses the gizzard firmly against the helical threads of the peeling rolls, thereby establishing a more positive engagement of the rolls with the lining on the gizzard and momentarily holding the gizzard in place while the rotating helical teeth on the rolls remove the pocket lining from the gizzard. The oscillating motion of the tampers periodically withdraws each tamper from the gizzards, so as not to unduly inhibit forward travel of the gizzards along the peeling rolls. A rotating gizzard removal roll 59 is transversely mounted above the peeling rolls 11 and 12 in line with the gizzard removal trough 15, and helical teeth on the gizzard removal roll displace the peeled gizzards from the peeling rolls and into the removal trough.
It should now be seen that each tamper 25 and 26 is driven apart from the rotating peeling rolls 11 and 12. This separate drive for the tampers is deemed to exist whether a common motor is coupled to drive both the tamper drive shaft 53 and the peeling rolls, or whether separate motors are provided for independent operation of the drive shaft and the viscera removal rolls. In either case, the free rotation of the peeling rolls 11 and 12 is unimpeded by any power-takeoff or similar linkage attached to the infeed end 14 of the rolls, as with the prior art, with the beneficial result that the bushings supporting those rolls at the infeed end are not subjected to the periodic or lateral loadings which can cause premature failure. The ball bearing blocks 54 for the tamper drive shaft 53 are designed to withstand the periodic load of the tampers, but those bearings are fewer in number than the bearings required for the peeling rolls.
It should also be apparent that the speed at which the tampers 25 and 26 oscillate is relatively easily varied independently of the speed at which the peeling rolls rotate. Likewise, the length of each tamper stroke is relatively easily adjustable independently of the peeler rolls. The present apparatus thus permits the operator to select the parameters of tamper operation which provide the best results, without interfering with the desired operating speed of the viscera removal rolls themselves.
It should be understood that the foregoing relates only to a preferred embodiment of the present invention, and that numerous changes and modifications therein may be made without departing from the spirit and scope of the invention as set forth in the following claims.
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A gizzard peeling machine including at least one pair of toothed rolls for grasping and peeling the pocket lining from a gizzard, and having a tamper for periodically pressing the gizzard inwardly against the peeling rolls. Oscillation of the tamper occurs without connection to the peeling rolls, so that the rolls and the support bushings for the rolls are unaffected by movement of the tamper.
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FIELD OF THE INVENTION
The present invention relates to an improved beach and dune erosion control system and method of installation. The system utilizes a large water or sand-filled geotextile container which can be of any desired length sufficient to extend along an entire dune surface being protected. Also it can be of any width extending landward a sufficient distance to provide a width and height for specific design protection characteristics. The container is right triangular wedge-shaped in cross-sectional form and includes a plurality of separate internal compartment cells extending the full length of the container along the dune surface. The pointed edge of the wedge is positioned seaward, the flat base of the container is placed upon a smooth excavated dune base surface, and the thick side of the wedge presents a vertical surface adjacent the usual landward and somewhat vertical eroded dune escarpment. The sloping upper wedge surface extends upwardly landward presenting soft revetment surfaces dissipating impacting turbulent wave action in a predetermined manner. In preferred form, the multi-celled geotextile container comprises three cells varying size, each cell extending the length of the container and increasing in height across the container's width landward. The cells are configured to present multiple stair-step somewhat rounded lobed shaped surfaces shore parallel to erosive, impacting, turbulent waves. Incoming wave forces are progressively dissipated as the wave moves upwardly landward on the rounded cell lobe surfaces. An improved method of container installation and filling the individual cells includes placing a deflated container along the dune surface to be protected so that it covers the length and width of the protected surface and pumping either water or sand slurry into prepositioned cell inlet ports until fluid exits an associated relief port. The procedure is repeated along the length of the container until each cell and the entire container is filled. The filled container can be several hundred feet in length and weigh several hundred tons when filled with wet sand. For example. a container 300 feet in length incorporating a three to one slope will weigh Approximately 800 tons when completely filled with wet sand. The weight and possible extreme size of the filled container results in degrees of protection not previously available. Also, the structure of this invention can be placed upon a dune surface and quickly filled with water for temporary protection when advised of an impending storm. After passage of the storm, the temporary protection is readily converted to permanent protection by displacing the water with sand.
DESCRIPTION OF THE PRIOR ART
Conventional attempts to regulate and prohibit beach and dune erosion usually involve installation of wood, steel, or concrete vertical seawalls; installation of a plurality of piles in close contact to form a wall, or the positioning of large rocks or interlocking concrete blocks upon the surface to be protected forming what is known as a hard revetment. These types of rigid shoreline structures have several disadvantages in that after a period of time the desired result is not obtained. Eventually high seas, wave attack and storm weather conditions will simply result in a test of whether the vertical seawall or rocks are capable of providing a sufficient resistive force to continue to reflect the wave action. Quite frequently storm forces are superior and the seawalls are breached or dislodged or the rocks are scattered about a recreational beach surface causing undesirable aesthetic appearances as well as failing to prevent erosion in a particular beach area. A particular disadvantage of a rigid vertical seawall is that after continual wave induced toe scour erosion against the wall and around the wall, the waves are eventually successful in undermining the lower edge of the wall causing the wall to topple over, or they are capable of working around the ends of the wall and getting behind the wall such that the wall is breached or dislodged and is ineffective as a wave force obstructing device. Likewise, a rock revetment generally results in serious accelerated erosion around the ends of the area covered by the rocks and in a manner similar to that occurring with a vertical seawall, the settling or dislodged rocks become ineffective to prevent erosion in the desired area. In addition, documented evidence of a global nature indicates that utilization of vertical seawalls or hard revetments can result in serious erosion of both the sandy recreational beaches fronting the structure as well as on the adjoining coastal properties at each end of the area that is attempted to be protected, because of the reflected wave action and accelerated wave wash around the ends of those inordinately hard surfaces in a soft sandy beach environment.
SUMMARY OF THE INVENTION
In view of the foregoing, a primary object of this invention is the provision of a Subsurface Dune Protection System employing a unitary geotextile container designed to extend a substantial distance along a dune surface being protected providing single container lengths and weights of erosion protection heretofore unknown.
Another object of this invention is the provision of a Subsurface Dune Protection System utilizing deflated geotextile containers that can be placed in the area to be protected and filled with fluid in situ permitting use of extremely large containers in a manner heretofore unknown.
A further object of this invention is the provision of a Subsurface Dune Protection System providing temporary and rapid protection by placing a deflated geotextile container having a substantial length and width upon dune surface and inflating it water upon notice of an impending storm.
A still further object of this invention is the provision of a dune protection system including a geotextile container that can be inflated with water providing temporary protection and later be filled with wet sand displacing the water for permanent protection.
An object of this invention is the provision of a Subsurface Dune Protection System providing a relatively soft, gently sloping, stepped, permeable wave impact surfaces, gradually dissipating wave forces in a manner preventing beach and dune erosion.
Another object of the invention is the provision of a flexible revetment presenting a soft wave impacting surface effective to reduce the erosive velocity of impacting waves and facilitate the deposit of waveborne sand particles upon the upper surface of the shore protective structure.
A further object of the invention is the provision of a dune protection system preventing dune erosion by controlling turbulent wave action in a way that sand is eventually restored to previously eroded areas.
A still further objective of the invention is the provision of a dune protection system presenting particular predetermined soft wave impacting surfaces dissipating the force of storm waves during severe high water conditions.
Yet another object of this invention is the provision of a Subsurface Dune Protection System having a predesigned wave absorption surface, which ascends as the system is installed landward so that the impacting waves are deterred in a predetermined predictable manner preventing dune erosion.
A further object of the invention is the provision of a Subsurface Dune Protection System installed underneath a beach and dune surface and being effective to prevent dune erosion while not normally being visible in the area protected.
Another object of the invention is provision of a Subsurface Dune Protection System that is readily installed without adversely affecting the natural appearance and function of the sandy recreational beach in an area protected by the restoration system.
A still further object of the invention is the provision of a Subsurface Dune Protection System utilizing a minimum of structural devices thus reducing interference with the aesthetic appearances of the protected beach area.
A still further object of the invention is the provision of a Subsurface Dune Protection System including components formed in a way that recreational use of the particular beach area is not interfered with although the system may infrequently become partially exposed.
Another object of the invention is the provision of a geotextile erosion control container including an outer layer of shielding material on its wave impacting surfaces deterring puncture of the geotextile container when debris is washed ashore.
A further object of the invention is the provision of a space between the container outer shielding layer and the upper impervious layer of geotextile material forming the container which can be permitted to be filled with sand and water by wave action or be filled with a cushioning material further resisting puncture by debris washed ashore.
Another object of the invention is the provision of a toe tube attached to the seaward pointed edge of the wedge-shaped container deterring wave under cutting of the container pointed edge.
A still further object of the invention is the provision of a geotextile container having all fabric seams structured to provide shear resistance to separating forces.
Additional objects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities in combinations particularly pointed out in the appended claims.
The foregoing objects of the invention are achieved by first excavating a base surface, when time permits in a non-emergency situation. A deflated geotextile container including three internal cells, each increasing in height as they progress landward, is placed upon the excavated surface in a shore parallel relationship. A plurality of fluid inlet ports are provided in each cell compartment of the geotextile container. The inlet ports connect with an interior fluid conducting manifold extending the length each cell. The manifold contains a plurality of discharge holes for uniformly filling the cell with wet sand. A fluid pumping system can be readily connected to any one of the inlet ports and depending upon pressure and volume capacities of the system, a particular length of a cell will be filled until fluid exits a specific relief port. The pumping connection is then changed to a downstream location and further filling of the cell is accomplished. The process is repeated until the cell is filled and the pumping system is connected to another cell. The process is continually repeated until all cells and the container is filled. When filled container walls forming the respective cells assume a curved somewhat elliptical shape effective to dissipate impacting wave forces. The pumping inlet fittings are removed and the inlet and relief ports are sealed completing placement of the erosion protection structure. The structure is covered with sand aesthetically finishing the project.
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate the preferred embodiment of the invention and together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an perspective view illustrating a Subsurface Dune Protection System installed in accordance with provisions of the invention.
FIG. 2 is a cross-sectional view of an empty geotextile container positioned to show the toe tube and the shape of the cells prior to filling with wet sand.
FIG. 3 is a cross-sectional view of a filled geotextile container illustrating the curved form of the outer and upper cell surfaces for dissipating impacting wave forces.
FIG. 4 is a fragmentary plan view illustrating a preferred form of welded seams utilized in construction of the geotextile container placing major portions of separating forces in shear stress.
FIG. 5 is a fragmentary plan view of strap restraint systems attached to a crest anchor tube and one fluid transfer tube showing distribution of forces across the length of the crest anchor tube.
FIG. 6 is a fragmentary cross-sectional view of a pumping connection to a cell inlet port for filling the cell with wet sand.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanied drawings.
The preferred embodiment of the Subsurface Dune Protection System of my invention includes a geotextile container 10 as shown in FIG. 1. A dune surface 12 is prepared to provide a base surface 14 adjacent eroded escarpment 16. The container 10 is positioned with an attached or integral sand filled toe scour tube 18 in a seaward position. Toe scour tube 18 can be formed of a rolled section 20 of impervious geotextile material and be covered with a second layer of shielding material 22 as shown in FIG. 2. More specifically, toe scour tube 18 is attached to seaward container cell 24, which in combination with cells 26 and 28 complete the structure of container 10. Each of the cells present curved somewhat elliptical convex surfaces 30, 32, and 34, which rise in height with an increase in distance landward. Also, each cell contains a fluid conducting manifold 36 secured to the inner surface of their respective curved upper walls 38, 40, and 42. The manifolds 36 can be formed by securing a sheet 37 of geotextile material to inner walls 38, 40, and 42 formed of fluid impervious material. A plurality of inlet ports 44 can also be positioned in the walls in alignment with the manifold for filling the respective cells with wet sand. The manifold sheet 37 contains a plurality of discharge holes 45 evenly distributing wet sand within the cells to the extent permitted by the available pump pressure and volume capacity of the pumping system. Ends 46, 48 and 50 of the cells 24, 26, and 28 are tapered downward, as shown in FIG. 1 for a purpose later to be described.
With reference now to FIG. 2, an empty container 10 shown in an unstressed unfilled condition. A base 52 has internal divider walls 54 and 56 attached at heat welded joints 58. An end wall 60 has a protecting shield layer 62, of relatively heavier gauge permeable geotextile material than that used for the inner walls, welded thereover with a space 64 therebetween forming a double walled panel. Inner walls 38, 40, and 42 also have a protecting shield layer 68, 70 and 72 welded thereover providing similar spaces 64 therebetween and forming double walled panels 74, 76, and 78. The base 52, internal dividers 54 and 56, toe scour tube 18 and panels 66, 74, 76, and 78 are secured together by welded joints 58, 80, 82, 84 and 86.
FIG. 3 illustrates configurations of cells 24, 26 and 28 when filled with wet sand. Each of the cells expand outwardly forming the convex wave impacting surfaces 30, 32, and 34 mentioned in reference to FIG. 1.
Referring to FIG. 4, a preferred form of a welded seam is shown. Inner walls 38 and 40, both formed of impermeable geotextile material, have outer shield layers 68 and 70, both formed of permeable relatively heavier gauge geotextile material, welded respectively thereto. Internal divider wall 56 includes a bent tab 88 engaging and being welded to inner surface of wall 40. A strip of geotextile material 90 includes tabs 92 and 94 bent at a right angle, the tabs respectively engaging and being welded to divider wall 56 and the inner surface of wall 40. A significant feature of these welded seams is that all separating forces are resisted in "shear" as distinguished from a "peal" resistance.
With reference to FIG. 5, inlet port 44 is cut into layers 38 and 68 at a specified location. A polyvinylchloride pipe fitting 96 having a gasket seal 100 fitted against a flange 98 is inserted within port 44. A second gasket 102 is fitted over the pipe fitting 96 and pressed against the upper surface of protect shield layer 68. A quick coupling nut, of conventional design is tightened against the gasket 102 connecting fitting 96 for transmission of a wet sand slurry into cell 24. The slurry is pumped into manifold 36 until fluid exits a relief port 106, shown in FIG. 1, indicating a section of the cell is properly filled. Nut 104 is loosened and attached at another port 44 and the process is repeated until the cell is filled. The inlet ports 44 and relief ports 106 are then covered with glued patches and the cell is ready to receive impacting waves from the surf 108.
FIG. 6 illustrates a mattress assembly 110 for sealing junctions when it is necessary to use two or more container assemblies. The mattress 110 is formed by use of two layers of geotextile material 112 and 114 welded together at seams 116 and 118 forming a flat central base section 120 surrounded on three sides by a U-shaped tubular section 122. The tubular section 122 is filled with sand forming a front barrier 124 at the base of the "U" which is positioned immediately landward of the toe scour tubes 18.
The two container assemblies 10 are placed to abut end to end at the centerline 126 with their respective toe tubes 18, cells 24, 26 and 28 all in contact on the mattress assembly 110. The tubular section 122 acts to seal the abutting joint behind the toe tubes 18.
Spaces 64 between the protect shield layers 68, 70 and 72 enhance protection of the impermeable layers 38, 40 and 42 in that the space can be filled with any known weather resistant fiber cushioning material or be left empty. The shield layer is preferably of a rather thick but porous geotextile material. Consequently, it has been found that it is likely sand will collect in the spaces 64 so that further puncture resistance is provided for the inner layers 38, 40 and 42.
After the Subsurface Dune Protection System is installed according to the previous description, a predetermined quantity of compatible sand fill is distributed over the entire system. The sand fill is contoured into a gently sloping beach and dune surface which may be planted with appropriate vegetation to assist in the stabilization of the fill material. The finished dune restoration and revegetation project atop the previously emplaced erosion control system allows for the full recreational use of the naturally appearing beach and dune areas, while providing substantial levels of storm protection hidden below.
A significant feature of the subject structure is the concept of filling a very large container in situ. The ability to place the empty structure at a specified location and fill it with hundreds of tons of water and sand affords a degree of erosion protection heretofore unavailable.
As can be readily seen and appreciated from the above description, the Subsurface Dune Protection System presents a relatively soft, stepped, wave absorptive surface, which is designed to gradually dissipate the force of waves impacting the beach and dune areas along the shorelines.
It is significant that a wave will first contact the seaward curved surface 30 of cell 24 and will continue upward engaging similar surfaces 32 and 34 of cells 26 and 28 as can be appreciated from FIG. 1. As the wave impacts surface 30 and continues upwardly against gravity, across the subsequent cell surfaces wave force and velocity is gradually dissipated. Each surface functions as a flexible wave tripping device producing water particle rotation and tumbling, thereby dissipating wave uprush in a manner similar to the phenomena of near shore waves cresting and breaking over natural reef structures.
It is known that wave action is an orbital rolling action as it impinges against a beach or dune surface and by interfering with this orbital rolling action in a series of stages or steps, the wave's force and velocity is gradually decreased, thus minimizing erosion.
As wave velocity decreases by impacting upon the successive cell surfaces waveborne sand particles carried in suspension by the water velocity begin to settle out of suspension onto the upper surface of the container structure and produce natural accretion process. Consequently, this invention is extremely significant in that it takes advantage of the natural phenomena of potentially millions of cubic yards of waveborne sand particles in suspension within the littoral system and near shore wave action normally impacting upon a beach and dune surface, and does so through the utilization of a relatively simple system working in harmony with nature.
Movement of the container is greatly inhibited by the combined size and weight of the three cells in the preferred embodiment, for example, a 300 foot unit will weigh approximately 800 tons.
Upon reaching the extremities of the project area in a shore parallel direction, the Subsurface Dune Protection System preferably is swept gradually landward over a graceful curve or arc, such as by curving cell end portions 46, 48 and 50 illustrated in FIG. 1. This minimizes the effects of the structure's existence on adjacent coastal properties. Right angles, such as vertical return walls on conventional hard erosion control structures are infamous for creating accelerated erosion on neighboring waterfront properties and are to be avoided. The graceful, wide, curving returns indigenous to the gently sloping Subsurface Dune Protection System design eliminates the turbulent rotor currents normally associated with abrupt right angle vertical return structures. Gentle, flowing curves assure the greatest possibility of maintaining a more linear hydrodynamic flow of shore parallel current during severe storm surge conditions.
It will be apparent to those skilled in the art that various modifications and variations can be made in the Subsurface Dune Protection System of the present invention without departing from the scope or spirit of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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A Subsurface Dune Protection System making use of a wedge-shaped geotextile container of such size it must be filled with a sand slurry or water in situ. The wedge-shape permits provision of a slope to an upper wave impacting surface for dissipation of wave forces and accretion of sand on a dune surface being protected. The container can be divided into cells so that each cell presents a particular wave impacting surface as the cells increase in height as they progress landward. The cells are formed by walls of impermeable material for filling with water in rapid emergency installations and can later be filled with wet sand as the water is displaced for a permanent installation. The impermeable walls cause the sand to remain wet substantially increasing weight of the container. The substantial length, width and weight of the container provide significant resistance to storm wave forces.
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BACKGROUND OF THE INVENTION
Computer-aided design (CAD) software allows a user to construct and manipulate complex three-dimensional (3D) models of assembly designs. A number of different modeling techniques can be used to create a model of an assembly. These techniques include solid modeling, wire-frame modeling, and surface modeling. Solid modeling techniques provide for topological 3D models formed from a collection of interconnected edges and faces. Geometrically, a 3D solid model is a collection of trimmed surfaces. The trimmed surfaces correspond to the topological faces bounded by the edges. Wire-frame modeling techniques, on the other hand, can be used to represent a model as a simple line drawing. Surface modeling can be used to represent a model's exterior surfaces. CAD systems may combine these, and other, modeling techniques. For example, parametric modeling techniques can be used to define various parameters for different components of a model. Solid modeling and parametric modeling can be combined in CAD systems supporting parametric solid modeling.
An assembly design contains various shapes (e.g., fillets, extrusions, and holes), hereinafter referred to as features. Many times, features are designed with the intent of providing a connection to a particular part. For example, a hole is a feature and may be designed as a connection for a fastener. The design engineer, when designing the hole, typically designs the hole with a specific fastener in mind, which in many cases, is an industry standard part.
When designing an assembly, a design engineer may need to incorporate a standard part in an assembly model. Rather than re-designing a standard part, the part may be retrieved from a database of existing parts. Commercially available component databases contain computer models for standard physical parts. Such databases are referred to as part libraries. Examples of commercially available part libraries are the Genius Fastener Library from Autodesk, Inc. of San Rafael, Calif., the Solid Edge Fastener Library available from Unigraphics Solutions Inc. of St. Louis, Mo., and the SolidWorks Toolbox from SolidWorks Corporation of Concord, Mass. (formally the Toolbox/SE Browser from CIMLOGIC, Inc. of Nashua, N.H.).
The SolidWorks Toolbox part library stores one part model for each class of parts, and a set of features or parameters for each class member. Using the 3D configuration capabilities of the SolidWorks® 2000 software, features and parameters for each unique part are stored as one or more attributes that reference the part model. For example, one configuration may have an attribute that defines a screw's drive head as having a slot or having a profile shaped as a hexagon. The 3D configurations are created as needed during the design process after the valid relationships in the database are displayed in a user interface dialog box and a design engineer selects those relationships desired in the part.
The SolidWorks Toolbox part library is extendable. A part may be added by first selecting a part name from a feature manager design tree or by picking a part in the modeling portion of the window. The design engineer may also modify the existing part library in such a way as to reduce the number of parts that may be retrieved. Reducing the size of the part library may be desirable to reflect existing inventory and to include only those parts that a corporation permits employees to purchase. To reduce the size of the part library, a part may be deleted or a permission necessary to access the part may be removed.
CAD systems that provide an interface to a part library enable design engineers to import pre-defined component parts into the CAD system's modeling space. To import a predefined part, the design engineer must first access the database then initiate a database search for the desired part. Conventional techniques for performing a database search include manual searches by a design engineer. The design engineer may scan an index containing filenames and/or part numbers and then select an item from the index. Alternatively, the design engineer may compose a database query that produces and issues a search command to the database system. The design engineer typically interacts directly with the database program in filtering and selecting among search results.
When the design engineer locates an appropriate part, a preview of the part may be displayed to allow the design engineer to view, and possibly reject, the part, before issuing a command to download the part into the CAD system's modeling space. The download command calls on one or more interface functions (i.e., software that controls communication between the part library and the CAD application), to retrieve the model of the standard part from the database and copy the model of the part to the CAD application's modeling space. After a part is imported into the modeling space, the design engineer may examine and analyze the imported part to be assured that the part is appropriate for the assembly. The part may then be inserted into the assembly model by establishing a connection with a feature in that model.
To insert the part into the assembly model, the part must be positioned relative to a feature in the assembly. The designer may issue commands via the user interface to move the part to the appropriate location within the assembly model and ensure that the part is properly aligned. Alternatively, existing technology may be used to automatically position (i.e., locate and align), a part with respect to a feature. The SolidWorks® 2000 software, available from SolidWorks Corporation of Concord, Mass., can infer mating relationships between a feature and a part by analyzing geometric characteristics of the feature and the part, then determining the correct position (including alignment) of the part with respect to the feature. Such mate inferencing is described in U.S. Pat. No. 6,219,049.
To infer mating relationships, the SolidWorks® 2000 software analyzes a characteristic set of geometries for a chosen part. For example, a bolt may include characteristic geometries of a cylinder for the shank and characteristic geometries of a plane for the face under the bolt's head. Complimentary geometries are then found in the feature, such as a cylindrical hole.
One technique that may be implemented for finding complimentary geometries of a chosen part and a feature is a logic table, in which characteristic geometries are related to mate types. In the logic table, a characteristic geometry, such as an axis, may be related to a concentric mate constraint, whereas a characteristic geometry, such as a plane, may be related to a coincident mate constraint. Possible target geometries that can satisfy mate constraints for the characteristic geometry may then be found using another table that identifies mating geometries. An axis with a concentric mate constraint requires a circular edge or conical face. A plane with a coincident mate constraint may have a mating geometry that is another coincident face. The part is then mated to the feature by positioning the characteristic geometries in the component with respect to target geometries in the feature.
During the modeling process, the design engineer may modify a feature. For example, the diameter of a hole may be enlarged or the depth of a hole may be increased. In either case, the part may no longer be appropriate for the feature. The design engineer may also decide to replace a part that was retrieved from a part library with another part in the library, which may cause the feature and newly retrieved part to become incompatible.
The design engineer must maintain the connection between the feature and the part when either the feature or the part is modified. If the design engineer changes the characteristics of the hole, a new fastener must be found and incorporated into the assembly model using the manual process previously described. If the design engineer changes characteristics of the fastener, the hole may need to be modified to account for the fastener's changed characteristics.
Before a feature is modified or a part is exchanged, the engineer must first remove the component that is no longer needed, then repeat the interactive process of incorporating a database component in an assembly model. Thus, the engineer must access the database application, find an appropriate part in the database, download the appropriate part from the database into the CAD system, and position the part with respect to a feature in the assembly.
One limitation of part selection and integration in a typical CAD systems is the speed and accuracy in which a part can be retrieved from a part library and integrated into an assembly model. This limitation results from the active role of the design engineer in selecting the part and integrating it with the model. The design engineer may need to use trial and error techniques to retrieve a part, or may need to re-measure the feature before retrieving an appropriate part (e.g., in the event that the design engineer cannot recall the correct size of the feature). Furthermore, typical CAD systems do not have a mechanism for establishing and maintaining an association between a feature and a connecting part in the part library. Although, a feature may be automatically created after a design engineer describes the feature, the description is not utilized to describe a part, or set of parts, that may connect to the described feature.
An example of automated feature creation is found in the SolidWorks® 2000 CAD system. Solidworks 2000 can automatically create holes using a feature generator known as the hole wizard tool. The hole wizard tool can define a hole feature based on a series of parameters specified by the user. For example, a ¼″ counterbore through-hole has an attribute that specifies the diameter of the hole and contains a value that is appropriate so that a ¼″ screw can fit without interference, an attribute that specifies the style of the hole and contains the value “counterbore,” and an attribute that specifies the depth of the hole and contains a value that is automatically calculated by the system after the system determines if the hole is a “through hole” or a “blind hole.” (“Through holes” pierce an object, whereas “blind holes” end before penetrating an object.) The appropriate hole feature, having an appropriate depth, is automatically generated by dimensioning a sketch of the hole feature in accordance with the specified parameters and preset parameters (e.g., chamfer angle). The parameters specified using the hole wizard tool become attributes that are contained in the data structure that defines a hole. However, the attribute is only used to geometrically recreate the feature for display purposes and to enable the design engineer to edit the parameters of the hole. To identifiy a fastener that fits the created hole, the design engineer must manually compose a database query that includes the parameters specified using the hole wizard tool.
Some commercially available CAD modeling systems integrate or interface to component databases, and some aid in the initial placement of those components by locating and aligning the component. However, modeling systems do not have the ability to find the features and automatically populate the features by retrieving a database component and placing that database component in an appropriate location with respect to the feature. Additionally, modeling systems do not have the ability to maintain the connection between a feature and a part that was initially retrieved from a database.
SUMMARY OF THE INVENTION
In one aspect, the invention is designed to provide a unique interface between a computer-aided modeling system and a database system that can automate part selection and integration with a model designed using a computer aided design (CAD) system. The unique interface is realized through an automated connection mechanism that infers the purpose of a model feature created by a user, and can automatically identify other model components compatible with the feature. For example, the system can infer that a collection of hole features created by a user will be filled by compatible fastener parts, and the system can automatically identify such compatible fasteners parts. These parts may be located in a library of standard parts or dynamically configured based on a part model.
In general, in one aspect, the invention features a computer-implemented method for construction of a model using a computer aided design system. The method includes constructing a feature in a three dimensional model based on data input by a user. Following construction of the feature, a part configured to compatibly couple with the feature is automatically identified based on design attributes of the feature. The part can be selected from a parts library that includes data representing parts and their geometric characteristics. In another aspect, the invention can automatically generating a part or other model component that can be coupled to the feature. The part generation includes querying a component model repository (i.e., a model library) to retrieve a component model. The model is retrieved based on compatibility between an attribute of the component model and a design attribute of the feature.
Implementations may include one or more of the following features. The part may be selected from a parts library and automatically positioned in a coupling relationship with the feature. The part may be generated based on a part model having an adjustable geometry. The generated part may then be stored in the part model library for reuse. The model data may details construction of the design model based on a hierarchical relationship among components, the components being selected from the group consisting of a part, an assembly, and a subassembly. Constructing a part or component from a parts model may be done by associating configuration data with an instance of the model, the configuration data representing a value of a modifiable attribute of the model. The inventions described herein may be embodied in computer systems and computer readable media.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Implementations can include one or more of the following advantages. An automated connection mechanism automates the process of finding standard part models in a database and incorporating the standard parts in an assembly model, thereby encouraging the use of standard industry parts that may be contained in a commercially available database. An automated connection mechanism notifies the design engineer when a modification of the assembly model causes a part to become incompatible with respect to a feature within the assembly. The design engineer then may command the system to perform another automated search for an appropriate part in the database. Furthermore, the automated connection mechanism may be extendible, allowing a design engineer to expand the database as needed. Efficiency, flexibility, and functionality of a computerized modeling system may be enhanced. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of a computer system.
FIG. 2 is an illustration of an image on the CRT.
FIG. 3 is an illustration of a hierarchical data structure.
FIG. 4 is an illustration of a hole wizard tool.
FIG. 5A is an illustration of an image on the CRT.
FIG. 5B is an illustration of an image on the CRT having connectors.
FIG. 6 is a flow chart of steps that connect a part to a feature.
FIG. 7 is a flow chart of steps that perform a grouping process.
FIG. 8 is a diagram of a model object and a configuration object.
FIG. 9 is an illustration of tables in a relational database.
FIG. 10A is an illustration of an assembly prior to having accessory parts added.
FIG. 10B is an illustration of an assembly after top-side accessory parts are added.
FIG. 10C is an illustration of an assembly after bottom-side accessory parts are added.
FIG. 11 is an illustration of a dialog box overlaid on a window containing a model.
FIG. 12A is an illustration of a window containing part previews.
FIG. 12B is an illustration of a window after a part is dropped.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a computerized modeling system 100 that includes a CPU 102 , a CRT 104 , a keyboard input device 106 , a mouse input device 108 , and a storage device 110 . The CPU 102 , CRT 104 , keyboard 106 , mouse 108 , and storage device 110 can include commonly available computer hardware devices such as a Pentium-based processor. The mouse 108 has conventional left and right buttons that the user may press to issue a command to a software program being executed by the CPU 102 . Other appropriate computer hardware platforms are suitable as will become apparent from the discussion that follows. Such computer hardware platforms are preferably capable of operating the Microsoft Window NT, Windows 95, Windows 98, Windows 2000, or UNIX operating systems.
Computer-aided design software is stored on the storage device 110 and is loaded into and executed by the CPU 102 . The computer-aided design software allows the user to create and modify a 3D model and implements aspects of the invention described herein. The CPU 102 uses the CRT 104 to display a 3D model and other aspects thereof as described later in more detail. Using the keyboard 106 and the mouse 108 , a user can enter and modify data for a 2D or 3D model. The CPU 102 accepts and processes input from the keyboard 106 and a mouse 108 . The CPU 102 processes the input along with the data associated with the 2D or 3D model and makes corresponding and appropriate changes to the display on the CRT 104 as commanded by the modeling software.
External database software may also be stored on the storage device 110 and loaded into and executed by the CPU 102 . Alternatively, external database software may run on a separate hardware platform 112 that is included via network hardware and software in the computerized modeling system 100 . The separate hardware platform 112 includes a CPU and a storage system, among other computer components.
A CAD application, executing on the CPU 102 may contain the database software directly in the CAD application, or may spawn a database program as a subordinate process. Alternatively, the database program may be installed as a server software process in the same or a different computer system, or may be dynamically linked to the CAD application.
In one embodiment, an external database (also known as a part library), is an add-in, which is a software program that extends the capabilities of another software program, such as a CAD application. One implementation of the external database uses Microsoft Object Linking and Embedding (OLE) technology to link an external database to the CAD application. The external database may also be a dynamically linked library (DLL), meaning that the database is linked to the CAD application at run-time rather than being linked with the CAD application at compile time. Many other database interfaces may be used, e.g., Microsoft Open Database Connectivity (ODBC), Structured Query Language database interfaces, and simple flat-file databases.
FIG. 2 shows a display generated on the CRT 104 by CAD software. The display includes a window 240 subdivided into a modeling portion 244 in which a 3D model 242 is rendered. A user can construct and modify the 3D model 242 in a conventional manner. The surfaces of the 3D model 242 can be displayed, or the 3D model 242 can be rendered using solid lines and dashed lines to show visible edges and hidden edges, respectively, of the 3D model. Implementations may also include other window areas, such as a feature manager design tree 246 , which helps the user visualize and manipulate the model 242 , shown in the modeling portion 244 , as well as components of the model 242 .
A CAD system may represent a 3D model using a hierarchical data structure. Hierarchical data structures can be used to represent solid models as combinations of components such as geometry, topology, operations, transformations, assemblies, subassemblies, parts, and other model data. FIG. 3 shows a hierarchical data structure known as a tree. The tree 300 includes nodes 301 – 312 arranged in parent-child relationships that identify model components and express relationships between modeled components. For example, node 310 may represent one part in a model, node 311 may represent a second part in the model, and their parent node 305 may represent a subassembly that contains the two parts. Thus, node 305 defines a relationship between its descendents that results in the formation of an object that is a subassembly. A modeled object may be represented by a root node 301 and nodes 302 – 312 connected to the root node 301 . Modeling software can construct (or render) a modeled object by traversing (“walking”) the nodes in the hierarchical data structure 300 . Walking the nodes 301 – 312 can include performing a breadth-first or depth-first traversal of the nodes 301 – 312 to locate descendent nodes of any given ancestor node. The model may then be constructed by performing the operations represented by the ancestor and descendent nodes.
While a design engineer is building a model using a CAD software system, features are constructed with the intention that a particular part will connect to a particular feature. The design engineer may capture his or her design intent by describing the intended use of the feature and having the description stored in the feature's data structure. Such descriptions that encapsulate the design intent of a feature are hereinafter referred to as descriptors. In one embodiment, the descriptor is a set of attributes that when taken together may be conceptualized as a descriptive text string. For example, the string ‘ANSI inch ¼″ socket head cap screw 1.85″ through hole’ represents descriptor attributes for a standard, size, type, and length, which together contain design intent of a hole feature. Other embodiments may encode descriptors as a single attribute.
The automated connection mechanism is driven by descriptors. A descriptor is stored in a feature's data structure when the design engineer creates the feature. The descriptor is later used to find and retrieve a standard part, for which the feature was designed, from a part library. To find and retrieve a standard part, the descriptor associated with the feature is used to automatically construct a database query that identifies a set of records in the part library. Thus, parts are selected from the parts library by matching (in whole or in part) attributes derived from a feature's descriptor with attributes of pre-defined standard parts models.
One method for ensuring that the feature descriptors and the keys in the part library match one another is to have the descriptors created automatically by a feature generator, such as the SolidWorks® 2000 hole wizard tool. The present invention extends the capability of the hole wizard tool to build a descriptor that stores the design intent of a feature for purposes beyond geometric re-creation and editing operations.
FIG. 4 shows the hole wizard tool's graphical user interface as extended to meet the requirements of the present invention. As shown in FIG. 4 , a hole definition dialog box 402 displays a set of property names and one or more parameters for the properties. A parameter value may be chosen from a pull-down menu, such as the pull-down menu 404 , that contains a list of acceptable values for the respective property. Pressing the Next button 406 instructs the system to continue creating the hole feature, which includes building a descriptor. The descriptor may be built by storing the parameters of one or more properties as feature attributes. The properties encapsulated in the descriptor may include a property that specifies an industry standard 408 (e.g., ANSI Inch, ISO, or DIN), and properties that specify a hole style 410 , a fastener type 412 , and a fastener size 414 .
In one embodiment, two databases are present. One database is a feature database and contains data used to model standard features, such as holes. The feature database may be an integrated component of the software module that generates a feature, such as a component of the hole wizard tool. The second database is a part library, which is a collection of parts. The part library contains data used to create models of standard components and is indexed by the descriptors that may be constructed by a feature generator.
FIG. 5A shows an image of an assembly 502 displayed in a window 500 . The assembly includes a flange 504 that contains a pattern of holes 506 . The automated connection mechanism may automatically select a fastener and populate all the holes 506 in the flange 504 with that fastener. This operation may be performed without any intervention from the design engineer. FIG. 5B shows an image of the assembly 502 in the window 500 after the pattern of holes are automatically populated with connectors 508 . The connectors may all be the same part because all the holes in the pattern are the same size.
Referring to FIG. 6 , a flow chart shows a procedure 600 that automatically selects a part compatible with a feature designed by a design engineer and couples that part to the feature. To begin the procedure 600 , a design engineer designs a feature that is intended as a receptacle for a particular part, and the design intent is made known to the modeling system (step 602 ). As previously described, a hole wizard feature generator may be used to express design intent. The modeling system then builds a descriptor from the design intent data (step 604 ), and associates the descriptor as an attribute in the feature's data structure (step 606 ). Descriptors may be associated with a feature in a number of ways, e.g., including descriptor data directly in a feature's data structure, by using pointers or links between the descriptor data and the data structure, or by using database keys or other information to associate the descriptor and feature data.
When one or more features need to be populated with connectors, the automated connection mechanism locates features within a scope specified by the design engineer and performs a process that organizes the features into groups (step 608 ), which will be discussed later in more detail. The part library is queried once for each group of features, with the goal of retrieving a part that is appropriate for the group (step 610 ). The retrieved part may be used once as a connector for the entire group, such as a group that is a set of coaxial and concentric holes, or the part may be used multiple times to populate all features in the group, such as a group that is a pattern of holes.
More than one part in the part library may be appropriate for populating a group of features. Therefore, the automated connection mechanism determines the best companion part for the feature, which is a decision that the design engineer may override. For example, in one embodiment, the automated connection mechanism reviews a list of valid lengths for a family of parts. Before retrieving a part, the automated connection mechanism determines which length would provide the best fit. If an appropriate length does not exist, a new configuration of the part family (within the specifications of the part library), is generated and stored. In the next step of procedure 600 , a part that matches the design intent of the feature is retrieved from the part library (step 612 ) and automatically inserted into the assembly model at a location determined by a positioning procedure (step 614 ). User intervention to retrieve and position the part is not required.
The insertion and positioning procedure may utilize the mate inferencing technology described in U.S. Pat. No. 6,219,049. As previously discussed, mate inferencing technology determines compatible geometric characteristics of the feature and the part by analyzing a characteristic set of geometries for a part, locating complementary geometries in a feature via one or more table lookup operations, then correctly positioning the part with respect to targeted geometries in the feature.
The design engineer has the option of accepting or rejecting the part selection. After the part is retrieved from the part library and inserted into the assembly, a checkmark (i.e., acceptance) symbol 509 and a cross (i.e., rejection) symbol 510 appear in the user interface, as shown in FIG. 5B . The design engineer may accept the part by clicking a mouse button while the cursor is over the checkmark, or may reject the part by clicking a mouse button while the cursor is over the cross symbol. Additionally, if not satisfied with the retrieved part, the design engineer may alter the part after the part is inserted in the assembly. If a part is modified, the modified configuration of the part may be added to the part library.
FIG. 7 is a flow chart that describes step 608 of FIG. 6 in more detail. In FIG. 7 , procedure 608 locates a set of features (e.g., features having descriptors or features that the system can identify as a particular feature), and performs a process that recognizes and groups similar features in the set. The procedure 608 is an event-driven mechanism activated by an external event. For example, the design engineer may activate a command that begins the process of locating features and populating those features with appropriate parts from a part library (step 702 ). The command may be activated in a conventional manner, such as selecting an item from a pull-down menu using a mouse device. Alternatively, the design engineer may choose the features to populate by selecting the specific features or by selecting one or more faces in the model using a mouse device.
Pressing a button in a feature generator dialog box may also trigger an event that activates the procedure 608 . The button may be pressed after a feature's design intent is specified, in which case, the scope of the database search may be limited to the feature being specified. The modeling system may then automatically build the descriptor, create the feature, and connect a part retrieved from a part library to the feature without any intermediate intervention from the design engineer.
When more than one feature is to be populated, the assembly model is analyzed to determine what features are present (step 704 ). Features are recognizable because the process that generates the features stores a tag that identifies the features (e.g., holes, fillets, and extrusions). As each feature is recognized, a filtering process collects identifiers for all features that have attributes determined to be appropriate due to the scope of the search (step 706 ). Examples of such features with appropriate attributes may be all holes having an attribute that contains the string “standard,” all holes that have descriptors, or all cylindrical extrusion cuts. For those features having appropriate attributes, a collection and sorting process forms logical groups of features that have similar geometry and attributes (step 708 ).
A logical grouping of features may cause the automated connection mechanism to recognize a series of holes positioned in such a way that one screw can pass through each hole in the series. For example, a logical group may consist of a pattern of holes aligned with a second pattern of holes in such a way that a hole from the first pattern is concentric and coaxial with a hole from the second pattern. If the holes have a common direction, a lexicographical sorting process uses the center of each hole in the group to determine the alignment of the holes. The centers are first sorted according to their x coordinate, then according to their y coordinate, then according to their z coordinate. If two or more holes are aligned, the procedure 608 infers that those holes were designed as a connection for one part, e.g., a screw, bolt, pin or other fastener.
Referring back to FIG. 6 , upon completion of the grouping process (step 608 ), the part library is queried to find and retrieve the appropriate part for each collection of grouped features (step 610 ). The parts are then retrieved (step 612 ) and inserted into the assembly (step 614 ), as discussed.
In some implementations, the underlying data structures that support 3D assembly models are not only hierarchical, but are also object-oriented. In an object-oriented program environment, a class defines a set of objects that have similar data structures, properties, and methods. An object is created as an instance of a particular class. For example, a screw may be an instances of particular class of screw, the class being defined by a model with variable parameters. A particular instance of a class (i.e., a particular type of screw) may be defined by configuration data that configures variable parameters of the screw's model. In such an implementation, the data structure of each part in the part library contains a configuration object that includes a pointer to a model object. The configuration object modifies the model object in some way. For example, the model of a screw may have configurations that modify the shape and size of the head of the screw, and the length of the screw. A configuration may also define a generic screw, as specified by the design engineer. The use of configurations permits the same model to have numerous unique sets of parameters. The use of configurable models allows parts to by dynamically created by the system.
Referring to FIG. 8 , the data structures for an object of the model class and an object of the configuration class are illustrated. The model object 802 defines all the model's characteristics, including the model's object hierarchy 804 . The components in a model object, such as first component 806 , determine whether the model object defines a part or an assembly. If the model object contains only one component, the model object defines a part; otherwise, the model object defines an assembly. A component (e.g., first component 806 ), stored in the model object may contain data that defines the component's geometry or may contain a pointer to another data structure that stores the data that defines the component's geometry.
Configuration objects are constructed with references to components in a model object, and a set of unique attributes for the particular configuration. As illustrated, an object that is an instance of the configuration class 808 contains a first component pointer 810 and an Nth component pointer 814 that refer to components in the model object, and attributes 812 / 816 that further specify parameters for the components.
When a part retrieved from the part library is inserted into an assembly model, a copy of the part's model object 802 and a copy of the part's configuration object 808 are added to the hierarchical data structure that defines the assembly model. After the part's model object 802 and configuration object 808 are added to the assembly model, the part is correctly positioned with respect to the feature. In situations where the same part is being used in the assembly model more than once, the model object 802 and the configuration object 808 are stored once and instanced for each reuse, thus conserving memory usage.
In one embodiment, the part library contains a relational database. A relational database stores data in related tables. A database query is constructed from the attributes in the descriptor to locate records in the related tables.
Referring to FIG. 9 , an example of the sequence of relational database lookup operations is shown. In the example, the descriptor is ‘ANSI inch ¼″ Socket Head Cap Screw 1.85″ through hole.’ The automated connection mechanism determined the length after ascertaining the depth of the hole and whether the hole is a through hole or a blind hole. If the hole is a through hole, the length of the screw should be greater than the depth of the hole; whereas, if the hole is a blind hole, the length of the screw should not exceed the depth of the hole.
Descriptor attributes are used in a prioritized order to locate records in the relational database tables. The attribute having the highest priority is the standard. Thus, the standard table 902 is searched for the record ANSI inch 904 . The next table searched is the ANSI inch type table 906 , which is searched for a socket head cap screw record 908 . Type tables also contain the name of the model. Thus, in this example, when the socket head cap screw record 908 is found, the name of the model for the family of socket head cap screws is retrieved and the model may be located within the part library.
Next, the socket head cap screw size table 910 is searched for a record containing the size ¼ inch 912 . After the size is found in the socket head cap screw size table 910 , the length table 914 is searched for the length ascertained by the automated connection mechanism. If the length is not found in a record, the automated connection mechanism selects a length greater than the ascertained length for a hole that is a through hole, or selects a length less than the ascertained length for a hole that is a blind hole. In this example, the length is described as 1.85″ through hole, and thus, the record 916 having the length 2.0″ is retrieved.
Before creating a configuration, the automated connection mechanism ensures that the configuration does not already exist. Configurations have unique names that identify the combination of values that will modify the model. The automated connection mechanism searches for the unique name and if found, a configuration does not need to be created. Other means of determining whether a configuration exist can be used (e.g., comparing attributes of a designed feature with attributes of model configurations). If a required configuration of a model does not exist, a configuration may be created using the values retrieved from the size table 910 and the length table 914 . The configuration stores the values for the size and length retrieved as attributes, which are used to modify a component specified in the model.
If the query does not locate a record in a table, a generic value may be used. The generic value may be a default value that was pre-defined by the system or a generic value specified by the user. One generic value that contains default values for all descriptor attributes may be available, or one generic value may be available for each table.
Another aspect of the present invention is that given the new association between the part and the feature, standard accessory components may be automatically retrieved from the part library and added to the assembly model. Standard accessory components contained in the part library include such parts as nuts and washers.
Each part in the database is indexed by properties of other parts with which the former part may be connected. Thus, the design engineer can embellish the connection to include top-side and bottom-side accessory components, such as a washer at the top of a screw, and a washer and lock nut at the bottom of a screw. The part and the part's accessory components may be re-used with additional features by instantiation operations.
Referring to FIG. 10 a, an assembly 1002 is shown in a modeling portion 1004 of a window 1006 . The assembly 1002 has hole features, two of which are through holes 1008 and two of which are counter-bored holes 1010 . After the hole features 1008 , 1010 are created, the system may perform process 600 to automatically select hex bolts to populate the holes 1008 and socket head cap screws to populate the holes 1010 . FIG. 10 b shows the assembly 1002 in the modeling portion 1004 of the window 1006 after the hex bolts 1028 are inserted in the holes 1008 and accessorized with washers 1038 . The washers 1038 may be referred to as top-side accessory components. Generally socket head cap screws, used to populate counter-bored holes 1010 , do not have top-side accessory components. FIG. 10 c shows a back-side view of the assembly 1002 in the modeling portion 1004 of the window 1006 . The hex bolts 1028 have bottom-side accessory components, which are nuts 1048 and two sets of washers 1058 , 1068 . The socket head cap screws 1020 have also been accessorized with nuts 1030 and two sets of washers 1040 , 1050 .
Referring to FIG. 11 , a dialog box 1102 aids the design engineer in selecting accessory components. The modeling system may display the dialog box 1102 after the design engineer indicates which features to accessorize. The design engineer is presented with only those accessory components that make physical sense with regards to forming a connection with the connector (e.g., accessory components having the appropriate size and use, in addition to being the correct standard). In the dialog box 1102 , the design engineer selects one or more accessory components using pull-down menus in the component category 1104 . A quantity for each selected accessory component is specified using pull-down menus in the quantity category 1106 . Additionally, the design engineer may set custom properties for each component in the properties category 1108 . An example of a custom property may be a thread for a hex nut. An accessory component is coupled directly to a connector, and therefore, a choice of accessory components may be determined based on attributes of connectors, rather than based on attributes of a feature. In some implementations, however, feature attributes may be used to select accessories. To retrieve an accessory component from the part library, two keys may be used: the first key may include attributes of the connector that the accessory is to be used with, the other key may identify a type of accessory component, for example, a top-side stacked component.
Another aspect of the invention is that the automated connection mechanism maintains all coupling relationships. When a feature and a part no longer have an appropriate coupling relationship due to a design change, the design engineer is notified so that the inappropriate coupling may be corrected. Maintaining coupling relationships is achieved using one or more watch objects. A watch object is cognizant of any parametric change in a feature that is coupled to a part retrieved from the part library. When a parametric change occurs, the watch object determines if the change caused the feature and part to become incompatible in such a way that the connection is no longer valid. If the connection is no longer valid, the design engineer is notified. The design engineer may then, for example, have the part automatically replaced with another part from the part library.
One watch object per connection is added to the assembly model once a part is retrieved from the part library and inserted into the assembly model. A watch object is a data structure that contains an array of programming objects. The programming objects monitor the parametric relationship between a feature and a connecting part. Each watch object has two pointers, one pointer is a reference to the feature and the other pointer is a reference to the connecting part incorporated in the assembly. The watch object may be added as a member (i.e., a node 301 – 312 ) of the assembly model data structure 300 ( FIG. 3 ) and resides at the same hierarchical level in the assembly data structure as the retrieved part.
Fundamental to every parametric system is a mechanism that notifies the system that a particular object needs updating. The update mechanism may be triggered when any attribute of the feature or any attribute of the connecting part has changed. The update mechanism may be implemented as a broadcast process or as a cached data mechanism that stores pertinent object data for both the feature and part at the time of creation, including a time stamp or version designation.
In an implementation where the update mechanism uses cached data, when a watch object is referenced (e.g., upon traversal of the hierarchical data structure), the watch object compares some of the cached data with the data currently defining the feature and the connector. If cached data differs from the data that currently defines the feature in a significant way, a query is constructed to retrieve a part from the part library. If the part retrieved differs from the connecting part incorporated in the assembly, the design engineer is notified. If cached data differs from the data that currently defines the current connector in a significant way, the design engineer is also notified.
To notify the design engineer that the feature and connecting part may no longer be compatible, a CAD system that has implemented a feature manager design tree may display an exclamation point beside the name of the modified feature in the feature manager design tree's graphical user interface. Another method used to alert the design engineer may display a dialog box, which may also serve the purpose of aiding the design engineer in correcting the inappropriate coupling. The design engineer may correct the inappropriate coupling by modifying the feature once again or by commanding the automated connection mechanism to replace the part. Still another implementation may permit the replacement to occur automatically (e.g., by establishing a preference to do so).
The watch element is only active if the part library is present as a functioning software component. For example, if a model has one or more parts that were initially downloaded from a part library, during subsequent modeling sessions the CAD system must have a properly functioning part library for the watch element to be active.
Additionally, all coupling relationships between parts and accessory components are maintained using watch objects. Thus, the preceding discussion also applies to parts accessorized with other parts.
Another aspect of the invention is that the automated connection mechanism may be activated by a drag operation, whereby the object being dragged is a graphical representation of one member of a family of parts in the part library. Members of various families of parts may be depicted and previewed in a user interface panel. The graphical depiction may be dragged then dropped on a feature that appears in the 3D-modeling portion of the modeling window.
FIG. 12 a shows an assembly 1202 in a window 1200 . A graphical depiction of a part 1208 is displayed in the user interface panel 1204 . The assembly 1202 has a feature 1206 , which is a through hole and may be the target of a drag and drop operation. FIG. 12 b shows the assembly 1202 in window 1200 after the graphical depiction of a part 1208 is dropped onto the feature 1206 . When the part is dropped on the feature, the automated connection mechanism determines which configuration in the part family is the best fit for the feature upon which the graphical depiction is dropped, then creates an appropriate part 1210 . The automated connection mechanism then automatically inserts the part 1210 in the model using a positioning procedure to correctly locate and align the part. Furthermore, a watch element is established for the connection, which permits the connection to be maintained.
In one embodiment, the feature is not changed if a part is dropped on a feature and the feature does not have a descriptor. Rather, the automated connection mechanism constructs a descriptor and stores the descriptor outside the feature's data structure. If the feature had a descriptor that does not match that of the connector that was dropped, the design engineer may permit the connector's descriptor to override the feature's descriptor.
The parts library may be extendible. In addition to functionality that is currently available, such as extending the part library by adding parts, a mechanism permits a design engineer to provide user-defined parametric connections that specify appropriate coupling relationships. A dialog box may be displayed to specify a descriptor for the part and to define the parametric connections. Additionally, the design engineer may modify the existing part library to reduce the number of parts that may be retrieved. Effectively reducing the size of the part library may be desirable to reflect existing inventory and to include only those parts that a corporation permits employees to purchase. To reduce the size of the part library, a part may be deleted or access to the part may be denied.
As should be appreciated by those skilled in the art, implementations of the described system may quickly and accurately populates features in an assembly model with appropriate connecting parts, including accessory components. The correct configuration of the connecting part is automatically chosen from a part library. The present invention may be applicable to many types of standards-based connections, for example, electrical connections or piping connections. Furthermore, although the description of the invention emphasizes parts, the present invention applies to other components as well, such as subassemblies.
The invention may be implemented in digital electronic circuitry, or in computer hardware, firmware, software, or in combinations of them. Apparatus of the invention may be implemented in a computer program product tangibly embodied in a machine-readable storage device for execution by a programmable processor, multiprocessor computer system, or computer cluster; and method steps of the invention may be performed by a programmable processor executing a program of instructions to perform functions of the invention by operating on input data and generating output. Each computer program may be implemented in a high-level procedural or object-oriented programming language, or in assembly or machine language if desired; and in any case, the language may be a compiled or interpreted language. Suitable processors include, by way of example, both general and special purpose microprocessors. Implementations may use a variety of database implementations including distributed databases, in-memory databases and data structures, flat-files storing data, or other data representations.
A number of embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. The present invention can be embodied in computer software code executable on a computer such as those well known in the industry, including IBM® compatible computers executing the Microsoft Windows® operating system, Sun® workstations, UNIX® or LINUX™ workstations, Apple® computers and any other computer device capable of executing software. In some parametric implementations, a design engineer may determine whether a feature or a part controls the parametric relationship between the two; alternatively, this relationship may be predetermined. The part library may be tightly integrated within the computer-aided modeling system (e.g., as programmed code and data structures), rather than reside as an external database. The part library and the features database also may be consolidated. The invention could also be used in conjunction with other computer-aided design software that addresses applications other than mechanical design.
Implementations may change the order in which operations are performed. Depending on the needs of an implementation, particular operations described herein may be implemented as a combined operation, eliminated, added to, or otherwise rearranged. Accordingly, other embodiments are within the scope of the following claims.
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Construction of a model using a computer aided design system includes constructing a feature in a three dimensional model based on data input by a user. Following construction of the feature, a part configured to compatibly couple with the feature is automatically identified based on design attributes of the feature. The part can be selected from a parts library that includes data representing parts and their geometric characteristics. The part also may be automatically generated based on a part model in a parts library. The part generation can include querying a database storing the part library to retrieve a part model, and then generating an instance of the part model based on design attributes of the feature so as to ensure coupling compatibility with the feature.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method of and a device for chip-cutting of workpieces, in particular for the cross-cutting and chamfering of extruded plastics material tubes or the like and in which a cutting tool may be fed radially to a rotational displacement of the object relative to the tool.
2. Description of the Prior Art
Methods and devices are already known for the cutting and chamfering of round sections--according to EP-Al No. 0103649--which preferably operate with a revolving cutting system for parting off solid or hollow sections such as extruded plastics material tubes or the like. Upon cutting extruded sections, the cutting system is co-entrained in the direction of extrusion, the section which is to be cut or chamfered being held by gripper elements at either side of the plane of rotation of the tools. Two discs are present in this device, which are driven by two rotors at different rotational speeds. The cutting tools are mounted in radially displaceable manner on the one disc and coupled in motion to the second disc via guiding elements, the guiding elements being located in guiding tracks extending eccentrically to a disc centre. A relative displacement of the two discs is caused by the different rotational speed and the tools are displaced in radial direction by the guiding tracks with respect to the disc bearing the same, in the direction towards the workpiece. The relative displacement of the tools may be interrupted by means of a clutch installed in the transmission line to the disc receiving the guiding tracks. It is possible furthermore to construct the guiding tracks in such a manner that the feed motion of the tools occurs in the manner of an intermittent displacement. The embodiment of a device of this kind requires a special structure of the discs carrying the tools and the control curvatures have no more than a fraction of the circumferential length of a single rotational displacement. The intermittent displacements which may be generated if appropriate by corresponding shaping of the guiding track, are consequently inadequate to prevent the appearance of comparatively long cuttings, which may be wound together, or drawn into the hollow section or caught on the workpiece carriers.
It is also known moreover that the feed drives for tool feed may be acted upon in pulsed manner, or rather in the case of piston/cylinder systems, that these may be displaced by brief pressure surges in mutually opposed directions, to secure tearing-off of the cuttings. These control systems require considerable control complexity and very greatly load the mechanism for transmission of the rotational and feed motions, whereby these are exposed to a high degree of wear.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object to provide a method and a device of the kind defined in the foregoing, which allows for producing cuttings of different required lengths in a simple manner under a constant, and in particular, continuous feed displacement of the tools. Beyond this, it should be possible for devices already in service for the processing by cutting of workpieces to be subsequently equipped for implementation of the method according to the invention, in a simple manner.
This problem of the invention is resolved in that the feed displacement of the tool has superimposed on it an undulant and in particular sinusoidal infeed displacement and that the undulant infeed displacements are displaced in phase, through 180° in particular, during two directly consecutive revolutions. The unexpected advantage of this solution consists in the finding that an undulant infeed displacement may be superimposed over the displacement required for tool feed, in order thereby to create a displacement wholly independent of the feed displacement, which at particular predetermined intervals lifts the tool off the cutting area or disengages the tool from the workpiece, thereby causing the cuttings to be torn off. Thanks to the phase displacement of the undulant feed motion during consecutive revolutions, material is removed in those areas in which the tool had been disengaged during the preceding revolution. A uniform removal of material is accomplished throughout the periphery thanks to the areas overlapping each other during consecutive revolutions, in which the tool is in engagement and out of engagement, respectively, in which connection it is assured that cuttings of approximately identical length are produced throughout the processing operation. Another advantage consists in that the application of this superimposed undulant infeed displacement is wholly independent of the rotational speed of the tools or of the magnitude of the feed, during a revolution of the tools relative to the workpiece. A short cutting or chip length may thereby be obtained even at rotational speeds of 300 to 400 revolutions per minute and at correspondingly large diameters of the objects which are to be processed. Short cuttings of this kind may simply be drawn off by suction by means of known suction installations.
It is also possible for the period of oscillation of the two undulant infeed displacements to be smaller than an even fraction of the duration of a tool revolution. It may moreover be accomplished in a simple manner by selection of the period of oscillation of the superimposed undulant infeed displacement that the cutting areas of the consecutive revolutions overlap each other to an equal and opposite extent, so that a uniform removal of material occurs along the periphery of the object to be processed, as an average taken over several rotational displacements.
It is also possible within the ambit of the invention that one amplitude of the undulant infeed displacement may be greater than the magnitude of the feed displacement during a full revolution of the tool. It is accomplished thereby that the tool is disengaged between two areas in which processing of the object occurs by cutting. This interrupts the forming of cuttings and the cutting or chip lengths may be predetermined in a simple manner as a function of the angle of rotation in which the tool is in chip-raising contact with the workpiece. This also facilitates the removal of cuttings and prevents the forming of long cuttings which may be caught on the tools or on the workpiece.
It is advantageous that a workpiece which is to be cut to length may be held fastat either side of a plane of rotation of the tool and that two tools may be provided which are arranged in mirror symmetry with respect to the centre on a diametral line extending through the centre of the rotational displacement, whereof the undulant infeed displacements occur simultaneously and identically. Thanks to the uniformity of the displacements in which the mutually opposed tools are thus moved simultaneously in the direction towards or away from the centre, a constant displacement of the workpiece is obtained despite the superimposed sinusoidal infeed displacements. Deleterious oscillations disturbing the operation of the machine and caused by this superimposed infeed displacement are prevented.
In accordance with the invention, it is also possible that the angle of rotation along which the tool is in chip-cutting engagement with the workpiece may be greater than the angle of rotation of the area in which the tool is not in chip-cutting engagement with the workpiece. It is an advantage that it is thereby possible to operate with a greater rate of advance for the feed displacement, since the sections in which no chip-cutting engagement occurs during the individual revolutions are short as compared to those in which a chip-cutting action had already occurred, and the energy is thus adequate for removal of the material present between the separate sections processed, even at a higher rate of removal of material. The object of the invention, consisting in limiting the cutting or chip lengths to predetermined sizes, is nevertheless also accomplished.
Provision is made according to another form of the method according to the invention that the tools may be displaceable in radial direction on a rotary tool carrier and are supported on a guiding member displaceable in a direction extending at right angles to the plane of rotation, which has a guiding surface extending obliquely to the plane of rotation, and is guided in a circular circulatory track which is displaced continuously at right angles to the plane of rotation for the purpose of tool feed. The undulant infeed displacement is generated by a distance variation between the circulatory track and the guiding member and is continuous and equal and opposite in consecutive sections. The undulant infeed displacement may thereby be transmitted with little play and does not require any great driving power because of the low weights displaced.
It is also advantageous if the undulant infeed displacement is interrupted immediately before or following cutting through by the tool, and if the tool thereupon makes a full rotational displacement at an unchanged position at a chip-raising position of the tool, since continuously machined surface along the periphery are thereby obtained in the finished product.
The invention also encompasses a device for the chip-raising processing of workpieces, in particular for cross-cutting and chamfering of extruded plastics material tubes, comprising clamping devices grasping the workpiece at either side of a plane of rotation, a tool displaceable at right angles to the longitudinal direction of the workpiece for chip-raising processing, which is displaceably mounted in a guiding track arranged parallel to the feed direction and is coupled to a feed drive, as well as a rotational drive for relative rotation between the workpiece and the tool and for application of the method of the invention.
This device is characterised in that the tool has an associated infeed device which is constructed to generate an undulant infeed displacement and situated between a supporting point of the feed drive and the tool. Thanks to the incorporation of the undulating infeed device, an advancing and retreating displacement of the tool continuously superimposed over the feed displacement may be obtained in a simple manner, whereby the tool is periodically disengaged from the workpiece and that cuttings of predeterminable length may thus be produced.
Provision is made according to another embodiment of the invention that the tool is located on a rotary tool carrier coupled to the rotational drive in a sliding guide aligned in radial direction, whereby play-free mounting and precise guiding of the tools are accomplished.
Provision is made according to a further embodiment that the tool is adjustably installed in a tool holder, which is displaceably mounted in the radially extending sliding guide of the rotary tool carrier, and supported under interpositioning of a spring system on a guiding surface of a guiding member displaceably mounted in a guide extending parallel to the longitudinal axis of the object and in a terminal portion oppositely situated to the guiding surface comprises a guiding device located in a circular circulatory track situated in a setting ring which is displaceable in the longitudinal direction of the workpiece with respect to a tubular support member. The support member carries the rotary tool carrier via a bearing system and the infeed device comprises a guiding roller located without play in the circulatory track and eccentrically mounted or constructed, a member utilised for the feed displacement being suitably constructed as a feed mechanism. The method according to the invention is thereby applicable with an extremely low amount of additional expenditure on components.
It is advantageous if a peripheral length of the guiding roller is smaller than an even fraction of a peripheral length of a guiding surface of the circulatory track allocated to the guiding roller, since it is possible thereby in a simple manner to obtain an overlap of the areas machined by means of the tool during consecutive revolutions, without needing mechanical displacing mechanisms or control systems.
It is possible for the guiding roller to have a frustoconical rolling surface which is aligned parallel to the guiding surface of the circulatory track, thereby preventing slip between the eccentrically mounted roller forming the infeed device, and the guiding surface of the guiding track.
Provision is made according to another form of the invention that the guiding roller is mounted in a roller carriage wherein is situated at least one support roller which is guided on a guiding surface oppositely situated to the guiding surface of the guiding roller. A spring may be placed between the support roller and the guiding roller which exerts a force directed in the direction of the guiding surface of the support roller and of the guiding roller, thereby obtaining play-free guiding of the eccentrically mounted roller on the associated guiding track, irrespective of the direction in which the tool is displaced by the eccentrically mounted roller and irrespective of the centrifugal forces occurring in the region of the tool.
It is advantageous if the circulatory track is formed as a U-shaped groove situated in the setting ring, the support roller bearing on the one and the guiding roller bearing o the other of the mutually opposed guiding surfaces of the U-shaped groove, and the spring is arranged between the guiding roller, mounted in the roller carriage via a spindle extending parallel to the parting plane, and the support roller, pivotable around a pivot pin transversely to the longitudinal extension of the groove, and the support members receive clamping devices, situated at either side of the parting plane for the object, are installed in a carriage which is displaceably guided along a guiding track aligned in the longitudinal direction of the object and is coupled to a reset drive. It is possible thereby to utilise the inventive device even in conjunction with continuously operating extruders since the feed device and the infeed or approach device may be entrained with the moving extruded section.
The guiding roller may be situated between two support rollers arranged one behind another in the peripheral direction of the circulatory track, whereby it is possible to assure play-free running of the eccentrically mounted roller.
Advantageously the guiding roller has a circular cross-section, since this causes identical accelerative and decelerative forces to occur between the approach device and the tool and impacts or percussive stresses on the device or on the associated drives are prevented in this manner.
The guiding surface of the roller carriage may slope at a smaller angle than 45° with respect to the longitudinal axis of the workpiece, since the magnitude of the approach motion occurring at right angles to the direction of displacement is thereby placed in a favourable ratio to the magnitude of the feed displacement.
In a further embodiment the guiding surface has a guiding surface portion extending parallel to the longitudinal axis of the workpiece in the area situated next to the terminal position of the tool, since an even cutting pattern is obtained on the cutting or processing surface without particular control operations or complementary devices.
The guiding surface allotted to the guiding roller may have allocated to it another guiding surface portion displaceable independently of the former in the longitudinal direction of the workpiece, which is coupled to a displacing drive, the guiding surface of the guiding roller and the guiding surface portion being associated with another support roller and the distance between one side of the support roller associated with the guiding surface portion and the support roller associated with the oppositely situated guiding surface preferably being greater than the minimum spacing between the axes of rotation of the support roller and the guiding roller plus half a diameter of the guiding roller and the large radius of the guiding roller. The superimposed approach motion may thereby be turned on and off at any time by a corresponding displacement of the guiding surface portions.
A revolving cam may be situated between the feed drive of the feed device and the tool, which is coupled to a rotational drive, the rotational drive preferably simultaneously driving the workpiece and the cam via a distributor gear, whereby the approach motion may be transmitted onward to the tool irrespective of the feed motion, and an appropriate coupling or phase shift of the undulantly occurring approach motion being obtainable, for example via the drive of the workpiece.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example, with reference to the accompanying, partly diagrammatic drawings, in which:-
FIG. 1 is a simplified partly fragmented elevation of a device for chip-cutting of workpieces,
FIG. 2 is a partly sectional end view of a workpiece to be processed, in which is depicted the path of displacement of the cutting edge of a processing tool, the illustration corresponding to a section taken along the lines II--II but throughout the cross-section of the workpiece according to FIG. 3,
FIG. 3 is a partly sectional side elevation of the device of FIG. 1 showing the mounting of the tools as well as the structure of the approach device in the device according to FIG. 1, in sideview and in cross-section;
FIG. 4 is a partly sectional view along the lines IV--IV in FIG. 3 showing the arrangement of guiding and support rollers in a roller carriage of the device of FIGS. 1--3,
FIG. 5 is a partly sectional plan view of the roller carriage, taken along the lines V--V in FIG. 4, and
FIG. 6 is a simplified plan view of a modified embodiment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates a device 1 for chip-removing processing of objects 2, e.g. an extruded plastics material tube 3. The plastics material tube 3 is moved forward continuously whilst coming from the extruder in the direction of extrusion--arrow 4--and is cut to the required lengths during this continuous forward displacement. To this end, the device 1 has a carriage 5 which is displaceable in and opposite to the direction of extrusion--arrow 4--along a guiding track 6 formed by guiding posts. To this end, the carriage 5 has clamping devices 7 whereof the clamping jaws 8 may be placed in contact with the plastics material tube 3 via clamping drives 9, e.g. hydraulically or pneumatically operated piston/cylinders systems, whereby the carriage 5 is coupled in motion to the plastics material tube 3 and is displaced by the plastics material tube 3 along the guiding track 6 in the direction of extrusion--arrow 4. To reset the carriage 5 against the direction of extrusion, a reset drive 10 is provided, for example a piston/cylinder system which may be acted upon by pressure fluid, by means of which the carriage 5 may be returned to its original position situated in the left-hand terminal portion of the guiding track 6 in the drawing. The length of the guiding track 6, whose the guiding posts are mounted in a machine table 11, is determined as a function of the processing period of the plastics material tube 3 by means of the device 1 and as a function of the feed of the carriage 5 or of the plastics material tube 3 in the direction of extrusion--arrow 4. The structure of such devices 1 entrained with the objects 2 which are to be processed under application of a carriage 5 and of a guiding track 6 is known and the construction of the parts of the device may be performed in accordance with the different proposals disclosed in the prior art.
The carriage 5 furthermore bears tubular support members 12,13 on which are fastened the clamping devices 7 or rather their clamping jaws 8 and the clamping drives 9. A tool carrier 14 is rotatably installed on the support member 12, apart from the clamping device 7. The tool carrier 14 is placed in rotation via Vee-belts 15 by a rotational drive 16. A setting ring 17 is displaceably arranged in the direction of extrusion--arrow 4--on the support member 12, between the tubular support member 12 and the annular seat of the tool carrier 14 wherein are situated the Vee-belt grooves for the Vee-belts 15, and is coupled in motion to a feed drive 19 of a feed device 20 via displacing arms 18. In the setting ring 17 is provided a circular track 21 wherein a guiding roller 22 of a roller carriage 23 cooperates with a tool 24, e.g. a cutting blade 25, to displace this cutting blade 25 from the idle position shown in solid lines into the position of engagement shown by pecked lines. A tool 26 comprising a chamfering cutter 27 is actuated by an analogous guiding roller and a corresponding guiding carriage. Whilst the plastics material tube 3 is being extruded continuously, a plastics material tube of the length required is cut off by means of the cutting blade 25 and the facing tube ends at either side of the cutting point are chamfered simultaneously. The continuous displacement of the tools 24 and 26 in the direction towards the plastics material tube 3 is indicated by an arrow 28. The double-headed arrows symbolically show that an undulant or rather oscillatory and in particular sinusoidally extending motion of a tool displacement device 29 is superimposed on this feed motion of the feed device 20.
In FIG. 2 is illustrated a cross-section through a plastics material tube 3 in the region of a cutting plane 30, FIG. 1, the displacement of a cutting edge 31 of the tool 24 with respect to the plastics material tube 3 being illustrated by solid lines for one revolution and by pecked lines for another revolution. As apparent from this illustration of the cutting line of the tool 24, a sector 32 along which the cutting edge 31 of the tool 24 is not in cutting engagement with the plastics material tube 3 is always smaller than a sector 33 along which a cutting engagement and thus a removal of material occurs. The resultant displacement of the cutting edge 31 substantially corresponds to an oscillatory trace in which the time integral of the oscillatory period during which the cutting edge 31 is in cutting engagement with the plastics material tube 3 amounts to a multiple of the time integral of the oscillatory period during which the cutting edge 31 is disengaged from the plastics material tube 3. This also emerges from the fact that an angle of rotation 34 through which the tool 24,26 is not in cutting engagement is smaller than an angle of rotation 35 during which a chip-removing machining operation occurs on the object 2.
The chip length may be controlled and altered in a simple manner by selection of the magnitude of the time interval of the two different operational stages, that is of the extents of the sectors 32,33 and of the angles of rotation 34,35.
As further apparent from the illustration in FIG. 2, the undulant approach displacement or rather the oscillatory displacement of the cutting edge 31 occurs under phase displacement during the processing operation, in directly consecutive revolutions. A phase displacement 36 indicated by a phase displacement angle is not an even fraction of a period of oscillation 37, so that as easily apparent from the illustration, an identical and opposed overlap of the sectors 32 and 33 is the result during two directly consecutive revolutions of the tool 24. This has the result that a substantially uniform removal of material occurs throughout the peripheral length and that the chip or cutting length may nevertheless be kept substantially identical. The sectors 32 in which the tool 24 is not in chip-raising engagement with the plastics material tube 3 are consequently situated in the sectors 33 of the preceding tool revolution, in which the cutting edge 31 had been in chip-removing engagement with the plastics material tube 3.
It is evidently also possible for the phase displacement 36 to amount to a quarter or a third or other even fraction of the period of oscillation 37.
As more clearly apparent from the illustration moreover, an amplitude 38 of the undulant infeed or approach motion and of the oscillatory displacement of the cutting edge 31 of the tool 24 is larger than a displacement 39 of a feed motion during a full revolution of the tool 24. It is thereby assured in a simple manner that an interruption of the processing displacement or rather of the cutter operation may be obtained continuously around the periphery of the plastics material tube 3 by means of the undulant infeed motion, and that the chip length may be maintained precisely.
The tools 24 and 26 are illustrated on an enlarged scale in FIG. 3. The cutting blade 25 as well as the chamfering cutter 27 are exchangeably clamped in tool holders 40,41. The structure and operation of the two tool holders 40,41 is identical, wherefore the fastening, mounting and displacement are described only in connection with the tool holder 41. The tool holder 41 is displaceably mounted in radial direction on the tool carrier 14 in a sliding guide 42 which is radially aligned with respect to a longitudinal axis 43 of the object 2 comprising the plastics material tube 3 which is to be processed. A roller 45 of the tool holder 41 is thrust without play against a guiding surface 46 of a roller carriage 47, via a spring system 44. This roller carriage 47 is displaceably mounted in a guide 48 extending parallel to the longitudinal axis 43. The displacement of the roller carriage 47 and its positioning in its setting with respect to the roller 45 of the tool holder 41 occurs by means of a guiding roller 49 which is guided in circular track 21 of the setting ring 17. The setting ring 17 is displaceable on a support member 12 in the longitudinal direction of the longitudinal axis 43. The roller carriage 23 facing the tool 24 and the setting ring 17 associated therewith are shown in their position prior to starting a processing operation, whereas the roller carriage 47 is shown in the position it has whilst the plastics material tube 3 is being processed by means of the tool 26. Whereas the setting ring 17, together with the circular track 21 formed by a U-shaped groove 50, is then at rest, the guiding rollers 49 as well as support rollers 51 situated opposite thereto roll along mutually opposed guiding surfaces 52 and 53. The guiding rollers 22 and 49 as well as the support rollers 51 associated with them, are jointly placed in rotation with the roller carriages 23 and 47 via the tool holder 14 engaging the Vee-belts 15, the tool carrier 14 being mounted in freely rotatable manner on the support member 12 via a bearing system 54. The roller carriages 23 and 47 are mounted or secured in the disc-like tool carrier 14 in guides 48 situated in cut-outs in the tool carrier, and the tool holders 40 and 41 are mounted or secured in the sliding guides 42.
Thanks to the displacement of the setting ring 17 by means of the feed drive 19--FIG. 1--the roller 45 of the tool 26 is displaced from the position shown by pecked lines by the action of the guiding surface 46 extending obliquely to the longitudinal axis 43 into the position illustrated by solid lines, thereby displacing the tool 26 from the pecked position in which it is out of chip-removing contact with the plastics material tube, into the operating position for chip-cutting processing of the plastics material tube 3.
An undulant approach motion is superimposed over this feed motion by means of the setting ring 17 thanks to an eccentric mounting of the guiding roller 49 on a spindle 55 of the roller carriage 47, the period of oscillation of this undulant approach motion corresponding to the peripheral length of the guiding rollers 22 and 49 respectively. The amplitude of the undulant approach motion of the tool displacement device 29 is determined by an eccentricity 56 between the centre line of the spindle 55 and the centre lines of the guiding rollers 22 and 49, respectively. It is also possible however to replace a circular periphery of the guiding rollers 22,49 by a cam-shaped periphery having a constant diameter along a part thereof while the diameter is reduced along the residual part of the periphery by the amount of the amplitude, a transition between these peripheral parts occurring as continuously as possible. Thanks to the spring system 44, as well as to respective springs 57 acting between the support rollers 51 and the associated guiding rollers 22 or 49, it is possible despite the accelerations of the tools 24,26 constantly directed in opposed directions, to secure play-free guiding of the guiding rollers 22 and 49 along the guiding surface 52 and to assure a smooth guiding of the cutting edges 31 of the tool 24 and 26.
The structure of the guide 48 of the roller carriage 47 as well as the arrangement of the guiding roller 49 or of the support rollers 51 allocated thereto, are more clearly apparent from FIGS. 4 and 5. To this end, guiding rails 58 of the guide 48 in which are guided guiding bars 59 of the roller carriage 47, are mounted on the disc-like tool holder section of the tool carrier 14 which has the grooves for the Vee-belts 15. A bearer element 60 of the roller carrier 47 bears the spindle 55 of the guiding roller 49. The support rollers 51 are rotatably journalled on spindles 61. Holders 62 for the spindles 61 are displaceable around pivot pins 63 in the longitudinal direction of the longitudinal axis 43 by the action of the spring 57 situated between the bearer element 60 and each holder 62.
As more clearly apparent from FIG. 5, the action of the spring 57 causes the guiding roller 49 as well as the support rollers 51 to bear without play on the facing guiding surfaces 52,53, respectively of the stationary circular track 21 formed by U-shaped groove 50. Whereas the feed motion is thus established by a displacement of this U-shaped groove via the setting ring 17 receiving the same with respect to the support member 12--as indicated symbolically by the arrow 28--the undulatory approach motion is caused by a relative displacement of the roller carriage 47 with respect to the guiding surface 52 facing its guiding roller 49--as shown by a double-headed arrow 64. The action of the feed drive 19--FIG. 1--is not deleteriously affected thereby. As apparent from the drawing, the guiding roller 49 is eccentrically mounted on the spindle 55 in the present embodiment. It would also be possible to mount the guiding roller 49 centrally on the spindle 55 and to form the same eccentrically over a part circumferential section, as denoted by dash and dash-dotted lines. This has the result that the processing by cutting of the object 2 occurs at a constant depth of penetration or thickness of material removal, whereas a relative displacement between the guiding surface 52 and the roller carriage 47 respectively occurs only across the eccentric section in which the tool 24 or 26 is disengaged from the object 2. No sinusoidal approach motion is accomplished in this case, but an approximately trapezoidal stepped path.
A modified embodiment of an inventive device 65 is shown in FIG. 6, in which an object which is to be processed or cut to lengths, for example a plastics material section 66, revolves about its longitudinal axis 67. A tool 68, e.g. a cutting blade 69, is movable in a longitudinal guide 70 aligned at right angles to the longitudinal axis 67, in the direction towards the object 66 against the action of a spring system 71. The feed motion is indicated by an arrow 72 and is performed by a feed device 73. This feed device 73 has a wedge-like surface in the present embodiment which is displaced parallel to the longitudinal axis 67 of the object 66 and which displaces a tool holder 74 bearing the tool 68 along the longitudinal guide 70 in the direction towards the object 66, via a roller and a support bracket.
Through the action of spring system 71, the periphery of the tool holder 74 bears on eccentrically mounted revolving cam 75 arranged between the roller of the feed device 73 and the tool holder 74. The cam 75 is placed in rotation via a drive spindle 76, the cam and spindle forming approach device 77--as shown by an arrow. The eccentricity 78 of cam 75 corresponds to the amplitude of an undulant approach motion, which is denoted by an arrow 79 in the region of the tool holder 74. The drive spindle 76 is driven via a rotational drive 80, which simultaneously places the object 66 in rotation through a universal joint shaft arranged to accommodate the feed displacement by the feed device 73.
The drive for the object 66 and the cam 75, under appropriate selection of the peripheral length of the cam 75, is so synchronized that the sections in which the tool 68 is in cutting engagement with the object 66 overlap the sections in which it is not in cutting engagement, during directly consecutive revolutions. As already described in particular in connection with the embodiment depicted in FIGS. 1 to 5, an approximately identical chip length is obtained during the processing operation, irrespective of the thickness of the object 2 to be severed.
It is evidently also possible in this embodiment to place the driving spindle 76 and the object 66 in rotation via separate rotational drives, in which connection it would then be appropriate however to synchronise their motions in a different manner, for example by means of an electronic control system or the like, to accomplish that--during consecutive revolutions of the object--the sections are always processed which had not been processed during the preceding revolution.
The cuttings produced by devices of this nature may for example be collected in a chute 81 as shown diagrammatically in the device according to FIG. 1, and discharged via a conveying passage 82 by a blower 83 into a central bin, for example as known in the case of other chip cutting processing machines, for example planing machines, wood-milling machines or the like.
It is evidently possible within the scope of the invention to generate the superimposed approach motion by other means, for example by means of oscillation generators situated in the path of transmission between the feed device and the tool and driven hydraulically, pneumatically or mechanically, to which end care should merely be applied to ensure that in accordance with the inventive method, the amplitude of these oscillations should at least correspond to the magnitude of the feed path during one revolution of the tool, but is preferentially larger, and that the sections in which the tools are in cutting engagement and out of cutting engagement overlap each other during two directly consecutive revolutions.
The peripheral length in the region of a contact plane 84--FIG. 3--is utilised to determine the peripheral length of the guiding surface 52 and of the guiding roller 49. In the cross-sectional area of the guiding roller 49 situated in the contact plane 84, the periphery of the same and simultaneously also the periphery of the contact line between the guiding roller 22,49 and the guiding surface 52 are determined by reference to a radius 85 of the contact plane 84 from a longitudinal axis 43.
As further indicated diagrammatically in FIG. 3 by dash-dotted lines, it is possible to provide another setting ring 86 comprising a guiding surface section 87 which cooperates with another support roller 88 rigidly installed on the roller carriage 23,47. To this end, the setting ring 86 is advanced so far in the direction of the roller carriage 23,47, until the same is guided solely by the mutually opposed support rollers 88 and 51 and the guiding roller 22,49, is thus disengaged from the guiding surface 52. This renders it possible during the final section of the cutting operation to turn off the undulant approach motion at any optional position of the roller 45 with respect to the guiding surface 46 by means of a feed displacement of the setting ring 86, and thereby to produce a completely smooth cutting surface or processing surface. If this setting ring 86 is installed on the setting ring 17 and is displaceable with respect to the same, it is also possible even in this position to undertake a corresponding feed of a magnitude which for example corresponds to the amplitude of the approach motion, so that possible rough spots in the surface processed are eliminated reliably.
On the other hand, it is also possible to provide the guiding surface 46 with a guiding surface portion 89 extending parallel to the longitudinal axis 43. This has the result that, at the end of the feed motion, the action of the tool displacement device 29 is turned off under simultaneously unchanged feed. It is accomplished thereby that protuberances left over from the preceding revolution, at which the tools 24,26, were out of cutting engagement, are cut down.
It is to be understood that the. magnitude of the amplitude, of the undulant approach motions, as well as the amount of the feed motion and of the oscillation period, have been illustrated to an exaggerated scale, to facilitate understanding of the inventive method and inventive device. It should be considered in this connection that the rotational speeds for such objects or tools may amount to between 300 and 400 r.p.m. and that accordingly, the feed may be of a magnitude of 1 mm and less per revolution. For example, the peripheral length of the contact line in the contact plane 84 may be 19.5 times greater than the peripheral length of the guiding rollers 22 and 49.
Whilst the invention and many of its attendant advantages will be understood from the foregoing description, it will be apparent that various changes may be made in the form, construction and arrangement of parts and in the method steps without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the form hereinbefore described merely being preferred embodiments thereof.
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The invention describes a method and a device for processing by chip-cutting of workpieces. It is preferentially applied for the cross-cutting and chamfering of extruded plastics material tubes. A chip-raising or cutting tool may be fed forward radially with respect to a rotational displacement of the workpiece in the direction of a center of relative rotation. An undulant approach motion is superimposed over the feed motion of the tool. The undulant approach motions of two directly consecutive revolutions are displaced in phase. As a result chip cuttings of uniform and predetermined length are produced with consequent facility in removal and avoidance of interference with the cutting operation.
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BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a stabilizer for a motor boat, and more particularly, to a motor mounted stabilizer for stablely maintaining the hull of the boat essentially parallel to the surface of the water.
2. Related Art
Motor boats experience performance problems due to the usual location of the motor at the rear (stern) of the boat, causing drag and and resulting in the front (bow) of the boat lifting out of the water. At high speeds, the lifting of the bow becomes more pronounced, blocking the view of the boat operator, and preventing safe steering of the boat. In an attempt to overcome this problem, many boat operators place passengers or other weight in the forward part of the boat so as to hold the bow down. However, the excess weight results in sluggish boat operation and reduced engine efficiency. Additionally, since a substantial part of the hull is out of the water, the boat tends to skip or slide during high speed turns.
A second performance problem occurring at high speed operation is known as "porpoising", that is, the tendency of the bow of the boat to oscillate between an extreme lifted position and a contact position with the water. This oscillation occurs rapidly, causing the bow to slam against the water surface, and then return to an extreme lifted position. "Porpoising" increases the difficulty of controlling the boat, as well as the roughness of the ride and passenger discomfort. Skipping or sliding during turns is also increased during "porpoising".
A third performance problem is experienced during acceleration from a stop. During acceleration, it is desirable to achieve "planing" mode, that is, when the flat surface of the hull is essentially in full contact with the water, as soon as possible. However, due to the above discussed tendency of the stern of the boat to sink beneath the surface of the water, causing the bow to be lifted out of the water during high-speed operation, planing of the boat during rapid acceleration is difficult or impossible to achieve. Thus, in order to obtain satisfactory acceleration, increased fuel consumption is required since the motor must operate at higher RPM to obtain high speed when a substantial part of the hull is out of the water.
One attempt to overcome the above problems is disclosed in Larson U.S. Pat. No. 4,487,152, which is directed to a boat stabilizer fitted over the cavitation plate on the motor post of the motor. The stabilizer is a generally delta wing shaped foil member and is attached at a position over the propeller to provide upward lift for the stern, apparently in the same manner as an airplane wing provides lift for the airplane as air rushes over it. However, in practice only limited success has been obtained with the wing stabilizer in eliminating the undesirable effect of "porpoising" at medium or high boat speeds. Furthermore, the wing-shaped stabilizer provides only minimal improvement in reducing skipping or sliding during turns.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a stabilizer for a motor boat which eliminates "porpoising" by maintaining the boat at a level plane with respect to the surface of the water, enabling safer and more efficient operation of the boat at medium and high boat speeds.
Another object of the present invention is to provide a stabilizer for a motor boat which allows the boat to achieve a level "plane" in a shorter time after the boat accelerates from a dead stop, and to maintain a level "plane" at a lower motor rpm.
Another object of the present invention is to provide a stabilizer for a motor boat which allows the boat to move at a higher speed when the engine operates at high rpm than when the motor operates at the same high rpm without the stabilizer.
Another object of the present invention is to provide a stabilizer for a motor boat which provides a more fuel efficient operation at all motor speeds and which allows the motor to be operated at a higher trimmed position at higher speeds.
Another object of the present invention is to provide a stabilizer for a motor boat which provides safer and more precise steering control during high speed turns, eliminating skidding and sliding, and which provides a tighter turning radius.
The present invention is directed to a motor boat stabilizer comprising a pair of hollow tubular members which are attached by a mounting bracket to the motor post of a boat motor. The motor housing includes an integrally formed cavitation plate disposed below the water line. The tubular members are attached on either side of the cavitation plate below the surface of the water and project rearwardly and downwardly. The tubular members are attached at an angle of between 10°-22° with respect to the plane of the cavitation plate, preferably at an angle of 20°. The tubular members are attached such that one end is adjacent a midpoint between the forward surface of the motor housing and the rear edge of the cavitation plate. The other ends extend approximately 7" beyond the rear edge of the cavitation plate. The tubular members may be made of stainless steel or any other suitable material. Three mounting arrangements are disclosed for attaching the tubular members to the cavitation plate such that the stabilizer may be adopted for different motor configurations.
Further object, features and other aspect of this invention will be understood from the detailed description of the preferred embodiments of the invention with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an outboard motor adapted with the tubular stabilizer of the present invention.
FIG. 2 is a view showing a first mounting arrangement of the tubular stabilizer of the present invention.
FIG. 3 is a view showing a second mounting arrangement of the tubular stabilizer of the present invention.
FIG. 4 is a view showing a third mounting arrangement for the tubular stabilizer of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1, motor 11 is disposed in a cut-out region of the upper part of boat hull 10. Motor 11 includes motor housing 14 which further includes motor post 12, and integrally formed essentially planar cavitation plate 15 projecting rearwardly therefrom. Propeller 13 is disposed on the lower part of motor post 12. Motor 11 is connected to hull 10 by pivot 9 such that motor 11 pivots about a substantially vertical axis to steer the boat. Additionally, although motor 11 is shown as an outboard motor, the invention may also be used with an inboard motor such that the stabilizer would be disposed on the hull at a position adjacent to propeller 13. Cavitation plate 15 is disposed below water line 16.
Stabilizer 20 includes hollow tubular members 17 and 18 disposed on either side of cavitation plate 15. The tubular members are attached to cavitation plate 15 and project rearwardly and below the cavitation plate at a downward angle. The angle between the rearwardly extending part of the tubular members and cavitation plate 15 is in a range between 10°-22°, and is preferably 20°. Tubular members 17 and 18 are disposed beneath water line 16. When cavitation plate 15 is disposed generally parallel to the surface of the water, tubular members 17 and 18 would be disposed beneath the surface at approximately a 20° angle with respect to the surface. Of course, if a power trimmer is used, the motor may be trimmed at various angles with respect to the transom, that is, the vertical rear surface of the hull. For example, the trim angle may vary between 16° out from the the transom (+16° with respect to the vertical plane), to 4° into the transom (-4°). Thus, although the angle of the tubular members with respect to the cavitation plate remains constant, the angle with respect to the surface will vary according to the trim angle of the motor.
Tubular members 17 and 18 may be constructed of stainless steel. However, other appropriate metallic or composite materials may be used to make the tubular members. The diameter of each tube is approximately 3"-31/2", but may vary as necessary according to the size of the boat. For example, for a 60' yacht, the diameter may vary between 6"-8". Additionally, the length of tubular members 17 and 18 will vary according to the distance between the rear edge of the cavitation plate and the inboard side of motor post 12. In general, the length of the tubular members should be such that when the forward end of the tubular member is disposed approximately halfway between the rear end of the cavitation plate and the forward end of the motor post, the rearward end of the tubular members will extend for approximately 7" beyond the rear edge of the cavitation plate. In a typical 70 or 90 horse power motor, the motor measures 24" from the rear edge of the cavitation plate to the forward end, and the hollow tubular members should be
(1/2×24")+7"=19",
in length. A typical 115 horsepower motor measures 30", and thus the tubular members should be 22" long.
Three preferred mounting arrangements are disclosed, as shown in FIGS. 2-4. With respect to FIG. 2, tubular members 17 and 18 are fixedly attached to starboard (right side) mounting bracket 21 and port (left side) mounting bracket 22 by welding or other suitable means. Each bracket 21 and 22 includes recessed channels 25 and 26, respectively, formed on the inner surfaces. The recessed channels correspond to the lateral surfaces of cavitation plate 15. A plurality of holes 23 are disposed through brackets 21 and 22, and corresponding holes are disposed in cavitation plate 15. Each mounting bracket is disposed on the cavitation plate such that the lateral surfaces of the cavitation plate fit into corresponding recessed channels 25 and 26, and is fixed to the cavitation plate by bolts disposed through the holes.
With respect to FIG. 3, a second mounting arrangement is shown. Tubular members 17 and 18 are disposed on mounting brackets 21 and 22 as in the arrangement of FIG. 2. Brackets 21 and 22 are attached at their rearward ends by bolt 31 disposed through bolt guides 32 projecting from the rear surface of the brackets. Nuts 33 are disposed on opposite ends of bolt 31 to secure the brackets at one end. The brackets are disposed on cavitation plate 15 as in FIG. 2.
The motor housing of the motor for which the second mounting arrangement is designed to be used includes an upper water cooling passage (not shown) which is essentially a hole disposed through the motor housing at a position above the cavitation plate. Upper strap 34 is disposed through the hole. Lower strap 35 is disposed beneath and immediately adjacent the cavitation plate. The straps are aligned with each other and are preferably 1/2 inch wide. The upper and lower straps are secured to brackets 21 and 22 by a single bolt 36 disposed through each end of the straps and through the corresponding bracket. The provision of the strap through the water cooling passage and the lower strap adjacent the cavitation plate securely maintains the stabilizater on the motor.
A third mounting arrangement is shown in FIG. 4. The tubular members and mounting brackets are similar to those shown in FIG. 2. Additionally, the third arrangement includes bolt guides 32, bolt 31 and nuts 33 on the rearward end of the mounting brackets as disclosed in FIG. 3. Furthermore, forward holes are disposed through the forward ends of brackets 21 and 22, in a direction substantially parallel to their horizontal surfaces. Bolt 41 is disposed through the forward holes, and is disposed at a location between the forward surface of motor post 12 and rearward of the stern. Nut 42 is disposed on bolt 41 to a securely retain bolt 41 in the holes, and to securely retain the mounting bracket and tubular member assembly on the cavitation plate. No holes need be drilled in cavitation plate 15 in the third mounting arrangement.
In operation of the boat, water enters the tubular members at the forward end, flows through the hollow tubular members, and is emitted at the rear end as a jetstream, thereby creating an upward force on the motor housing and thus the stern of the boat, urging the bow of the boat downwardly. Thus, undesirable "porpoising" is substantially eliminated. Additionally, the downward force acting on the bow causes the boat to "plane" much faster after starting from a stop. Increased control of the boat during high-speed turns is obtained, and skipping, slipping and skidding is significantly reduced. The turning radius of the boat is also reduced. Cavitation, that is, the tendency for air pockets to be formed in the water about the propeller and reducing the propulsion efficiency, is also reduced. The rounded design of the tubular members and the smoothness of the mounting brackets result in minimal resistance to movement through the water. All of the above advantages further result in increased efficiency of operation of the motor such that the boat moves at a higher speed for a given horsepower output of the motor. Thus, the boat may be operated at the same speed as without the stabilizer, with a corresponding increase in fuel efficiency since more of the horsepower of the motor goes into forward propulsion of the boat, rather than into undesirable "porpoising". Finally, the stabilizer of the present invention substantially reduces the risk that the boat will become substantially airborne during high speed operation.
This invention has been illustrated and described in connection with the preferred embodiments. These embodiments, however, are merely for example only and the invention is not restricted thereto. It will be understood by those skilled in the art that other variations and modifications can easily be made within within the scope of this invention as defined by the appended claims.
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The present invention provides a stabilizer attached to the cavitation plate on the leg of a motor boat motor. Two elongated tubular members are attached by mounting brackets to the motor's cavitation plate. The tubular members are attached at a downward angle away from the boat so that an upward force is created by the hydrodynamic jet action of water flowing through the tubular members at the rear of the boat when the boat moves in a forward direction. The upward jet created force at the rear of the boat keeps the boat horizontal and stable at increasing speeds and at high speeds.
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BACKGROUND
[0001] The present invention relates to a dispenser pump button, and in particular to a dispenser pump button which makes it possible to prevent a cap from being contaminated, in such a way that a nozzle is normally positioned in a button body, but when the button body is pressed, the nozzle moves forward and gets exposed to the outside of the button body for thereby discharging contents.
[0002] A dispenser, in general, is engaged to the top of a sealed container filled with gas, liquid or contents and is configured to discharge a certain amount of the contents when it is pressed. The dispenser is applied to various sealed containers which store cosmetics, perfume, drugs or food. At the top of the dispenser is disposed a button with which to press the dispenser. The contents are discharged through the nozzle as the user handles the button.
[0003] At the button of the dispenser is provided a nozzle through which contents are discharged out. The inner sides of the cap of the cosmetic container may be contaminated by the leftover cosmetics which remains in the nozzle after the user used cosmetics. The cosmetic cap is equipped with a button pressing prevention function and a contamination prevention function of the cosmetics. The contaminated cap may further contaminate the cosmetics and may make the exterior of the container look bad.
[0004] In order to prevent the contamination of the cap which occurs as the nozzle is exposed to the outside, there is suggested a structure which makes it possible to discharge contents in a state that the nozzle is positioned in the button. If the contents are discharged in a state that the nozzle is positioned in the button, the cap can be prevented from being contaminated; however it is hard to discharge the contents to where the user wants. In this case, the contents may stain the button or the decorated portions in the middle of the discharge of contents, thus causing more contaminations.
SUMMARY OF THE INVENTION
[0005] Accordingly, the present invention is made in consideration of the above mentioned problems. It is an object of the present invention to provide a dispenser pump button which makes it possible to prevent a cap from being contaminated, in such a way that a nozzle is normally positioned in a button body, but when the button body is pressed, the nozzle moves forward and is exposed to the outside of the button body for thereby discharging contents.
[0006] It is another object of the present invention to provide a dispenser pump button which makes it possible to prevent contents from going spoiled, in such a way that the air does not flow in the cosmetic container when it is normally used as a discharge hole of a nozzle is closed with an opening and closing rod provided at a discharge part.
[0007] It is further another object of the present invention to provide a dispenser pump button in which a guide member performs a piston function while a button body moves upward, for thereby sucking in the contents remaining in the nozzle, by which to minimize the remaining amount of the contents in the nozzle, so the contamination of the contents can be prevented, and the problems, which occurs due to the solidification of contents at the nozzle, can be prevented.
[0008] To achieve the above objects, there is provided a dispenser pump button which is positioned at the top of a pumping member and pressurizes the pumping member when a user presses for thereby discharging contents with the aid of pumping operations, comprising a button body which includes a content flow passage formed at an inner center portion for the contents to flow and communicates with the content flow passage, and a discharge part communicating with the content flow passage for thereby discharging the contents; a nozzle which is engaged to the discharge part and discharges out the contents, and moves back and forth when the button body moves up and down and is equipped with a discharge hole at its front side for the sake of discharge of the contents, and a guide groove formed at its side for guiding the forward and backward movements; a guide member which is engaged to the inner side of the button body and is equipped with the guide groove of the nozzle and allows the nozzle to move back and forth when the button body moves up and down; and an elastic part one side of which is supported against the guide member, and the other side of which is supported against the inner side of the button body for thereby allowing the button body to move upward by providing an elastic force in an upward direction.
[0009] In addition, an opening and closing rod is provided at the button body for opening and closing the discharge hole of the nozzle, and the opening and closing rod extends from a bottom wall surface of the discharge part to the top and is vertically bent in a forward direction.
[0010] In addition, part of the bottom of the nozzle is cut away so as to prevent any interference with the opening and closing rod when it is engaged to the discharge part.
[0011] In addition, the guide member comprises a suction part engaged to the content flow passage and providing a piston function of sucking the contents which remains in the nozzle; an engaging part which is formed in a cylindrical shape extending down the suction part and is engaged to the top of the pumping member; and a spring support part which surrounds the suction part and extends from the suction part and forms a mounting part on which to mount the bottom of the elastic part.
[0012] In addition, the guide protrusion comprises a pair of protrusion pieces protruding upward from the center of the suction part, and a guide bar which connects the protrusion pieces at the end portions of the protrusion pieces and is engaged to the guide grove.
[0013] In addition, a content inflow hole is formed at the bottom of the guide protrusion for flowing in the contents which move through the engaging part.
[0014] In addition, the button body includes an extension part which surrounds the content flow passage at an outer side of the content flow passage and extends downward, and a fixing part is engaged to the extension part so as to fix the guide member to the button body and is hollow.
[0015] The present invention makes it possible to prevent a cap from being contaminated, in such a way that a nozzle is normally positioned in a button body, but when the button body is pressed, the nozzle moves forward and is exposed to the outside of the button body for thereby discharging contents.
[0016] The present invention makes it possible to prevent contents from going spoiled, in such a way that the air does not flow in the cosmetic container when it is normally used as a discharge hole of a nozzle is closed with an opening and closing rod provided at a discharge part.
[0017] In addition, the guide member has a piston function when the button body moves upward for thereby sucking in the contents remaining in the nozzle, by which to minimize the remaining amount of the contents in the nozzle, so the contamination of the contents can be prevented, and the problems, which occur due to the solidification of contents at the nozzle, can be prevented.
BRIEF DESCRIPTION OF DRAWINGS
[0018] FIG. 1 is a disassembled perspective view illustrating a construction of a dispenser pump button according to a preferred embodiment of the present invention.
[0019] FIG. 2 is a cross sectional view illustrating a construction of a dispenser pump button according to a preferred embodiment of the present invention.
[0020] FIG. 3 is a perspective view illustrating an engaged state of a nozzle and a guide member of a dispenser pump button according to a preferred embodiment of the present invention.
[0021] FIG. 4 is a cross sectional view illustrating a state that a dispenser pump button is engaged to a container body according to a preferred embodiment of the present invention.
[0022] FIGS. 5 and 6 are views illustrating the operation states of a dispenser pump button according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The present invention will be described with reference to the accompanying drawings. The same reference numerals of each drawing represent the same elements.
[0024] FIG. 1 is a disassembled perspective view illustrating a construction of a dispenser pump button according to a preferred embodiment of the present invention. FIG. 2 is a cross sectional view illustrating a construction of a dispenser pump button according to a preferred embodiment of the present invention. FIG. 3 is a perspective view illustrating an engaged state of a nozzle and a guide member of a dispenser pump button according to a preferred embodiment of the present invention.
[0025] FIG. 4 is a cross sectional view illustrating a state that a dispenser pump button is engaged to a container body according to a preferred embodiment of the present invention. FIGS. 5 and 6 are views illustrating the operation states of a dispenser pump button according to a preferred embodiment of the present invention.
[0026] The present invention is directed to a dispenser pump button which is disposed at the top of a dispenser container and moves up and down when a user presses, and presses a pumping member 30 . Here the typical dispenser container comprises a container body 10 which stores contents and is equipped with a piston 11 disposed at an inner lower portion and ascending and descending in the middle of the use of the content, a support part 20 which is engaged to the top of the container body 10 and supports the pumping member 30 , a pumping member 30 which is engaged to the top of the support part 20 and performs a pumping operation when the button member is pressed, and an over cap 40 which surrounds the pumping member and is engaged to the top of the container body 10 .
[0027] The container body 10 , the support part 20 , the pumping member 30 and the over cap 40 are already open to public, so the descriptions thereon will be omitted. The construction of the dispenser pump button according to the present invention will be described in details.
[0028] As shown in FIGS. 1 to 6 , the dispenser pump button according to a preferred embodiment of the present invention comprises a button body 100 , a nozzle 200 , a guide member 300 and an elastic part 400 .
[0029] The button body 100 is disposed at the top of the pumping member 30 engaged to the container body 10 and pressurizes the pumping member 30 when the user presses it for thereby discharging contents based on the pumping operations.
[0030] To the top of the container body 10 is engaged the support part 20 which supports the pumping member 30 . At the inner lower end of the container body 10 is disposed a piston 11 which ascends and descends in the middle of the use of the contents.
[0031] At an inner center portion is formed a content flow passage 110 through which the contents flow. At an end portion of the content flow passage 110 is formed a discharge part 120 which communicates with the content flow passage 110 for thereby discharging contents.
[0032] The present invention has features in that at the button body 100 is provided an opening and closing rod 121 which opens and closes a discharge hole 210 of the nozzle 200 . The opening and closing rod 121 extends upward from the lower wall surface of the discharge part 120 and vertically bends forward for thereby opening and closing the discharge hole 210 when the nozzle 200 moves back and forth. When the cosmetic container is not used, the discharge hole 210 of the nozzle 200 is closed so as to prevent the input of the air into the button body 100 , so the spoilage of the contents can be prevented.
[0033] The opening and closing rod 121 is integrally formed at the button body 100 . It is therefore possible to reduce the manufacture time which takes when separately manufacturing the opening and closing rod 121 and assembling it to the button body 100 .
[0034] In the button body 100 is formed an extension part 130 which extends downward as if it surrounds the content flow passage 110 along an outer side of the content flow passage 110 , and to the extension part 130 is engaged a fixing part 500 having a hollow part 510 for thereby supporting the guide member 300 , so it is possible to prevent an escape of the guide member 300 from the button body 100 .
[0035] The nozzle 200 is engaged to the discharge part 120 for thereby discharging out the contents and moves back and forth when the button body 100 moves up and down, and at its front part is formed a discharge hole 210 through which to discharge contents, and at its side part is formed a guide groove 220 so as to guide the forward and backward movements.
[0036] It is preferred that part of the lower end of the nozzle 200 is cut away so as to prevent any interference which may occur due to the presence of the opening and closing rod 121 when it is engaged to the discharge part 120 .
[0037] The guide member 30 is engaged to an inner side of the button body 100 and allows the nozzle 200 to move back and forth when the button body 100 moves up and down and comprises a suction part 310 , an engaging part 320 , a spring support part 330 and a guide protrusion 340
[0038] The suction part 310 is engaged to the content flow passage 310 . In the present invention, as shown in FIG. 6 , the suction part 310 provides a piston function through which to suck the contents which remains in the nozzle 200 by the distance that the button body 100 moves along when the button body 100 moves upward, by means of which it is possible to reduce in maximum the amount of contaminants which remain in the nozzle 200 and are stuck to in the nozzle.
[0039] The engaging part 320 extends down the suction part 310 and is engaged to the top of the pumping member 30 and fixes the guide member 300 to the pumping member 30 and transfers the pumping member 30 a press force when the button body 100 is pressed.
[0040] It is preferred that the engaging part 320 is formed in a cylindrical shape the inner side of which is hollow so as to move the contents discharged from the pumping member 30 .
[0041] The spring support part 330 surrounds the suction part 310 and extends from the suction part 310 and forms a mounting part 331 for mounting the bottom of the elastic part 400 for thereby supporting the bottom of the elastic part 400 .
[0042] The guide protrusion 340 protrudes upward from the center of the suction part 310 and is engaged to the guide groove 220 and allows the nozzle 200 to move back and forth when the button body 100 moves up and down and comprises a pair of protrusion pieces 341 protruding upward from the center of the suction part 310 , and a guide bar 342 which connects the protrusion pieces 341 at the end portions of the protrusion pieces 341 and is engaged to the guide grove 220 .
[0043] It is preferred that a content inflow hole 343 is formed at the bottom of the guide protrusion 340 for the contents moving through the engaging part 320 to flow through the content inflow hole 343 .
[0044] The elastic par 400 is positioned at the inner side of the button body 100 and contracts when the user pressurizes the button body 100 and releases when the pressurization by the user is released and provides an elastic force in an upward direction for thereby allowing the button body 100 to move upward. One side of the elastic part 400 is supported against the mounting par 331 of the guide member 300 , and the other side of the same is supported against the inner side of the button body 100 .
[0045] The operations of the dispenser pump body according to a preferred embodiment of the present invention will be described with reference to FIGS. 5 and 6 . FIGS. 5 and 6 are views illustrating the operation states of a dispenser pump button according to a preferred embodiment of the present invention.
[0046] As shown in FIGS. 5 and 6 , according to the dispenser pump button according to a preferred embodiment of the present invention, when the user pressurizes the button body 100 , the button body 100 moves downward. At this time, the nozzle 200 moves forward by the guide protrusion 340 of the guide member 300 , and the button body 100 gets to expose to the outside, and the discharge hole 210 which remains closed by the opening and closing rod 121 gets opened. When the button body 100 is further pressed in a state that the nozzle 200 is exposed to the outside, the engaging part 320 engaged to the pumping member 30 transfers the pressure to the pumping member 30 , so the pumping member starts pumping. As a result, the contents stored in the container body 10 rises and can be finally discharged to the outside through the discharge hole 210 of the nozzle 200 .
[0047] When the user releases the pressurized state of the button body 100 , the elastic part 400 which remains contracted by the pressurization of the button body 100 gets to release for thereby providing an elastic force in an upward direction. At this time, the nozzle 200 moves backward by the guide protrusion 340 of the guide member 300 and is inserted into the button body 100 , so the nozzle 200 hides in the interior of the button body 100 . When the nozzle 200 is inserted into the interior of the button body 100 , the discharge hole 210 of the nozzle 200 is closed by the opening and closing rod 121 , so the air is prevented from flowing into the interior of the button body 100 , whereby the spoilage of the contents can be prevented.
[0048] According to the present invention, the nozzle 20 normally remains hidden in the interior of the button body 100 . When in use, the nozzle 200 gets exposed to the outside for thereby discharging contents. So, it is possible to prevent any contamination of the nozzle which used to happen as the nozzle is being exposed to the outside and to prevent any contamination for thereby improving the construction of the dispenser pump body.
[0049] The construction that the opening and closing rod 121 extends from the bottom wall surface of the discharge part 120 to the top and is vertically bent in the forward direction was described above; however it may extend downward from the top wall surface of the discharge part 120 and may be vertically bent in the forward direction. In this case, part of the end of the top of the nozzle 200 may be cut away.
[0050] As the present invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it should also be understood that the above-described examples are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its spirit and scope as defined in the appended claims, and therefore all changes and modifications that fall within the meets and bounds of the claims, or equivalences of such meets and bounds are therefore intended to be embraced by the appended claims.
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A dispenser pump button is designed so as to have a structure in which, when the button body is pressed, a nozzle which is normally positioned within the button body moves forward so as to be exposed to the outside from the button body and enable contents to be discharged, in order to prevent a cap from being contaminated.
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FIELD OF THE INVENTION
This invention relates to skin care compositions containing retinoids which are generally applied topically to improve the quality of the skin. More particularly, this invention relates to skin care compositions comprising retinol (Vitamin A alcohol) and further comprising irritation ameliorating quantities of glycolic acid.
BACKGROUND OF THE INVENTION
Skin care compositions containing retinoids have become the focus of great interest in recent years. Retinoic acid, also known as Vitamin A acid or tretinoin, is well-known for the treatment of such skin conditions as acne and products containing retinoic acid are commercially available in various forms from the Dermatological Division of Ortho Pharmaceutical Corporation.
More recently, however, wider use of retinoids has been suggested for treatments other than ache such as, for example, the treatment of skin against photoaging and sun damage. Many individuals who have had a good deal of sun exposure in childhood will show the following gross cutaneous alterations in later adult life: wrinkling, leatheriness, yellowing, looseness, roughness, dryness, mottling (hyperpigmentation) and various premalignant growths (often subclinical). These changes are most prominent in light-skinned person who burn easily and tan poorly. These cumulative effects of sunlight are often referred to as "photoaging". Although the anatomical degradation of the skin is most advanced in the elderly, the destructive effects of excessive sun exposure are already evident by the second decade. Serious microscopic alterations of the epidermis and dermis occur decades before these become clinically visible. Wrinkling, yellowing, leatheriness and loss of elasticity are very late changes.
The problem of skin aging is addressed in U.S. Pat. No. 4,603,146 wherein Vitamin A acid in an emollient vehicle is suggested as a treatment. Further, in U.S. Pat. No. 4,877,805, it is suggested that a number of retinoids are useful for restoring and reversing sun damage of human skin.
When considering the use of retinoids in skin care products, it is believed that certain retinoids such as, for example, retinol (Vitamin A alcohol), would be preferred over retinoic acid. This is because retinol is an endogenous compound naturally occurring in the human body and essential for good growth, differentiation of epithelial tissues and reproduction. Retinol is also preferred because it has a much larger safety margin than other retinoids such as retinoic acid. Accordingly, attention has turned toward formulating skin care compositions which contain retinol. Such compositions have been proposed such as those disclosed in a pending patent application, U.S. Ser. No. 719,264, filed on Jun. 27, 1991 by Clum et al. and commonly assigned to the assignee of this application; the disclosure of which is hereby incorporated by reference.
The benefits from the use of retinol as set out above notwithstanding, it has been noted that skin care compositions containing retinol to some degree exhibit undesirable skin irritation as manifested by flaking, erythema and dermal edema.
Accordingly, there is a need for a composition comprising retinol which manifests less retinol induced irritation.
SUMMARY OF THE INVENTION
In accordance with the teachings of this invention, a skin care composition is provided comprising retinol as an active ingredient. The retinol irritating properties of the composition are ameliorated by employing a retinol irritation ameliorating amount of glycolic acid.
The glycolic acid is present in an amount effective to ameliorating such indicia of retinol skin irritation as transepidermal water loss (hereinafter "TEWL") and skin fold thickness (hereinafter "SFT"). TEWL measures a change in barrier function (i.e. the thinning of the stratum corneum results in increased TEWL) and SFT in an indication of dermal edema. Both a decrease in barrier function and an increase in dermal edema are characteristic indications of irritation resulting from the topical application of retinol. Such effective amounts of glycolic acid are preferably greater than about two percent by weight of the composition and still more preferably from about five to about ten percent by weight glycolic acid, based on the weight of the composition.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graphical representation of data illustrating the SFT effect of retinol containing compositions comprising 0% and 2% glycolic acid;
FIG. 2 is a graphical representation of data illustrating the SFT effect of retinol containing compositions comprising 0% and 5% glycolic acid; and
FIG. 3 is a graphical representation of data illustrating the SFT effect of retinol containing compositions comprising 0% and 10% glycolic acid.
DETAILED DESCRIPTION OF THE INVENTION
As described above, the composition of this invention comprises retinol and glycolic acid as a retinol irritation ameliorator. As described in the aforementioned application, U.S. Ser. No. 719,264, the retinol composition comprises a therapeutically effective amount of retinol in a vehicle for topical application. Preferably, the vehicle is chosen, in accordance with the teaching of the referred to prior filed application, to include a system for insuring long shelf life and stability for the retinoid.
Accordingly, the retinol concentration in the composition may range from about 0.001 to about 5.0%, by weight of the total composition, and preferably from about 0.001 to about 1.0%. The composition is preferably chosen as water-in-oil emulsion, as such has been found to be particularly protective of the stability of the retinol activity. The ratio of the oil phase to the water phase can vary from about 5:95 to about 99:1, by weight. Additionally, the composition preferably comprises a chemical stabilizing system selected from the group consisting of:
a) a chelating agent and at least one oil-soluble antioxidant;
b) a chelating agent and at least one water-soluble antioxidant; and
c) antioxidant present in each of the oil and water phases of said emulsion;
The water-soluble antioxidants which are useful in the compositions of the present invention include ascorbic acid, sodium sulfite, sodium metabisulfite, sodium bisulfite, sodium thiosulfite, sodium formaldehyde sulfoxylate, isoascorbic acid, thioglycerol, thiosorbitol, thiourea, thioglycolic acid, cysteine hydrochloride, 1,4-diazobicyclo-(2,2,2)-octane and mixtures thereof as well as any other known water-soluble antioxidant compatible with the other components of the compositions.
The oil-soluble antioxidants which are useful in the compositions of the present invention include butylated hydroxytoluene (BHT), ascorbyl palmitate, butylated hydroxyanisole (BHA), α-tocopherol, phenyl-α-naphthylamine, hydroquinone, propyl gallate, nordihydroguiaretic acid, and mixtures thereof as well as any other known oil-soluble antioxidant compatible with the other components of the compositions.
The antioxidants would be utilized in a stabilizing effective amount and may range in total from about 0.001 to 5.0% based on the weight of the total composition, preferably from about 0.01 to 1.0%. The amount of antioxidants utilized in the compositions of the present invention is dependent in part on the specific antioxidants selected, the amount of and specific retinoid being protected and the processing conditions.
In certain aspects of this invention, the compositions include a chelating agent. The retinol compound of this invention is sensitive to metal ions and in particular to bi- and tri-valent cations and in certain instances, degrade rapidly in their presence. The chelating agent forms a complex with the metal ions thereby inactivating them and preventing them from affecting the retinol compound. Chelating agents which are useful in the compositions of the present invention include ethylenediamine tetraacetic acid (EDTA) and derivatives and salts thereof, dihydroxyethyl glycine, citric acid, tartaric acid, and mixtures thereof. The chelating agents should be utilized in a stabilizing effective amount and may range from about 0.01 to 2.0% based on the weight of the total composition, preferably from about 0.05 to 1.0%.
The skin care compositions of the present invention comprising a water-in-oil emulsion can be in the format of cream or lotion formulations, as desired, by varying the relative quantities of the oil and water phases of the emulsion. The pH of the compositions should be in the range of from about 4 to about 9, and preferably from about 4 to about 7.
Mineral oils, animal oils, vegetable oils and silicones have all been used in cosmetic creams and lotions of the emulsion type. In addition to such oils, other emollients and surface active agents have been incorporated in the emulsions, including glyceryl trioleate, acetylated sucrose distearate, sorbitan tiolate, polyoxyethylene (1) monostearate, glycerol monoleate, sucrose distearate, polyethylene glycol (50) monostearate, octylphonoxypoly (ethyleneoxy) ethanol, decaglycerin penta-isostearate, sorbitan sesquioleate, hydroxylated lanolin, lanolin, triglyceryl diisotearate, polyoxyethylene (2) oleyl ether, calcium stearoyl-2-lactylate, methyl glucoside sesquistearate, sorbitan monopalmitate, methoxy polyethylene glycol-22/dodceyl glycol copolymer(Elfacos E200), polyethylene glycol-45/dodecyl glycol copolymer(Elfacos ST9), polyethylene glycol 400 distearate, and lanolin derived sterol extracts, glycol stearate and glyceryl stearate; alcohols, such as cetyl alcohol and lanolin alcohol; myristates, such as isopropyl myristate; cetyl palmitate; cholesterol; stearic acid; propylene glycol; glycerine, sorbitol and the like. Thickeners such as natural gums and synthetic polymers, as well as preservatives such as methylparaben, butyl paraben, propylparaben and phenoxyethanol, coloring agents and fragrances also are commonly included in such compositions. Other active ingredients such as sunscreen materials and antimicrobial materials may be utilized in the compositions of the present invention provided that they are physically and chemically compatible with the other components of the compositions.
In accordance with this invention, the above described retinol composition further comprises glycolic acid as a retinol irritation ameliorating component. Glycolic acid (2-hydroxyethanoic acid) is one of the class of alpha hydroxyacids of which for example, lactic acid (2-hydroxy propanoic), malic acid (2-hydroxybutane-1,4,dioic acid) are also close members. It is naturally occurring, as are other alpha hydroxyacids obtained from fruits, sugar cane, and yogurt and its effects on skin and skin disfunctions have been already studied. (See, for example E. J. Van Scott and R. J. Yu, Control of keratinization with alpha hydroxy acids and related compounds, Arch Dermatol 110 586-590 (1974); E. J. Van Scott and R. J. Yu, Commentary: Ichthyosis and keratinization, Arch Dermatol 118 860-861 (1982); E. J. Van Scott and R. J. Yu, Hyperkerarinization, corneocyte cohesion, and alpha hydroxy acids, J Am Acad Dermatol 11 867-879 (1984); E. J. Van Scott, Dry skin et cetera, corneocyte detachment, desquamation, and neo strat, Int J Dermatol 26 90 (1987); E. J. Van Scott, Alpha hydroxy acids effective for acne, warts, dry skin, Skin & Allergy News 18 35 (1987); E. J. Van Scott and R. J. Yu, Alpha hydroxy acids: Procedures for use in clinical practice, Cutis 43 222-228 (1989).
Further, in European Patent Application 87117405.8 published Jul. 6, 1988, Scott and Yu disclosed employing an alpha hydroxy acid salt, ethyl pyruvate, with retinoic acid as a treatment for oily skin. In U.S. Pat. No. 5,153,230 to Monzour H. Jeffrey, it is suggested that glycolic acid is in itself useful for treating aging skin and may be combined with Vitamin A palmitate in such composition.
In view of these references, however, it is totally surprising that glycolic acid may be employed in a retinol containing composition to ameliorate the irritating effects of the retinol component. For example, Scott and Yu in Arch Dermatol/Vol. 110, October 1974, p588 have stated that glycolic acid, particularly in concentrations of from 5 to 10%, when used as the sole active ingredient, has acted as an irritant and hence, lower concentrations are recommended. Additionally, the authors further noted that one effect of glycolic acid is an abrupt loss of the entire abnormal stratum corneum in patients with lamellar ichthyosis. Accordingly, it is entirely surprising that glycolic acid, when combined with a specific irritating retinoid, retinol, can have an irritation ameliorating effect on the combination.
To illustrate the invention and the advantages flowing therefrom, the following examples are given. In each of these examples, the retinol containing compositions are emulsions prepared in accordance with the following procedure:
The ingredients shown under the heading "Aqueous Phase ingredients" in the table below are combined and heated until dissolved at a temperature of 55° to 60° C. and then cooled to 55° C. or until clear and then adjusted to a pH of 4.7 using a 50% by weight sodium hydroxide solution. The pH adjusted Aqueous Phase is then heated to 75° C. The ingredients shown under the heading "Oil Phase Ingredients" are combined and heated to 75° C. The Aqueous Phase is then added to the oil phase and heating is terminated. When the mixture reaches a temperature of 45° to 50° C. the fragrance is added and additionally, the ionized water is added to weight. The mixture is then homogenized for one minute. The retinol mixture is then added with stirring and the combined mixture is allowed to cool with stirring to room temperature.
__________________________________________________________________________ 3 4 5 6 0.01 RETINOL 0.01 RETINOL 0.01 RETINOL 0.01 RETINOLCOMPOSITION: 1 2 0.0 GLYCOLIC 2% GLYCOLIC 5% GLYCOLIC 10% GLYCOLICFor 500 g CONTROL VEHICLE ACID ACID ACID ACID__________________________________________________________________________Aqueous Phase IngredientsDeionized Water 0 266.75 266.75 256.75 241.75 216.75Sorbitol 0 25.0 25.0 25.0 25.0 25.0Dehydroacetic Acid 0 1.25 1.25 1.25 1.25 1.25EDTA 0 0.5 0.5 0.5 0.5 0.5Glycolic Acid 0 0.0 0.0 10.0 25.0 50.0Ascorbic Acid 0 0.5 0.5 0.5 0.5 0.5Oil Phase IngredientsMineral Oil 0 125.0 125.0 125.0 125.0 125.0.sup.1 Elfacos C-26 0 30.0 30.0 30.0 30.0 30.0.sup.2 Elfacos E-200 0 25.0 25.0 25.0 25.0 25.0.sup.3 Elfacos ST-9 0 15.0 15.0 15.0 15.0 15.0.sup.4 Dow Corning 580 Wax 0 5.0 5.0 5.0 5.0 5.0.sup.5 Dimethicone 0 5.0 5.0 5.0 5.0 5.0.sup.6 BHT 0 0.25 0.25 0.25 0.25 0.25.sup.7 Chemoderm 6401/B 0 0.75 0.75 0.75 0.75 0.75Retinol Mixture 0 0.115 0.115 0.115 0.115 0.115BHA 0 0.0011 0.0011 0.0011 0.0011 0.0011BHT 0 0.0039 0.0039 0.0039 0.0039 0.0039Retinol 0 0.0506 0.0506 0.0506 0.0506 0.0506Tween 20 0 0.0594 0.0594 0.0594 0.0594 0.0594__________________________________________________________________________ .sup.1 Elfacos C26 = Hydroxyoctacosanyl Hydroxystearate .sup.2 Elfacos E200 = Methoxy PEG22/Dodecyl Glycol Copolymer .sup.3 Elfacos ST9 = PEG45/Dodecyl Glycol Copolymer .sup.4 Dow Corning 580 Wax = Stearoxytrimethylsilane .sup.5 Dimethicone = Dimethicone (C.sub.2 H.sub.6 OSi) × C.sub.4 H.sub.12 Si .sup.6 BHT = Butylated Hydroxytoluene .sup.7 Chemoderm 6401/B = Fragrance
Each of the compositions are tested for Transepidermal Water Loss (TEWL) and Skin Fold Thickness (SFT) as markers for retinol irritation. This is accomplished by treating male hairless mice (Skh/hr1, Charles River, Wilmington, Mass.), 6-8 weeks of age. The mice upon receipt were fed ad libitum on Purina Chow #5015 and watered ad libitum for one week prior to use. The mice were then randomly assigned to treatment groups of seven mice each. Each group (with the exception of the control) was treated daily for seven days with one of the compositions set forth below applying 0.1 ml of such composition over the entire dorsal trunk and spreading it by gentle inunction. The study animals remained on a twelve hour light/twelve hour dark cycle before, during and after dosing. TEWL and SFT measurements were taken from each animal just prior to daily retreatment. Care was taken that subsequent TEWL and SFT readings were made as close to twenty-four hour intervals after the treatment as possible to reduce sampling error.
The skinfold thickness test (SFT) was carried out as follows. A fold of dorsal skin parallel to the long axis of each animal was picked up with the fingers. A Mitutuyo Pocket Thickness gauge (cat. #7309, MRO Industrial Supply, Manville, N.J.) was held open, slipped over the fold of skin at a site on the lower midback. The spring-loaded arm of the gauge was released and the gauge slid slightly forward to ensure that no more than 2 thicknesses of skin were picked up. A single reading×0.01 mm at the same site was made for each mouse at each interim. When the skin was edematous and the pressure of the spring caused the gauge reading to slowly decline, the reading was taken after the gauge stopped.
The transepidermal water loss (TEWL) measurements were performed as follows. The evaporimeter employed is an instrument for the quantitative determination of water evaporation, i.e. water transport by diffusion, from or to surfaces in contact with the atmosphere. Mice were held gently and the left flank area held up to the probe of an EP-1 ServoMed Evaporimeter (ServoMed, Stockholm, Sweden), so that an airtight seal was formed. A standard deviation setting of 0.1 was used, and one reading was taken per mouse. The TEWL in g/m 2 /h was recorded at each time point.
The result of the TEWL testing is summarized in the following table.
__________________________________________________________________________Effect of Glycolic Acid and Retinol on TEWL in Groups of Seven MiceTEWL - MEAN VALUES ONLYPRODUCT Untreated .00% + 0% .01% + 0% .01% + 2% .01% + 5% .01% + 10%DAY Control (vehicle) glycolic glycolic glycolic glycolic__________________________________________________________________________0 7.5 7.9 7.7 7.7 8.1 8.41 9.1 10.1 11.8 12.1 12.4 14.12 7.9 14.7 19.6 29.5 21.5 15.53 8.7 16.8 29.1 37.4 23.6 21.14 7.4 12.3 24.0 29.2 17.2 18.55 7.9 12.5 18.3 26.8 16.8 22.06 8.5 17.8 22.5 36.6 22.3 18.77 8.7 19.4 26.1 30.2 22.2 21.0__________________________________________________________________________
As can be seen in the above table, the TEWL for the group tested with composition 2, the vehicle, showed irritation based on the increase TEWL and this effect was aggravated substantially when a group was treated with the retinol containing, glycolic acid free, composition 3. A concentration of glycolic acid of as high as 2% by weight (composition 4) further aggravated the irritation. On the other hand, both a 5% glycolic acid composition (composition 5) and a 10% glycolic composition (composition 6) all tended toward ameliorating this irritation.
The results of the skin fold thickness measurements (SFT) are depicted in FIGS. 1-3. As can be clearly seen from the figures, a 2% glycolic acid addition did little to ameliorate the irritation as manifested by SFT in a 0.01% retinol composition (FIG. 1). On the other hand, a 5% glycolic acid addition and still more, a 10% glycolic acid addition, significantly ameliorated such irritation (FIGS. 2 and 3).
Each of the compositions set forth in Table III below was tested for cumulative irritation on human skin. Twenty-five human subjects were screened to ensure that they were in good health and that they did not have allergies or sensitivities to cosmetic products, toiletries and/or topical drugs. They were further questioned to ensure that they did not have any pre-existing or dormant dermatologic conditions, were not on chronic medication, were not pregnant or nursing, participating in other clinical studies or were abusers of alcohol or drugs. The subjects did not receive any experimental drugs within 30 days prior to admission into the study.
The compositions were applied in the following manner. Between about 0.2 and 0.3 ml of the test liquid composition was applied to an occlusive clinical patch. A patch loaded with composition was applied to the left or right upper back area. The patches were applied to the left or right scapular area starting from the top to the bottom of the back and lateral to the midline. The position of the patches was marked with gentian violet.
Each test product was applied under an occlusive patch to the designated test site three times per week (Mondays, Wednesdays and Fridays) for a total of six applications over a fourteen-day period. The patches remained in place for 48 hours during the week (Monday and Wednesday applications) and for 72 hours during the weekend (Friday applications)- After each 48-hour or 72-hour occlusive period, the patches were removed and the test sites graded according to the following scale:
0--No visible reaction
0.5--Minimal erythema
1--Mild erythema
2--Intense erythema
3--Intense erythema+induration+vesicular erosion
4--Intense erythema+induration+bullae
Each site was cleansed with sterile saline after which fresh test material and patches were applied to each test site. If grade 3 or 4 irritation was observed on any test site, no further applications were made to the site and the maximum score (4) was assigned for the duration of the study. The six daily scores for each test site for each subject was summed to yield a total score for 14 days. A grand total for a test sample was obtained by summing the 14-day totals for all subjects. Using 4 as the maximum daily score, the maximum score per evaluation for 25 subjects would be 100 and the maximum grand total for 6 evaluations would be 600. Thus, if the grand total scores are used, the minimum would be 0 with a maximum of 600.
In this test, three dose levels of glycolic acid (0%, 5% and 10%) were formulated with three doses of retinol )0.00%, 0.15% and 0.30%) to produce nine test compositions. The test compositions contained the formulation set forth in Table III, and the varying amounts of glycolic acid and retinol were added, with water to make up the remainder of the formulation. Thus, the nine test compositions contained, respectively, 0% glycolic acid and 0% retinol, 0% glycolic acid and 0.15% retinol, 0% glycolic acid and 0.30% retinol, 5% glycolic acid and 0% retinol, 5% glycolic acid and 0.15% retinol, 5% glycolic acid and 0.30% retinol, 10% glycolic acid and 0% retinol, 10% glycolic acid and 0.15% retinol, and 10% glycolic acid and 0.30% retinol. The test compositions were tested on 29 human subjects using the foregoing protocol to measure skin irritation. Two of the subjects were excluded from analysis because they dropped out of the study. The results of the cumulative irritation study were calculated by summing the six daily irritation ratings made over the 14-day study period for each subject. Twenty-seven subjects were tested. The maximum score on any day for any subject was 4, therefore the maximum possible indiex was 648 (27×4×6). The results of the study were as follows:
______________________________________ Cumulative Irritation Indices RetinolGlycolic Acid 0.00% 0.15% 0.30%______________________________________0% 8.0 46.0 54.05% 7.0 28.0 47.510% 8.0 23.5 49.5______________________________________
From these results it can be seen that glycolic acid, when tested without retinol, produced only minimal irritation that was approximately equivalent to the base formulation without glycolic acid or retinol. When retinol was tested alone, without glycolic acid, both doses (0.15% and 0.30%) produced more irritation than the base formulation. The irritative effects of 0.15% and 0.30% retinol were about equivalent. The test demonstrates that, at levels of 0.15% retinol, the addition of glycolic acid provided ameliorative effects: at a level of 5% glycolic acid, irritation was reduced by about 40%; at a level of 10% glycolic acid, irritation was reduced by about 50%. The cumulative irritation of 0.30% retinol compositions was essentially unchanged by the presence of glycolic acid.
Thus, a preferred range of amounts of glycolic acid effective to ameliorate irritation at a retinol level of about 0.01 to about 0.15% is between about 0.01 and about 10% by weight of the composition.
The glycolic acid at the preferred pH range may be present in the formulation as a free acid or in the form of a salt. It may be in the form of inorganic alkali salts such as sodium glycolate or may be in the form of an organic salt such as an amine salt.
TABLE III______________________________________Ingredient % w/w______________________________________Light Mineral Oil NF 25.00Hydroxyoctacosanyl Hydroxystearate 6.00(Elfacos 26)Sorbitol Solution 5.00Methoxy PEG-22/Dodecyl Glycol Copolymer 5.00(Elfacos E200)PEG-45/Dodecyl Glycol Copolymer 3.00(Elfacos ST9)Stearoxytrimethylsilane 1.00Dimethicone (50 cstk) 1.00Methylparaben, NF 0.30Propylparaben, NF 0.20Chemoderm 6401/B 0.15Quaternium 15 (Dowicil 200) 0.10Edetate Disodium, USP 0.10Ascorbic Acid 0.10Butylated Hydroxytoluene, NF 0.0550% Aqueous NaOH Q.S. pH 4.7Purified Water, USP Q.S. 100%______________________________________
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This invention relates to skin care compositions containing retinoids which are generally applied topically to improve the quality of the skin. More particularly, this invention relates to skin care compositions comprising retinol (Vitamin A alcohol) and further comprising irritation ameliorating quantities of glycolic acid.
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[0001] This application is based on the provisional application No. 60/431,980 filed on Dec. 10, 2002
REFERENCE
[0002] [1] F. Behbahani et al, “CMOS Mixers and Polyphase Filters for Large Image Rejection,” IEEE Journal of Solid - State Circuits , vol. 36, no. 6, June 2001, pp. 873-887.
BACKGROUND
[0003] 1. Technical Field of Invention
[0004] RF Receiver Architecture with Tracking IR Polyphase Filtering-David H. Shen, Nov. 20, 2003 Page 1 The present invention relates to radio receivers and methods for the reception of RF (radio frequency) communications signals in multiple frequency bands. In particular, it relates to integrated circuit based radio receivers using on-chip tuning methods to improve performance and manufacturability.
[0005] 2. Background of the Invention and Discussion of Prior Art
[0006] At the present time, the vast majority of RF communications receivers are of the superheterodyne type. This type of receiver uses one or more IF (intermediate frequency) stages for filtering and amplifying signals at a fixed frequency within an IF chain. This radio architecture has the advantage that fixed filters may be used in the LO chain. In order for the receiver to be useable over multiple bands, its typical architecture is as the dual-band receiver shown in FIG. 1. An RF signal arriving at an antenna 11 passes through a band-select RF filter 13 , an LNA (low noise amplifier), 15 , and into an image filter, 17 , which produce a band-limited RF signal. This band-limited RF signal then enters a first mixer 19 , which translates the RF signal down to an intermediate frequency by mixing it with the signal produced by the first LO (local oscillator) 21 . The undesired mixer products in the IF signal are rejected by an IF filter, 23 . The filtered IF signal then enters an IF amplifier stage, 25 , after which the outputs feeds into the second mixer 27 which translates it down to yet another intermediate frequency by mixing it with the signal produced by a second LO, 28 . The signal is then sent to the baseband processing. Tuning into a particular channel within the band-limited RF signal is accomplished by varying the frequency of each LO, 21 and 28 .
[0007] In order to reduce size, power consumption, and cost, it would be advantageous to integrate the electronic components of radio receivers and reduce the number of filters and mixers. The superheterodyne design, however, requires high quality, narrowband IF bandpass filters that are typically implemented off-chip. These filtering components impose a lower limit to the size, materials cost, assembly cost, and power consumption of receivers built using the superheterodyne design. Moreover, the necessity for mixer and local oscillator circuits operating at high frequencies contributes greatly to the power consumption and general complexity of the superheterodyne receiver. In particular, the high-frequency analog mixers require a large amount of power to maintain linear operation. Although many variations of the superheterodyne design exist, they all share the limitations of the particular design just described.
[0008] The growing demand for portable communications has motivated attempts to design radio receivers that permit the integration of more components onto a single chip. Recent advances in semiconductor processing of inductors are allowing more and more of these filters to be implemented on-chip.
[0009] A second receiver design is the direct-conversion, or zero-IF, receiver shown in FIG. 2. An antenna 57 couples a RF signal through a first bandpass RF filter, 59 , into a LNA, 61 . The signal then proceeds through a second RF filter 63 , yielding a band-limited RF signal, which then enters a mixer, 65 , and mixes with an LO frequency produced by an LO, 67 . Up to this point, the direct-conversion receiver design is essentially the same as the previous receiver design.
[0010] Unlike the previous designs, however, the LO frequency is set to the carrier frequency of the RF channel of interest. The resulting mixer product is a zero-frequency IF signal—a modulated signal at baseband frequency. The mixer output, 67 , is coupled into a lowpass analog filter 69 before proceeding into baseband information signal for use by the remainder of the communications system. In either case, tuning is accomplished by varying the frequency of LO, 67 , thereby converting different RF channels to zero-frequency IF signals.
[0011] Because the direct-conversion receiver design produces a zero-frequency IF signal, its filter requirements are greatly simplified—no external IF filter components are needed since the zero-IF signal is an audio frequency signal that can be filtered by a low-quality lowpass filter. This allows the receiver to be integrated in a standard silicon process from mixer 65 onwards, making the direct-conversion receiver design potentially attractive for portable applications.
[0012] The direct-conversion design, however, has several problems, some of which are quite serious. As with the other designs described above, the RF and image filters required in the direct-conversion design must be high-quality narrowband filters that must remain off-chip. Moreover, this design requires the use of high-frequency mixer and LO circuits that require large amounts of power. Additionally, radiated power from LO, 67 , can couple into antenna 57 , producing a DC offset at the output of mixer, 65 . This DC offset can be much greater than the desired zero-IF signal, making signal reception difficult. Radiated power from LO 67 can also affect other nearby direct-conversion receivers tuned to the same radio frequency.
[0013] In summary, although the prior art includes various receiver designs, each one has significant disadvantages including one or more of the following: the necessity for several external circuit components, the consumption of large amounts of power, poor signal reception, poor selectivity, distortion, and limited dynamic range.
OBJECTS AND ADVANTAGES OF THE INVENTION
[0014] Accordingly, it is a primary object of the present invention to provide a multiple frequency band radio receiver design, which has increased integration and decreased power consumption without the operational problems associated with previous receiver designs. It is a further object of the invention to provide an equivalent performance to the traditional multi-band superheterodyne receiver of FIG. 1. A novel method for polyphase filtering is introduced. This method allows the polyphase fitler to have reduce sensitivity to resistor and capacitor manufacturing variations and allows for the polyphase filter response to be enhanced compared to the prior art.
SUMMARY OF THE INVENTION
[0015] The present invention achieves the above objects and advantages by providing a new method for RF communications signal reception and a new receiver design that incorporates this method. This method includes a method for using a variable intermediate frequency, and on-chip image-rejection filtering that tunes out process variations and tracks the variable intermediate frequency. The highly integrated solution allows for significant cost savings, board area savings, and power savings compared to prior art solutions.
DESCRIPTION OF DRAWINGS
[0016] [0016]FIG. 1 is a block diagram of a superheterodyne receiver considered as prior art.
[0017] [0017]FIG. 2 is a block diagram of a direct-conversion receiver considered as prior art.
[0018] [0018]FIG. 3 is a block diagram of a receiver constructed with the principles of the invention.
[0019] [0019]FIG. 4 is an example of an implementation the tracking polyphase filter with tunable capacitors.
[0020] [0020]FIG. 5 is an example of the implementation of a tunable capacitor.
[0021] [0021]FIG. 6 is an example of an implementation the tracking polyphase filter with tunable resistors.
[0022] [0022]FIG. 7 is an example of a tunable resistor.
[0023] [0023]FIG. 8 is an example of the R-C tuning circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] [0024]FIG. 3 is a block diagram of a RF communications receiver constructed in accordance with the principles of the present invention. It includes an antenna 73 for coupling a RF signal into the input of a bandpass RF filter, 74 . The output of the analog bandpass RF filter, 74 , connects to the input of an LNA, 75 , whose output couples to the input of two mixers, 76 and 77 . The in-phase (I) mixer, 77 , is driven by the local oscillator, 79 , output. The quadrature-phase (Q) mixer, 76 , is driven by the output of a 90 degree phase shifter, 78 , whose input is connected to the local oscillator, 79 , output. The mixer outputs are differential in-phase signals 83 and 84 and differential quadrature signals 81 and 82 that are frequency translated to a variable intermediate frequency. The mixer outputs, 81 , 82 , 83 and 84 , are inputs into a tracking polyphase filter, 80 . The tracking polyphase filter, 80 , response is tunable to the variable intermediate frequency and is also calibrated against resistor and capacitor variations through a tuning circuit, 116 .
[0025] The outputs, 85 - 88 , of the tracking polyphase filter, 80 , are amplified by intermediate frequency amplifiers, 89 and 90 . The outputs of the intermediate frequency amplifiers are connected to the inputs of the second mixers, 89 and 90 , that mixes with a divided version of the local oscillator, 79 , to frequency translate the desired signal to baseband. The frequency divider, 93 , divides the frequency of the first local oscillator, 79 , to form a second local oscillator frequency that tracks the first local oscillator. This causes the first intermediate frequency to be variable. In order for the polyphase filter, 80 , to effective suppress the image frequencies of a variable intermediate frequency, its center frequency should vary with the local oscillator, 79 . The tracking intermediate frequency filter ensures that the image rejection is strongest for the unwanted image signal regardless of the value of the variable intermediate frequency. This method guarantees high performance throughout the frequencies of the received band. The generation of the second local oscillator frequency through frequency divider, 93 , is more power efficient and lower noise than utilizing a second local oscillator.
[0026] A polyphase filter is an integrated filter known in the art that can produce selective image rejection of either positive or negative frequencies by combining the I and Q signals with an R-C filter network [1]. The polyphase filter can pass a desired frequency while rejecting an image frequency. A conventional polyphase filter image rejection response is limited by resistor and capacitor component variations. In addition, the use of a variable intermediate frequency causes the filter response to be mismatched with the image frequency. These factors prevent a high quality image rejection response from the polyphase filters. Polyphase filters can be cascaded to improve image-response at the cost of reducing the gain of the desired signal.
[0027] [0027]FIG. 4 gives a possible implementation of the tracking polyphase filter, 80 , in a form that can be implemented with on-chip resistors, 100 - 103 , and capacitors, 104 - 107 , which can be adjusted by tuning a switched-capacitor array. There are many ways of generating a variable capacitor array, including binary-weighted parallel capacitors or linearly-weighted parallel capacitors. The control voltages for the capacitor array can be generated by the tuning circuit, 108 . The voltage inputs, 81 - 84 , of the tracking polyphase filter, 80 , are filtered to produce voltage outputs, 86 - 88 . The tracking polyphase filter, 80 , can be implemented as a single-ended or differential circuit.
[0028] [0028]FIG. 5 is a possible implementation of the switched capacitor array. Terminals 109 and 110 are connected to a binary-weighted switched capacitor array. Capacitors 111 - 113 are connected to switches 114 - 117 , which can be programmed by digital control.
[0029] [0029]FIG. 6 gives another possible implementation of the tracking polyphase filter, 80 , in a form that can be implemented with on-chip tunable resistors, 120 - 123 , and fixed capacitors, 124 - 127 . There are many ways of generating a variable resistor array, including binary-weighted parallel resistors or linearly-weighted parallel resistors. In addition, binary or linearly weighted series resistors can also be used. An analog control voltage can be used to adjust a MOS device in the triode region for continuous control. The control signals for the resistor array can be generated by the tuning circuit, 128 . There are many known ways in the art to generate a circuit to tune the R-C values, such as a phase-locked loop. The voltage inputs, 81 - 84 , of the tracking polyphase filter, 80 , are filtered to produce voltage outputs, 86 - 88 .
[0030] [0030]FIG. 7 is a possible implementation of a parallel switched resistor array. Terminals 130 and 131 are connected to a binary-weighted switched resistor array. Resistors 132 - 134 are connected to switches 135 - 138 , which can be programmed by digital control.
[0031] [0031]FIG. 8 gives a possible implementation of a phase-locked loop based tuning circuit. Reference frequency, 140 , is a fixed frequency input to the circuit. Amplifier, 144 , in combination with a delay element formed by R-C network, 142 and 143 , form the basis of an oscillator that is tuned by digital control signal 141 . The digital control signal, 141 , is generated by an up/down counter, 146 , with up and down signals generated by the phase-frequency detector, 145 . The tuning circuit, when locked, forces the R-C time constant to track the frequency of the reference, thus tuning out the manufacturing process variations of the resistors and capacitors. By changing the reference frequency, 140 , to track the variable intermediate frequency, the polyphase filter, 80 , can be made to track the intermediate frequency.
[0032] The tracking polyphase filter, 80 , can be one stage or multiple stages of polyphase filters. The polyphase filter can be an active or passive network. The polyphase filter can be tuned by varying the resistors or the capacitors, and there are many possible implementations of the tuning circuit. These and other modifications, which are obvious to those skilled in the art, are intended to be included within the scope of the present invention. Accordingly, the scope of the invention should be determined not by the embodiment described, but by the appended claims and their legal equivalents.
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A RF communications receiver is disclosed which permits greater integration on standard silicon chips and consumes less power than previous receivers. A new method for using a tracking polyphase filter for image rejection of variable intermediate frequencies is introduced. This method allows for reduce sensitivity to resistor and capacitor manufacturing variations and allows for the polyphase filter response to be enhanced compared to the prior art.
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BACKGROUND OF THE INVENTION
The present invention relates to structure fishing, and in particular to a fish attracting device suitable for use in structure fishing wherein the device can be submerged in bodies of fresh water or sea water. The fish attracting device according to the invention, once submerged in a fresh water body, attracts fish, e.g., bass, in bountiful quantities and provides a habitat for them.
Fish attracting devices for fresh water environments are known in the art. For example, U.S. Pat. No. 4,916,845 to Aydelette, Sr. describes a fish attracting device that includes a plurality of spaced apart disks located on a shaft 28. The shaft includes an anchor at the bottom for maintaining the device on the floor of the river or lake. The anchor includes a perforated container for a weighting material and bait. A buoy is connected to the upper end of shaft 28 to locate the fish attracting device.
U.S. Pat. No. 4,727,672 to Hill et al. includes a stem member 44 and dependent leaf like structures 64. While each of these devices may offer some shelter from above, e.g., the fish may hide under the disks or leaves, there is no lateral shelter because the supporting shaft or stem in extremely narrow. In addition, these device are expensive to manufacture.
In addition to the above fish attracting devices, there are numerous teachings in the art of artificial habitats, including artificial reefs. U.S. Pat. Nos. 3,933,124 (Ledoux, st al.), 4,212,268 (Chapman), 4,441,453 (McKickle et al), and 4,860,690 (De Santo et al) exemplify such structures. Ledoux, et al. create an artificial habitat by depositing helicoidal elements on the floor of the sea or fresh water body. Chapman discloses a totally artificial environment for small crustaceans. McMickle et al. disclose a plurality of devices having individual strands of a buoyant material attached to an anchor. The devices are deposited on the bed of the water body to form a habitat. De Santo et al. teach a marina dock and habitat dock located below a dock structure.
Artificial reefs for fish are also known. U.S. Pat. No. 4,334,499 to Baass uses a tire filled with concrete to form the artificial reef. U.S. Pat. Nos. 3,561,694 (Ishida), 4,316,431 (Kimura), 4,913,094 (Jones et al), 4,947,791 (Laier et al) and 4,993,362 (Jimbo) exemplify other artificial habitats. Some of these devices require exact placement of the habitat on the bed or floor of the water body. This necessitates the use of a diver who must enter the water and physically construct the habitat. This is time consuming and expensive.
The fish attracting device of the instant invention is lightweight, can be easily placed at a desired location and avoids the disadvantages of the fish attracting and habitat devices of the prior art.
SUMMARY OF THE INVENTION
The instant invention provides a fish attracting device that simulates a natural environment. In particular, the fish attracting device, e.g., the BASSIN STUMP, is shaped with the exterior appearance of a tree stump. The fish attracting device provides a habitat for the fish to congregate and hide.
The fish attracting device of the invention can be formed from a single piece of plastic, by molding or any other technique known to those skilled in the art, or from a plurality of connectable sections. The fish attracting device is sized to provide a habitat for fish, e.g. bass, and may be a few feet in diameter or larger, e.g., 5, 10, or 15 feet in diameter. The device includes an outer trunk-shaped wall having a textured outer surface that may resemble the texture of tree bark. Other textured surfaces are also possible.
The outer trunk-shaped wall has an upper end and a lower end. The outer wall is inclined, or slanted away, from a major longitudinal axis of the device to form a base having a larger dimension than the top. The trunk-shaped outer wall, in its preferred design, flares downwardly and outwardly away from the longitudinal axis of the fish attracting device and terminates at an edge that may be scalloped in shape.
The upper end of the trunk-shaped wall is connected to a tapered inner, downwardly extending chamber by an annular wall. The annular wall preferably contains openings for passing fluid, e.g., water, air, therethrough when the device is placed in the body of water. Alternatively, the openings may be located in the trunk-shaped wall, at the upper end thereof. The annular wall is preferably planar, but may be any shape that facilitates its manufacture. The number and size of the openings is sufficient to allow the device to sink to the floor of the water body.
The tapered inner, downwardly extended chamber has an outer wall that extends downwardly and is slanted or inclined inwardly toward the major longitudinal axis of the device so that the cross-sectional area of the upper end of the chamber is larger than the lower end of the chamber. The wall is in the shape of a tube having a circular, rectangular, or irregular cross-section. The only requirement is that the outer wall of the tapered inner chamber be sufficiently tapered so that many fish attracting devices according to the invention can be stacked in a nesting relationship. The openings that are preferably located in the annular wall, could also be located in the outer wall of the inner chamber at the upper end. The openings could also be in more than one wall, e.g. the trunk-shaped wall and the annular wall.
The lower end of the chamber wall is connected to an upwardly directed, substantially centrally positioned, hollow member by an annular member or wall. This hollow member includes an outer wall that is slanted or inclined inwardly towards the major longitudinal axis of the fish attracting device whereby the member tapers upwardly so that the upper end has a smaller cross-section than the lower end. The substantially centrally disposed member is of any cross-section, such as circular, elliptical, pyramidal, etc. The substantially centrally positioned member is closed at the upper end by a cap or wall. The cap includes at least one opening for the passage of a fluid, water or air therethrough. A ring or like structure is also located on the cap whereby a rope, chain, or similar device can be attached to the fish attracting device for positioning on the bed of the lake, river, ocean, etc. The ring is fixed in an upright position. Alternatively, the ring can be pivotally connected, e.g., hinged. Additionally, the ring facilitates the removal of the fish attracting device. The uppermost end of the substantially centrally positioned member, including the ring, terminates below the upper edge of the outer trunk-shaped wall.
The fish attracting device according to the invention is lightweight in design. This is because the tapered inner chamber and upwardly extending central member are essentially hollow in design and the base formed by the trunk-shaped wall is either substantially or completely open. A substantially open base is one that does not substantially impede the flow of water upwardly through the base of the fish attracting device. Thus, the inner surface of the trunk-shaped wall cooperates with the outer surface of the inner chamber to form an essentially open, upwardly extending chamber that communicates with the open/ hollow chamber of the central member.
The device can also include a material that will maintain the device in a submerged state. For example, rock, pebbles, gravel, lead weights, or sinkers can be used as a weighting material. Preferably, the weighting material is environmentally safe and will not float in water. The weighting material is located within the inner downwardly depending chamber, and is maintained in position by a removable cover. The cover includes threads, or similar interlocking features, that cooperate with corresponding structure on the outer surface of the substantially central member, at the upper end thereof, or on an inner surface of the outer wall of the downwardly extending chamber. In its preferred embodiment the annular cover includes internally located threads that cooperate with respective threads on an upper end of the cone-shaped central member.
Alternatively, the weighting material can be designed to be located within or connected to the trunk-shaped wall, e.g. the bottom edge of the outer trunk-shaped wall so that it is not necessary to add additional material to the device.
The inner upwardly extending, substantially central member is hollow and terminates below the upper end of the outer trunk-shaped wall. This allows a plurality of fish attracting units to be stacked in a nesting arrangement. As a result, more than one device can be loaded into a boat prior to their placement at a desired or selected location.
The device may be formed so that the outer textured wall, the first annular wall, the outer slanted wall of said inner downwardly extending chamber, the second annular wall and the wall forming the central member are integral with one another. In other words, the fish attracting device can be a unitary, one piece unit.
Alternatively, the fish attracting device of the instant invention can be formed from a plurality of sections. The respective sections will mate with one another and include flanges, tabs, or similar structure that will permit the sections to be fastened together. The fastening elements may be located on either the inner or outer surface of the outer trunk-shaped wall. The sections may be fastened by threaded nuts and bolts or equivalent fasteners known in the art. The tabs or flanges may extend inwardly towards the major longitudinal axis, or outwardly therefrom and could be provided with features that allow the sections to be snapped together. The device could be formed from split halves or quarter sections. The multiple section concept allows the device to be stored easily.
The instant invention can be used for structure fishing, or any fishing that can be improved by providing a habitat for fish. The first step is selecting an appropriate location in a stream or lake for the placement of the instant fish attracting device. After the selection is made, the device is transported to the selected location. If the device is fromed from several sections, the device is assembled. At that point, if gravel is to be used as the weighting material, the gravel is poured into the inner, downwardly extending chamber and the cover inserted into place so that the gravel cannot be spilled or dislodged. The device, or devices, are then lowered into position. The location of the fish attracting device is recorded by techniques well known to the skilled practitioner so that the location can be returned to at a later time.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the fish attracting device in accordance with one embodiment of the present invention;
FIG. 2A is a cross-section view of FIG. 1;
FIG. 2B is a cross-section view of FIG. 1 that also includes a gravel cover;
FIG. 3 is a top view of FIG. 2B;
FIG. 4 is a perspective view of the gravel cover of FIGS. 2B and 3;
FIG. 5 an expanded view of the fish attracting device in accordance with a second embodiment of the present invention; and,
FIG. 6 is an enlarged view of the connecting flanges of FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
With reference to all the Figures, the fish attracting device 1 includes an outwardly flared outer wall 3, having a textured bark-like outer surface 5. The bottom end 6 of device 1 flares outwardly away from axis 4 and includes scallops 14 that from edge 7. The upper end 8 of device 1 is connected to downwardly depending, inner chamber 21 by annular member 9. Annular member 9 contains through-holes or openings 11 through which a fluid, e.g., water may pass. Annular member 9, shown as a planar annular wall, is connected to the inner slanted wall 23 of inner chamber 21.
Inner chamber 21 includes tapered outer wall 23 that is tubular in shape and is slanted, or inclined, inwardly from top end 20 to bottom end 22 along axis 4. Inner chamber 21 also includes an upwardly extending central member 28. Member 28 has a wall 25 that tapers inwardly from the lower end 26 to the upper end 27 along axis 4. Member 28 is closed at the upper end 27 by top wall or cap 16. An annular wall 24 joins bottom end 22 of outer wall 23 to the lower 26 of the tapered tubular wall 25. Cap 16 includes through-holes or openings 17 and a ring-like structure 15. (FIG. 3) Ring like structure 15 includes an opening 18 through which a rope 13 or similar device is placed to position the fish attracting device on the floor of the water bed.
Gravel 19, or similar weighting material, is located within chamber 21 that is located between inner tapered tubular wall 23 and tapered tubular wall 25.
As more clearly shown in FIG. 2A, tubular wall member 25, is a hollow truncated chamber 30 and has external threads 27. External threads 27 cooperate with the internal threads 33 on cover 29. Cover 29 also includes air openings 31.
Walls 25 and 28 can also be curved in shape. The device is lightweight due to chambers 21, 30, and 34. The walls of the device are shaped and designed so that a plurality of fish attracting devices 1, according to the instant invention, may be stacked within one another in nesting relationship.
A second embodiment of the fish attracting device of the instant invention is shown in FIGS. 5 and 6. In FIG. 5, the fish attracting device 1 is formed from two similar sections 36 and 38. Sections 36 and 38 each include flanges or tabs 40. The flanges or tabs include openings 42 to received bolts 44. It is also possible to use a single flange instead of a plurality of flanges or tabs. Although ring 15 is shown as being split, it is within the scope of the instant invention to have the ring on only one side of top wall or cap 16. FIG. 6 shows flanges 40 on the inside wall surfaces 48 of sections 36 and 38. The flanges 40 are fastened together by bolts 44 and nuts 46.
The fish attracting device according to the instant invention can be used in the following exemplary manner. The first step is selecting an appropriate location in a stream or lake for the placement of the fish attracting device of the invention. After the selection is made, the fishing attracting device or devices are loaded into the boat and transported to the desired location. If the device 1 is fromed from multiple section, e.g., 36 and 38, it can be assembled at any time prior to placement in the water. The operator than places the weighting material 19 into chamber 21. Cover 29 is then fastened in place, if desired. Next a rope 13 is fed through opening 18 in ring 15 and the device lowered into the water. The weighting material 19 forces the device 1 to sink whereby water and any trapped air passes upwardly through holes 11 and 17 in device 1.
It should be understood, however, that the foregoing description of the invention is intended to be merely illustrative, thereof, and that other modifications and embodiments may be apparent to those skilled in the art without departing from the spirit of the invention.
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A fish attracting device which simulates a tree stump to provide a habitat for fish to congregate. The device includes an outer textured wall that resembles the bark on a tree trunk and an inner chamber secured to the outer textured wall. A structure for deploying the device within a body of water is secured to the inner chamber.
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BACKGROUND OF THE INVENTION
Vibration damping means are generally utilized for a friction clutch in the drive line of an automotive vehicle between the engine and the manually operated transmission to overcome objectionable rattle and vibration when the clutch is engaged and provides a torsional coupling between the engine and transmission. A conventional vibration damper and clutch assembly includes a hub having an internally splined barrel receiving the externally splined end of the transmission input shaft and an integral radial flange, a clutch plate journalled on the hub and carrying the friction facings at its periphery, a spring retainer plate journalled on the hub on the opposite side of the flange from the clutch plate and connected thereto by stop pins extending through peripheral notches in the hub flange, and damper springs which are located within axially aligned sets of spring windows formed in the clutch plate, hub flange and spring retainer plate.
The above described clutch and vibration damper assembly provides for a substantially constant rate of energy dissipation, and friction washers may be sandwiched between the plates and hub flange to provide for an additional friction damping action to supplement the resilient damping action of the springs. However, this damper assembly has proved to be inadequate where specialized problems occur at idle conditions or under engine full load. One specific problem resides in transmission gear rattle in the neutral position with the clutch engaged at idle rpm. The gear rattle is caused by motor impulses urging the gears of the transmission to oscillate through their tooth backlash space; the impacting of the gear teeth producing the objectionable rattle.
The present invention resides in a multi-stage vibration damper assembly which will overcome the problem of objectionable gear rattle at idle rpm and also cushion the torque transference between damping stages without impacting the damper parts.
SUMMARY OF THE INVENTION
The present invention comprehends the provision of a novel multi-stage torsional vibration damper which will provide a low spring rate substantially frictionless first stage to eliminate idle gear rattle in series with a substantially frictionless medium spring rate second stage and a high spring rate third stage with damping friction. The second stage acts to cushion impacting of the damper parts during torque transference from the low rate first stage to the high rate third stage. The first stage comprises a low rate compression spring, substantially frictionless, floating suspension of an inner hub within an outer hub using a pair of second stage springs as its rotational travel stop. This floating spring suspension allows the outer hub to oscillate with engine impulses without transmitting them to the inner hub and vehicle transmission gears.
The present invention also comprehends the provision of a novel three stage torsional vibration damper assembly utilizing resiliently cushioned inner and outer hubs to provide a floating spring suspension as well as damper springs between the outer hub and the clutch and spring retainer plates to provide for the second and third stages of travel. The second stage is accomplished by the compression of two of the four damper springs for the third stage for a given deflection until the inner and outer hubs contact; wherein the inner and outer hubs will squeeze together rather than impact. These same two springs will compress for a further deflection along with the two remaining springs and the addition of damping friction for the third stage of travel.
The present invention further comprehends the provision of a novel multi-stage torsional vibration damper assembly having a low spring rate first stage to eliminate transmission gear rattle occurring during the neutral transmission position due to engine impulses at idle rpm. At a predetermined increased rpm, the first stage cushioning effect becomes inactive by the action of centrifugal weights which lock the inner and outer hubs together and allow a normal rate final stage damping to operate in a conventional manner.
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 of a vehicle friction clutch assembly employing the novel multi-stage damper of the present invention.
FIG. 2 is a cross sectional view of the damper assembly taken on the irregular line 2--2 of FIG. 1.
FIG. 3 is a partial rear elevational view similar to FIG. 1 with portions broken away.
FIG. 4 is a partial rear elevational view with parts broken away showing movement in the first stage of travel.
FIG. 5 is a partial rear elevational view similar to FIG. 4 but showing the parts at the end of the second stage of travel.
FIG. 6 is a partial rear elevational view similar to FIG. 4 but showing the parts at the end of the third stage of travel.
FIG. 7 is a rear elevational view of the inner hub.
FIG. 8 is an elevational view of a friction plate for the damper assembly.
FIG. 9 is a rear elevational view with parts broken away showing a second embodiment of the vibration damper device.
FIG. 10 is a cross sectional view taken on the irregular line 10--10 of FIG. 9.
FIG. 11 is a rear elevational view of the inner hub for the damper of FIG. 9.
FIG. 12 is a partial rear elevational view with portions broken away of a third embodiment of the damper assembly.
FIG. 13 is a partial cross sectional view taken on the irregular line 13--13 of FIG. 12.
FIG. 14 is an enlarged rear elevational view of a centrifugal weight coacting between the inner and outer hubs of FIG. 12.
FIG. 15 is a partial rear elevational view with parts removed showing a fourth embodiment of the damper assembly.
FIG. 16 is an enlarged rear elevational view showing the centrifugal weight coacting with the hubs of FIG. 15.
FIG. 17 is a partial rear elevational view with portions broken away of a fifth embodiment of the vibration damper assembly.
FIG. 18 is a partial cross sectional view taken on the irregular line 18--18 of FIG. 17.
FIG. 19 is a rear elevational view of the outer hub of FIG. 17.
FIG. 20 is a rear elevational view with portions broken away of a sixth embodiment of the damper assembly.
FIG. 21 is a cross sectional view taken on the irregular line 21--21 of FIG. 20.
FIG. 22 is an elevational view of a friction back plate for the assembly of FIG. 20.
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 8 disclose a friction clutch and vibration damper assembly 10 with a hub assembly including an inner hub 11 (FIG. 7) having a barrel 12 with an internally splined central passage 13 and oppositely disposed flange portions 14,14. A generally planar clutch driven plate 15 has a central opening 16 journalled on the barrel 12 and includes two pairs of oppositely disposed spring windows 17 and 18, four openings 19 radially beyond the windows for receiving the ends of stop pins 21, and a plurality of openings 23 adjacent the outer periphery 22 for rivets 24 to secure cushion springs 25 thereto. A pair of oppositely disposed annular friction facings 26 are secured, as by rivets 27, to the cushion springs.
A spring retainer plate 28 is also generally planar and has a central opening 29 encompassing the barrel 12, two pairs of spring windows 31,32 axially aligned with the windows 17,18, respectively, and openings 33 adjacent the periphery to receive the opposite ends of the stop pins 21 securing the plates together in spaced relation. As seen in FIG. 7, each flange portion or arm 14 is provided with outwardly diverging edges 34 terminating in an arcuate periphery 35 having an elongated notch 36 adapted to be axially aligned with but of a greater length than the spring windows 17 and 31. Also, each diverging edge 34 terminates in a corner notch 37 adjacent the periphery 35 for a purpose to be later described.
The hub assembly also includes an outer hub 38 comprising an annular ring 39 having elongated notches 41 in the outer periphery receiving the stop pins 21 extending between the plates 15 and 28 and an inner periphery 42 conformably receiving the arcuate peripheries 35 of the inner hub flange portions 14. Extending radially inwardly from the ring 39 are flange portions 43 having inwardly converging edges 44 terminating in concave ends 45 conformably receiving the inner hub barrel 12 between the inner hub flange portions 14. The edges 44 have corner notches 46 at the intersection with the inner periphery 42, and each portion contains a spring window 47 axially aligned with and of the same length as the spring windows 18 and 32 in the plates.
Each window has a central notch 48 on the inner edge thereof to receive locating tabs 52 on a pair of annular friction plates 51,51 (FIG. 8) located on the opposite surfaces of the inner hub flange portions 14 and outer hub flange portions 43; the inner hub flange portions 14 being thinner than the outer hub flange portions 43 so that the inner hub 11 may freely move between the friction plates 51,51. Also located between the rear friction plate 51 and the spring retainer plate 28 is an annular thrust plate 53 (FIG. 2) having a plurality of axially extending tabs 54 received in notches 55 in the retainer plate 28, and a Belleville spring or washer 56 is positioned between the thrust plate and spring retainer plate to urge the thrust plate against the rear friction plate 51 to control the friction damping characteristics of the friction plates during use.
In the neutral transmission position, the engine impulses cause torque to be applied through the friction facings 26, clutch and spring retainer plates 15 and 28 and damper springs 57 in the axially aligned windows 18, 32 and 48 to rotate the outer hub 38 (arrow A in FIG. 4) to compress a pair of diametrically opposed small idle rattle damper springs 58 received in the facing corner notches 37 and 46 in the inner and outer hub arms 14 and 43, respectively; the springs 58 acting in the radial gaps 49 between the inner and outer hub flange portions to cushion the engine impulses from being transmitted to the inner hub 11 and thus to the transmission gearing. In the drive transmission position, the small springs 58 are immediately compressed, and the plates 15 and 28 move a pair of damper springs 59 in windows 17,31 against the notches 36 in the inner hub flange portions 14, compressing them partially to cushion the impact of the outer hub 38 against the inner hub 11 at gaps 49. When the gaps 49 are closed, the plates 15 and 28 also drive springs 57 against the outer hub 38 abutting the inner hub 11.
Plates 15 and 28 can now rotate compressing both sets of springs 57 and 59 until the stop pins 21 abut the edges of the notches 41 in the outer hub 38. The inner hub 11 moves freely between the friction plates 51,51, but the outer hub 38 is tabbed to the plates and moves with friction relative to the plates 15 and 28 and thrust plate 53.
FIGS. 9 through 11 disclose a second embodiment 61 of clutch damper assembly similar to the assembly of FIGS. 1 through 8 with like parts receiving the same reference numeral with a script a. In this embodiment, the clutch plate 15a carrying the friction facings 26a and the spring retainer plate 28a are secured together in spaced relation by stop pins 21a to encompass the outer hub 38a and the inner hub flange portions 14a. As seen in FIG. 11, the inner hub 11a has a barrel 12a and oppositely disposed flange portions 14a with diverging edges 34a and arcuate peripheral surfaces 35a containing damper spring notches 36a. A corner notch 62 is provided in each of the flange corners to form part of the elongated notch for the stop pins 21a. Also, on oppositely disposed edges of the flange portions are provided small spring recesses 63 to receive the ends of a pair of small damper springs 58a.
The outer hub 38a again includes an annular ring 39a with inwardly extending flange portions 43a having spring windows 47a with notches 48a to receive the tabs 52a of friction plates 51a. A pair of oppositely disposed converging edges 44a contain spring recesses 65 facing the recesses 63 and the corners where the flange portions intersect the ring have elongated notches 64 which form approximately three-fourths of a slot for a stop pin; the corner notch 62 forming the remainder of the slot. As in the previous embodiment, the notches 36a have a greater length than the aligned spring windows in the plates 15a and 28a. This assembly operates in substantially the same manner as the first embodiment and, although not shown, a thrust plate and Belleville washer as shown in FIG. 2 could be utilized with the friction plate if better control of the friction damping in the third stage of travel is desired.
A third embodiment of clutch damper assembly 67 is shown in FIGS. 12 through 14 wherein like parts will receive the same numeral with a script b. This embodiment includes an inner hub 11b with oppositely disposed flange portions 14b having diverging edges 34b terminating in arcuate peripheries 35b; the edges including corner notches 62b for stop pins 21b and spring recesses 63b for small damper springs 58b. A generally T-shaped notch 68 is formed in each flange portion 14b with the narrow or stem portion 69 of the notch opening into the periphery 35b. A generally T-shaped centrifugal weight 71 is located in each notch 68 and has a head 72 and a stem 73 projecting through the narrow portion 69. The notch 68 is of a greater width than that of the head 72 to receive a pair or retractor spring 74,74 yieldably urging the weight radially inward toward the barrel 12b.
The outer hub 38b comprises an annular ring 39b having oppositely disposed flange portions 43b with spring windows 47b for damper springs 57b, corner notches 64b and spring recesses 65b in the edges 44b facing the recesses 63b springs 58b. Also, the inner periphery 42b of the annular rings has a pair of oppositely disposed notches 75,75 normally radially aligned with the portions 69 of notches 68 to receive the ends of stems 73 of the weights 71. Further, the windows 47b have notches 48b to receive the tabs 52b of friction plates 51b. Although not shown, a thrust plate and Belleville washer could be positioned between the friction plate 51b and the spring retainer plate 28b, in the manner shown in FIG. 2, to control the friction damping characteristics, if necessary.
For the first stage of damping to cushion the engine impulses while the clutch is engaged and in neutral transmission position at idle rpm, the radial gap 49b between the inner and outer hub flange portions permits relative rotation of the outer hub 38b relative to the inner hub 11b, and the small damper springs 58b cushion the impulses to prevent them from being transmitted to the inner hub 11b. When engine rpm is increased to a predetermined level, the centrifugal force of the rotating clutch assembly moves the weights 71 radially outwardly against the force of springs 74 so that the stems 73 engage the notches 75 (FIG. 14) to lock the outer hub 38b to the inner hub 11b, and rotation of the plates 15b and 28b causes compression of the damper springs 57b, and relative rotation of the plates to the hub assembly causes friction damping through the friction plates 51b. Once the centrifugal weights lock the hubs together, the substantially frictionless first stage is then inoperative.
FIGS. 15 and 16 disclose a fourth embodiment of clutch damper assembly 77 which is substantially identical to the embodiment of FIGS. 12-14 except for the omission of the notches in the inner periphery 42c of the annular ring 39c of the outer hub 38c. In this version, the first stage provides a low spring rate substantially frictionless damping to cushion engine impulses in the same manner as previously described. However, when the engine reaches a predetermined rpm, the centrifugal weights 71c acting against the yieldable springs 74c move radially outward to wedge against the inner periphery 42c and frictionally lock the inner hub 11c and outer hub 38c together so that the damper provides a resilient and friction damping operation in the manner previously described.
A fifth embodiment of clutch damper assembly 79 is shown in FIGS. 17, 18 and 19 which is similar to the embodiment of FIGS. 12-14. In this embodiment, the inner hub 11d has a pair of oppositely disposed flange portions 14d with diverging edges 34d having spring recesses 63d and corner notches 81. The arcuate periphery 35d has a generaly U-shaped notch 82 receiving a generally U-shaped centrifugal weight 83; the notch 82 and weight 83 having facing spring recesses 84,84 on the opposite sides to receive retractor springs 85.
The outer hub 38d includes an annular ring 39d having elongated notches 41d in the outer periphery for the stop pins 21d joining the clutch plate 15d and spring retainer plate 28d, a generally circular inner periphery 42d interrupted by a pair of oppositely disposed inwardly extending flange portions 43d having converging edges 44d, inward corner portions 86 adjacent the edges and adapted to be conformably received in the corner notches 81, and a recess 87 adapted to receive the outer edge of each weight 83. The edges 44d are provided with spring recesses 65d facing the recesses 63d to receive the idle rattle springs 58d.
The inner end of each flange portion 43d has an arcuate recess 88 providing a reduced thickness inner end, with the recesses providing piloting of the friction plates 51d; each flange portion having a central opening 89 to receive the inwardly bent tabs 52d of the friction plates. The inner circumference of the friction plates acts to pilot rotation of the inner hub 11d, and the gaps or spaces 49d are provided between the inner and outer hub flange portions 14d and 43d for the first stage of operation.
Each outer hub flange portion 43d is provided with a pair of spring windows 47d to receive the damper springs 57d for the single stage of resilient damping with friction damping once the inner and outer hubs have been locked together by the centrifugal weights 83 at a predetermined value of rotation, such as 800 rpm. This embodiment operates in substantially the same manner as the version of FIGS. 12-14.
FIGS. 20, 21 and 22 disclose a sixth embodiment of clutch damper assembly 91 wherein the device has been simplified and the components rearranged. In this version, the inner hub 11e has a pair of oppositely disposed flange portions 92 with slightly converging edges 93,93 terminating in arcuate outer edges 94,95. In the upper edge 94, as seen in FIG. 20, the flange portion has a generally U-shaped notch 82e receiving a centrifugal weight 83e; both the notch and the weight having oppositely facing recesses 84e for retractor springs 85e. In the lower edge 95, a recess 96 faces a corresponding recess 107 in the outer hub 38e for an idle rattle spring 97.
The outer hub 38e includes an annular ring 39e with elongated notches 41e in the outer periphery to receive the stop pins 21e joining the plates 15e and 28e, and an inner periphery having a pair of generally parallel chords forming edges 98,98 with central arcuate edge portions 99,99 piloting the inner hub 11e; the chordal edges forming a generally rectangular opening receiving the inner hub with gaps 101 between the flange portions 92 and the edges 98 for the idle rattle stage. Each edge 98 adjacent the arcuate surfaces 102 and 103 formed from the inner periphery of the outer hub 38e has recesses 104 receiving resilient impact cushions 105 to prevent metal to metal contact between the inner and outer hubs.
The arcuate surface 102 has a recess 106 to receive the outer end of the centrifugal weight 83e, and the arcuate surface 103 has the idle rattle spring recess 107 facing the recess in the edge 95 of the inner hub flange portion. Each outer hub segment 108 formed by the chordal edges 98 has a spring window 109 axially aligned with windows in the plates 15e and 28e to receive the damper springs 57e for the single stage torsional damping stage with friction damping. Between the opposite surfaces of the inner and outer hubs and the plates 15e and 28e are located a pair of friction back plates 111 (FIG. 22), each plate having a central opening journalled on the inner hub barrel 12e, an outer circumference 112 generally coinciding with the arcuate surfaces 102,103 and a pair of oppositely disposed notches 113 coinciding with the spring windows 109 to receive the damper springs 57e. Also, annular friction shims 114 are located between the back plates 111 and the plates 15e and 28e. This embodiment of damper assembly operates in substantially the same way as the three previous embodiments to provide an idle anti-rattle stage and then at a predetermined rpm, the inner and outer hubs lock up through the centrifugal weight so that the torsional damper springs and friction damping take over.
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A multi-stage torsional damping device for a vehicle clutch having a low-rate primary stage to eliminate transmission gear rattle occurring during neutral transmission position and a normal rate resilient and friction damping stage. The first stage consists of a low spring rate, substantially frictionless floating suspension of an inner hub within an outer hub to allow the outer hub to oscillate with engine impulses. A medium rate substantially frictionless second stage may be utilized to cushion the torque transference from the first stage to the normal rate last stage and provides compaction of some of the compression springs for the last stage for a given deflection with negligible friction until the hub parts abut, and the third stage consists of compaction of all of the compression springs and additional deflection with friction. Alternatively, centrifugal weights may be used to lock the inner and outer hubs together at a predetermined rotation level, after which a normal damping operation is effected.
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BACKGROUND TO THE INVENTION
THIS invention relates to an apparatus for use in the drying of grain and more particularly but not exclusively, to a grain storage bag having grain drying capabilities.
In the specification the term grain should be interpreted to include a variety of harvested crops that are found in agriculture, including but not limited to cereal grains, grain legumes and oilseeds.
Grain drying, as used in this specification, refers to the removal of some of the moisture from grain by mechanically moving air through the grain after it has been harvested. Grain in the field dries naturally as the crop matures, giving up moisture to the air until the grain moisture is in equilibrium with the moisture in the air. However, grain often needs to be dried even further after harvesting before it can be delivered to the market. If no drying facility is available the harvesting process may come to a standstill, which in turn adversely influences production cost and the planting of a next batch of crop.
A number of grain drying methods and apparatuses have been proposed in the past, and include drying floors, bin-type dryers, drying wagons and drying cribs and solar dryers. However, these methods all have disadvantages associated therewith, including the high capital cost of the drying facilities, the complicated nature of some of the drying facilities, and the limited control associated with some of the drying facilities.
It is accordingly an object of the invention to provide an apparatus for use in drying grain that will, at least partially, alleviate the above disadvantages.
It is also an object of the invention to provide an apparatus for drying grain which will be a useful alternative to existing grain drying facilities.
SUMMARY OF THE INVENTION
According to the invention there is provided an apparatus for use in drying grain, the apparatus including:
an elongate flexible container suitable for receiving grain, the container being at least partially sealable once grain has been introduced therein; the container having an air inlet arrangement, and an air outlet arrangement, with the air inlet arrangement being in flow communication with the air outlet arrangement through an internal volume of the container; and fluid displacement means for facilitating airflow from the air inlet arrangement to the air outlet arrangement.
There is provided for the flexible container to be in the form of an elongate cylindrical container, and for the air inlet arrangement and the air outlet arrangement to be located towards opposing sides of the container.
The air inlet arrangement may be in the form of a header that extends adjacent a side of the container, the header having at least one inlet that is in flow communication with the fluid displacement means, and a plurality of outlets that are in flow communication with the internal volume of the container.
Preferably, a longitudinal axis of the elongate container is horizontal, and the header is substantially parallel to the longitudinal axis of the container.
The air inlet arrangement may be located at a distal zone of the header, and may alternatively be located at a proximal zone of the header. There is also provided for the air inlet arrangement to include a plurality of inlets.
The outlets of the air inlet arrangement may be defined by a plurality of apertures in the header that overlie corresponding apertures in the sidewall of the container.
The air outlet arrangement may be in the form of a plurality of apertures provided in a sidewall of the container opposite the sidewall where the inlet arrangement is located.
In another embodiment, the air outlet arrangement may be in the form of a collecting header that extends adjacent a side of the container opposite the side where the air inlet arrangement is located, the header having a plurality of inlets which are in flow communication with the internal volume of the container, and an outlet which is in flow communication with the environment. The inlets of the air outlet arrangement may be defined by a plurality of apertures in the header that overlie corresponding apertures in the sidewall of the container.
There is provided for the container to be in the form of an elongate bag, and more particularly a polymeric silo bag.
The air displacement means is preferably in the form of a fan.
A heater may also be provided to heat the air being displaced into the container.
A further embodiment of the invention provided for the air inlet arrangement to be in the form of a plurality of air inlet pipes extending longitudinally into the container, and for the air-outlet arrangement to be defined by one or more apertures provided in an upper wall of the container.
The air inlet pipes may include apertures in sidewalls thereof, which apertures are in flow communication with an internal volume of the container. Open ends of the pipes may be in flow communication with a fluid displacement means.
A still further embodiment of the invention provides for the air inlet arrangement to be in the form of a plurality of air supply pockets located below the container, the air supply pockets having inlets that are in flow communication with a fluid displacement means, and outlets that are in flow communication with an internal volume of the container.
Inflatable lifting pockets may be provided in-between air supply pockets, and will serve to displace the bottom wall of the container upwardly.
According to a further aspect of the invention there is provided a method of drying grain, the method including:
providing an elongate flexible container suitable for receiving grain, the container being at least partially sealable once grain has been introduced therein, and the container having an air inlet arrangement, and an air outlet arrangement, with the air inlet arrangement being in flow communication with the air outlet arrangement through an internal volume of the container; filling the container with grain; and inducing airflow from the air inlet arrangement to the air outlet arrangement.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the invention is described by way of a non-limiting example, and with reference to the accompanying drawings in which:
FIG. 1 is a cross-sectional end view of the apparatus in accordance with one embodiment of the invention;
FIG. 2 is a cross-sectional plan view of the apparatus of FIG. 1 ; and
FIGS. 3 a to 3 c are schematic illustrations of a number of alternative inlet configurations for the apparatus of FIGS. 1 and 2 .
DETAILED DESCRIPTION OF INVENTION
Referring to the drawings, in which like numerals indicate like features, a non-limiting example of an apparatus for drying grain in accordance with the invention is generally indicated by reference numeral 10 .
With reference to FIGS. 1 and 2 , the apparatus 10 comprises a container 20 , which is in the form of an elongate flexible bag, which is made of a suitable polymeric material. The container is similar to storage bags already known in the trade, and which are sometimes referred to as silo bags. The detail design of the bag, as well as the loading and unloading of theses bags are not relevant to the invention.
The container 20 is cylindrical in nature, and comprises a continuous sidewall. For the purposes of clarity, reference will however be made to a first end 21 , a second end 22 , a first sidewall 23 , a second sidewall 24 , a bottom wall 25 and an upper wall 26 . The container differs from similar containers found in industry, in that a plurality of inlet apertures 27 are provided in the first sidewall 23 , and a plurality of outlet apertures 28 are provided in the second sidewall 24 . The apertures on each side is aligned in a linear configuration, and a centerline through the apertures are generally parallel to a longitudinal axis of the container.
An air inlet arrangement 30 is provided adjacent the first sidewall 23 of the container 20 . The air inlet arrangement 30 is in the form of an elongate tubular header 31 that extends along at least part of the length of the container 10 . The header 31 has at least one inlet 32 which is in flow communication with a fluid displacement means 50 , which is typically in the form of a fan. The inlet(s) can be closed off when there is no air flow through the system, so as to prevent the unwanted ingress of moisture and contaminants. The inlet configuration may differ, and is described in more detail below. A plurality of outlets 33 are provided in a sidewall of the header 31 , and are configured and dimensioned to overlie the inlet apertures 27 provided in the container, thus bringing the header in flow communication with an internal volume of the container 10 .
An air outlet arrangement 40 is provided adjacent the second sidewall 24 of the container 20 . The air outlet arrangement 40 is also in the form of an elongate tubular header 41 that extends along at least part of the length of the container 10 . The header 41 has at least one outlet 42 which is in flow communication with the environment. The outlet(s) can be closed off when there is no air flow through the system, so as to prevent the unwanted ingress of moisture and contaminants. A plurality of inlets 43 are provided in a sidewall of the header 41 , and are configured and dimensioned to overlie the outlet apertures 28 provided in the container, thus bringing the header in flow communication with an internal volume of the container 10 .
In use, the container 10 will be loaded with grain 11 to be dried and stored. The inlet 32 of the air inlet arrangement 30 will be opened, as will the outlet 42 of the air outlet arrangement 40 , so as to define a flow passage from the air inlet arrangement 30 through the internal volume of the container 20 and into the outlet arrangement 40 . When the fan 50 is activated, dry air will be forced through the container 20 , and more particularly will be forced past the grain 11 inside the container. The air may be ambient air, but may also be heated by way of a heater (not shown). The air flow will result in the removal of moisture from the grain in a convective manner. Once a desired dryness has been achieved the fan 50 will be stopped, and the inlet 32 of the inlet arrangement 30 , as well as the outlet 42 of the outlet arrangement 40 will be closed.
A number of inlet configurations are shown in FIGS. 3 a to 3 c , and entails an inlet at one distal end ( FIG. 3 a ), an inlet at a proximal zone ( FIG. 3 b ) which will also entail the use of a distribution plenum 51 , and a plurality of inlets along the length of the header ( FIG. 3 c ).
In is envisaged that the container may first be filled with grain, and that the air inlet arrangements will only be mounted on and secured to the container after the container has been filled with grain.
It is foreseen that other configurations may also be used to achieve the same result, which is to dry grains in an elongate flexible container. For example, the inlet arrangement may be in the form of a plurality of perforated pipes that extends longitudinally into the container, and which are located towards a bottom zone of the container. In this case the outlet arrangement will be at the top of the container, resulting in air flow in a vertical, upwardly direction. In a further example, the inlet arrangement may be in the form of a number of air supply pockets located immediately below the container, and which supply air through apertures in the container that corresponds with openings in the air supply pockets. In this embodiment it will be necessary to lift the bag and its contents in order to prevent the air supply pockets from collapsing, and lifting pockets will therefore be provided. The lifting pockets will not have outlets, thus enabling them to be inflated and to act as lifting cushions.
It will be appreciated that the above is only one embodiment of the invention and that there may be many variations without departing from the spirit and/or the scope of the invention.
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An apparatus for use in the drying of grain and more particularly but not exclusively, to a grain storage bag having grain drying capabilities, includes an elongate flexible container having an air inlet arrangement and an air outlet arrangement, with the air inlet arrangement being in flow communication with the air outlet arrangement through an internal volume of the container. The apparatus also includes fluid displacement elements for causing airflow from the air inlet arrangement to the air outlet arrangement.
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FIELD OF THE INVENTION
[0001] The invention relates to methods for identifying microorganisms in a sample by spectrometric means.
[0002] In the invention, a robust mass spectrometric identification of the species of unknown microbes is supplemented with a detailed analysis of the subspecies and varieties by means of infrared spectrometry, primarily in order to identify medically important varieties such as pathovars (for example EHEC and EPEC) and antibiotic-resistant microbes (for example MRSA). The detailed analysis by means of infrared spectrometry requires knowledge of the microbe species in order to use a species-specific and species-restricted database (library) of reference IR spectra, and especially in order to carry out species-specific, standardized culturing of the microbes. The mass spectrometric identification of the microbes is carried out by means of similarity comparisons between their mass spectra and reference spectra of microbes across all taxonomic domains in an extensive database (library). The detailed analysis of the subspecies and varieties, on the other hand, is performed using IR spectra, in essentially the usual way, via a mathematical-statistical classification analysis, here applied to a quantity of reference IR spectra of the subspecies and varieties of only a single species of microbe. This identification has at least two steps and is primarily of interest for medical diagnostics.
BACKGROUND OF THE INVENTION
[0003] The rapid, error-free identification of microorganisms plays a prominent role in clinical microbiology in particular, but also in food analysis, monitoring and control of biotechnological processes, and monitoring of rivers and lakes. Microorganisms, which are also referred to as germs and microbes below, are generally microscopic organisms, which include bacteria, unicellular fungi (e.g. yeasts), microscopic algae and protozoa.
[0004] Identifying a microorganism means classifying it in the taxonomic hierarchical scheme: domain, kingdom, phylum, class, order, family, genus, species, and subspecies. The identification of bacteria, however, can additionally encompass varieties, such as serotypes or pathovars.
[0005] The term serotype or serovar (short for serovariety) is used to describe varieties within subspecies of bacteria which can be differentiated with serological tests. They differ in respect of antigens on the surface of the cells, and are identified in conventional microbiology with the aid of specific antibodies. The taxonomic hierarchy for serotypes is as follows: genus>species>subspecies (subsp.)>serotype, for example with the extended binomial species name Salmonella enterica subsp. enterica serotype Typhi, short form Salmonella Typhi.
[0006] A pathovar (from the Greek pathos, meaning “suffering” or “disease”) is a bacterial strain or group of strains with the same properties that is differentiated from other strains within the species or subspecies on the basis of its pathogenicity. Pathovars are designated by means of a ternary or quaternary extension to the binomial species name. The bacterium Xanthomonas axonopodis, for example, which can cause citrus canker, has various pathovars with different host specializations: X. axonopodis pv. citri is one of them. The abbreviation “pv.” stands for “pathovar”. The virulent strains of human pathogens also have pathovars, but in this case they are designated by an addition before the name. For example, the intestinal bacterium Escherichia coli, which is mostly completely harmless, has the highly dangerous pathovars enterohaemorrhagic E. coli (EHEC), enteropathogenic E. coli (EPEC), enterotoxigenic E. coli (ETEC), enteroinvasive E. coli (EIEC), enteroaggregative E. coli (EAEC) and diffusely adherent E. coli (DAEC). The pathovars, in turn, can contain different serotypes. EHEC has many known serotypes, with around 60 percent of all identified EHEC serotypes being 0157, 0103 and 026. Particularly dangerous is the serosubtype 0157/H7.
[0007] In a broader sense, the identification of microbes can also encompass varieties which differ in other medically relevant properties, in particular their resistance to antibiotics (especially beta-lactam antibiotics and glycopeptide antibiotics), but also their toxin formation (“toxivars”) or their receptiveness to the same or similar bacteriophages (“phagovars”). In general, the term “biovars” is used if a group of microbes of one species or subspecies have biological properties in common. One example of an antibiotic-resistant variety is MRSA: Methicillin-resistant Staphylococcus aureus.
[0008] The term “strain” describes a population that was grown from a single organism and is kept in a (often national) repository for microbial strains. An internationally standardized strain designation is added to the nomenclature chain, comprising genus, species, subspecies and variety. The individual organisms of a strain are genetically identical; different strains vary slightly in their genetic make-up.
[0009] Two spectrometric methods have recently become widely used in microbiological laboratories for the identification of microbes. One of these is mass spectrometry (MS), and the other is infrared spectrometry (IR). It must be noted here that, strangely enough, no research group so far uses the two methods in parallel, or indeed in combination. On closer examination, this can be explained by the fact that the research fields of these groups are different in most cases, as are the aims of the identifications.
[0010] It is always favorable to use mass spectrometry when microbes of a completely unknown species have to be identified quickly and easily, down to the taxonomic level of the species, with no prior knowledge whatsoever. In general, the method works very well as long as the microbes can be cultured on or in nutrient media. It is preferable to produce colonies on gelatinous nutrient media in Petri dishes. The method is very robust: the age and nutrition of the colony have practically no effect on the mass spectrometric identification; nor are the quantities, preparation methods or storage periods of the samples on the mass spectrometric sample supports of any great importance. This means that the method of sample propagation and preparation does not require any strict standardization. Moreover, only very little sample material is needed, so tiny colonies are sufficient. The peaks of the mass spectra indicate microbe proteins that are exceedingly common or easy to ionize; 60 to 85 percent of these peaks belong to the 40 to 60 different proteins making up the ribosomes. Since each ribosome occurs several thousand times in each cell, and since the masses of the ribosomal proteins for the different microbe species are all characteristically different from each other, the uniform incidence of these proteins makes them ideal for an identification. After successful cultivation, the method identifies the taxonomic species of the microbes under investigation in a matter of minutes by using automated computer programs to compare their mass spectra with the reference mass spectra of an extensive spectral library, which may contain thousands of reference mass spectra of microbes across all taxonomic domains. The method has a very high identification certainty. In only a few cases is it not possible to differentiate between two microbe species with certainty. On the other hand, it is rarely possible to identify subspecies or even varieties, and, according to current knowledge, this will scarcely change on the basis of the methods currently in use, which are optimized for sensitivity, speed and identification accuracy. The principal reason for this is that the varieties do not differ in respect of their ribosomal proteins.
[0011] With infrared spectrometry, in contrast, it is possible to identify subspecies and varieties such as serotypes and pathovars, in some cases even individual strains within a species, if a suitable library of reference spectra for the subspecies and varieties of this species is available. The compiling of this library, however, usually requires that species-specific culture, preparation and measuring specifications are accurately adhered to, which is quite different to the situation with mass spectrometry.
[0012] The IR spectra are based on thousands of vibrations of the functional groups and the polar bonds in the biological material; these in turn originate from all the components of the microbial cells such as DNA, RNA, proteins, internal structures, membranes, and cell walls, right through to energy stores. There are no unequivocal assignments of molecules to individual characteristics in the spectra, albeit certain spectral ranges can be preferably assigned to certain molecular species: the fatty acid range from 3050 to 2800 cm −1 with vibrations of the CH 2 and CH 3 groups, the amide range from 1750 to 1500 cm −1 with peptide bonds, the polysaccharide range from 1200 to 900 cm −1 . The range from 900 to 700 cm −1 is called the “fingerprint range”. It contains something from all the molecules and is very important for differentiating between the species.
[0013] The identifications depend on tiny differences in the IR spectra, which is why all method steps for identification via IR spectra are usually standardized, from the cultivation of the microbes with prescribed durations and temperatures on prescribed nutrient media through to the preparation and measurement of the samples. Oxygen content and moisture level above the nutrient medium must be controlled. Small deviations from the standardized method, such as a deviation in the culture period of more than half an hour or the culture temperature of more than one Kelvin, are enough to make the identification more difficult or falsify it.
[0014] In order to compile a library of reference IR spectra, microbes of a selected group are cultured and measured under standardized conditions. The spectra of this reference library are then subjected all together to a mathematical-statistical classification procedure. Several mathematical-statistical methods are used, such as ANN (artificial neural network analysis), PCA (principal component analysis), PLS-DA (partial least-square discriminant analysis), SVM (support vector machines), hierarchical cluster analyses or other classification techniques. After a learning and verification phase with the aid of the IR spectra from the library, the classification algorithms can then be applied to the infrared spectrum of the microbes of a sample, which were cultured in the same way. The algorithms provide the taxonomic classification, such as species, subspecies, serotype, pathovar and even strain. If, however, the microbe in the sample does not belong to the closely related group, the detailed IR analysis can provide totally incorrect results. As an example, the pathovar EHEC may be falsely indicated if the microbes are not E. coli, as assumed, but relatively harmless Citrobacter, for example.
[0015] These differences in handling and results mean that the fields of application for MS and IR are different. In clinical diagnostics, only mass spectrometry is used in practice, because unknown pathogens must be assumed across all taxonomic domains. The same applies to the monitoring of rivers and lakes and in all other areas where a fast identification of any type of microbes without any prior knowledge of the microbiological species is of paramount importance. The microbes here can belong to all the taxonomic domains of bacteria, archaea and eukaryotes, including unicellular algae or fungi, such as yeasts.
[0016] In contrast, if the aim is to detect sources of contamination and transmission routes of microbes in contaminated food or infected livestock, it is important to determine subspecies and varieties for a reliable identification of the infection sources. In this case, it can usually be assumed that the species of the microbes is known, at least after a single microbiological determination. Nowadays, therefore, IR spectrometry is used mainly where the species of the microbes is known, but it is important to accurately determine the subspecies and possibly the variety. If, for example, endemic salmonella poisoning occurs, and if it is suspected that the salmonella originate from an aquaculture of Thai shrimps, it is not sufficient to detect salmonella in the Thai shrimps. According to current taxonomy, there are two species of salmonella, one of which ( Salmonella enterica ) has five subspecies, but these have around 2600 different serovars as varieties between them. To come back to the shrimps, one then has to prove that the same salmonella variety is involved. The salmonella from a stool sample are therefore grown in a salmonella -specific culture broth, and IR spectrometry is used to examine the serotype of the selectively grown salmonella. This serotype must then be traced back to the Thai aquaculture.
[0017] Thus, infrared spectrometry is to be found mainly in food production, veterinary medicine and public health authorities, whereas clinical diagnostics is dominated by mass spectrometry.
[0018] Nowadays, the mass spectrometric identification method is also used around the world for medical diagnostics; in European and many other countries, methods and mass spectrometers from individual companies have already been clinically approved, as they meet the appropriate legal stipulations. Statutory approvals are being prepared in other countries. In the mass spectrometric method, the microbes are first cultured to form colonies. The nutrient medium for the culture is usually in an agar in a Petri dish, and by this method the cultivation of pure “isolates” in separate microbe colonies is achieved in hours or days, depending on the vigor of the microbes. It is not absolutely imperative to grow the microbes on agar, however. They can also be grown in liquids. If the colonies superimpose or mix, it is possible to obtain isolated colonies, again in the usual way, in a second cultivation. The tiny quantity of 10 4 to 10 6 microbes, hardly visible to the naked eye, which is transferred from a selected colony onto the mass spectrometric sample support by means of a small swab (preferably with a hygienically clean wooden toothpick), is then sprinkled with a strongly acidified solution of a conventional matrix substance (usually α-cyano-4-hydroxycinnamic acid, HCCA, or 2,5 di-hydroxybenzoic acid, DHB) for a subsequent ionization by matrix-assisted laser desorption (MALDI). The acid (usually formic acid or trifluoroacetic acid) attacks the cell walls, and the organic solvent (usually acetonitrile) of the matrix solution can penetrate into the microbial cells and cause their weakened cell walls to burst osmotically. The sample is then dried by evaporating the solvent, causing the dissolved matrix material to crystallize out. The soluble proteins of the microbes, and also other substances of the cell to a very small extent, are incorporated into the matrix crystals in the process.
[0019] The matrix crystals with the incorporated analyte molecules are bombarded with focused UV laser pulses in a mass spectrometer, thus generating ions of the analyte molecules in the vaporization plasmas. These ions can then be measured in the mass spectrometer, separated according to their mass. Simple time-of-flight mass spectrometers are commonly used for this purpose. The mass spectrum is the profile of the mass values of these analyte ions, which are very predominantly protein ions. The ions with the most useful information in terms of an identification have masses of between approximately 3,000 daltons and 15,000 daltons (1 dalton=1 atomic mass unit). In this method, the protein ions are very predominantly only singly charged (charge number z=1), which is why one can also simply talk about the mass m of the ions here, instead of always using the term “mass-to-charge ratio” m/z, as would otherwise actually be necessary in mass spectrometry.
[0020] Instead of simple time-of-flight mass spectrometers, it is also possible to use other types, such as time-of-flight mass spectrometers with orthogonal ion injection; and instead of the ionization by MALDI, it is certainly possible to use other types of ionization, such as electrospraying (ESI), although they provide more complicated mass spectra. A different ionization method for the generation of simple mass spectra is chemical ionization (CI), which can be used with laser-desorbed plasmas, for example.
[0021] The mass-separated profile of the soluble proteins, i.e. the mass spectrum, is very characteristic of the microbe species concerned because every species of microbe produces its own, genetically determined proteins, each having a characteristic mass. As has already been mentioned, around 60 to 85 percent of the proteins originate from the ribosomes. These are complexes of DNA and proteins which always have the same structure and which always contain between 40 and 60 different species-specific proteins in precisely the same number and composition. Each bacterial cell contains several thousand, and up to ten thousand, ribosomes; cells of eukaryotes contain several hundred thousand ribosomes. This means that not only the masses, but also the incidences of these soluble, more highly concentrated proteins are genetically predetermined; they do not depend on the nutritional conditions or the maturity of the colony, as do the lipoproteins, or the fatty acids which act as energy stores, for example. The protein profiles, especially those of the ribosomal proteins, are similarly characteristic of a microbe species as fingerprints are of an individual person. Reference libraries with reference mass spectra for thousands of microbes, which are legally approved for use in medical applications, are now available.
[0022] This mass spectrometric method of identification has proven to be extremely successful. The certainty of a correct identification is far greater than with the microbiological identification methods currently in use. In various studies it has been possible to prove that, with hundreds of different species of microbe, the identification certainty was far greater than 95 percent, and usually more than 98 percent. In cases of doubt, where there were deviations from current microbiological identification methods, genetic sequencing has confirmed that the mass spectrometric identification was correct in the vast majority of cases.
[0023] To identify the microbes, mass spectra from around 2,000 daltons up to high mass ranges of 20,000 daltons, for example, are measured, but it has been found that the mass signals in the lower mass range up to around 3,000 daltons can be evaluated less well because they can originate from substances whose presence is essentially random and variable, such as fatty acids, which are stored according to the nature of the nutrition. The best identification results are obtained by evaluating the mass signals in the mass range from around 3,000 to 15,000 daltons. The ultra-sensitive mass spectrometers now used for this purpose have only a low mass resolution, which means that the isotope groups, whose mass signals each differ by one dalton, cannot be resolved in this mass range. Only the envelopes of the isotope groups are measured.
[0024] This method of identifying microbes in principle requires a pure culture of microbes, a so-called “isolate”, in order to obtain a mass spectrum that is free of superimposed signals of other microbes. It has, however, been found that mass spectra of mixtures of two microbe species can also be evaluated, and that both microbe species can be identified. The identification certainty suffers only slightly. If more than two microbe species are involved in the mass spectrum, or if these two microbe species are present in very different concentrations, the identification probability and identification certainty decrease considerably.
[0025] Microbe identification by IR spectrometry is also based on pure cultures of microbes on suitable nutrient media. Here, however, age- and nutrition-related differences in the microbes must be avoided by maintaining standard conditions, since all components of the cells contribute to the IR spectra in all wavelength ranges in each case. The microbes, which are grown on standardized agar under standardized conditions, are suspended in pure water and deposited on an IR-transparent support plate. Care must be taken to ensure that the microbes are deposited in a uniform layer. The layer is dried and the absorption of the microbes on the support plate is measured in an infrared spectrometer. A Fourier Transform spectrometer (FT-IR), which has a high resolving power, is normally used. The spectra typically measured range from 4000 cm −1 to 500 cm −1 . Several hundred spectra are measured and summed at acquisition rates of 20 spectra per second in order to improve the signal-to-noise ratio.
[0026] In a slightly modified embodiment, the IR spectra can also be measured in reflected light, in which case they are prepared on a metallically reflective support, made of aluminum, for example. It is also possible to use Raman spectroscopy, which has the advantage that the microbe spectra can also be measured in liquids.
[0027] There are other fields, besides food inspection and veterinary medicine, where there is a need to classify microbes in as much detail as possible according to subspecies and variety, but in these other fields the species of the microbe is usually completely unknown initially. In medical diagnostics, for example, knowledge about the pathogenicity, toxicity, virulence, and particularly the antibiotic resistance of the microbes is extremely important. These properties can certainly be very different for different subspecies or varieties of one microbe species.
[0028] The subspecies, serotypes, pathovars and further variations of the microbes are determined from their microbiological characteristics, for example from their attachment behavior (serotypes), their toxicity, their pathogenicity (pathovars), their virulence, and also from their resistance or non-resistance to the different antibiotics. There is (as yet) no detailed knowledge about which of these variations can be differentiated spectrometrically.
[0029] In view of the foregoing, there is a need to identify microbes from a wide range of taxonomic classes, where the classification should also extend in particular to manifestations below the taxonomic level of the species, i.e. subspecies, pathovars, toxivars, serotypes, and especially resistance to antibiotics.
BRIEF DESCRIPTION OF THE INVENTION
[0030] The invention provides a method for identifying unknown microbes in a sample, wherein a mass spectrometric determination down to the taxonomic level of the genus or species is followed by a detailed determination of a lower taxonomic level or variety by means of infrared spectrometry, using restricted reference libraries of infrared spectra. These libraries can be either genus-specific, containing only infrared spectra of microbes of one genus, or species-specific, containing only infrared spectra of microbes of one species.
[0031] The invention is based on the finding that infrared spectroscopy can currently penetrate to lower levels of taxonomic classification (including the determination of varieties) than mass spectrometric identification is able to, but only if the reference infrared spectra used in the mathematical analysis belong only to a small group of closely related microbes, and in particular only if the infrared spectra were obtained in compliance with standardized specifications for the culture, preparation and measurement of the microbes of this group of related microbes. If reference IR spectra of all microbes across all taxonomic domains are brought together in a library and used for the classification, one cannot then expect that the resulting identification of bacteria in a sample will do much more than determine whether the bacteria are Gram-positive or Gram-negative, where applicable. The results improve if the reference library is limited to bacteria and, additionally, the microscopic distinguishing features of the bacteria are taken into account, and if each library of IR spectra that is created is restricted to either club-shaped ( corynebacteriaceae ), or spherical (cocci), or rod-shaped (bacilli) bacteria, or other morphologies. If, in a still further restriction, the reference library consists only of IR spectra of different pathovars of a single microbe subspecies, then it is often possible to unequivocally determine the pathogenic type of the microbes in a sample by means of infrared spectrometry, if the sample microbes do in fact belong to this subspecies. However, if the infrared spectrum of the microbes under investigation does not belong to the expected initial group after all, the method can lead to incorrect results, which, in the case of medical diagnostics, can be life-threatening. For optimal results, the specifications for the culture, preparation and measurement differ from microbe species to microbe species.
[0032] The invention provides methods, for example, whereby a mass spectrometric determination of the microbe species is followed by a detailed determination of the subspecies and/or the variety by means of infrared spectrometry, for which purpose a species-specific library of reference IR spectra is used. Once the microbe species is known, a decision can be taken as to whether a further detailing according to subspecies or variety is necessary, and can be carried out. For the classification according to subspecies or variety, a database of IR spectra restricted to this species and containing reference spectra of the different subspecies and varieties must be available. When the answer to the question of necessity and possibility is in the affirmative, an IR spectrum can be analyzed for subspecies or varieties. If required, the microbes can be cultured further in exact accordance with the standard specifications for this species, which are in the appropriate IR spectral database, and the microbes can be prepared for the subsequent acquisition of an IR spectrum. For optimum results, it may be necessary to apply an individual set of culture and preparation conditions for each microbe species which is optimal for the IR identification of the varieties. This set of conditions also forms the basis of the IR spectra, meaning that an individual IR reference database must be compiled for each microbe species.
[0033] The invention therefore involves an approach with at least two stages: first, the determination of the microbe species by means of the mass spectrometric method, then the determination of subspecies and variety, such as pathovar or serotype, by means of infrared spectrometry. If, as is known for some genera, mass spectrometry can only determine the genus with certainty, but not the species, IR spectrometry can be used to determine the species of the microbes on the basis of an appropriately compiled genus-specific library of IR spectra. A three-stage method may then become necessary to determine subspecies and variety.
[0034] In another method according to the invention, an infrared spectrum used for the detailed determination can be acquired before a mass spectrum used for the mass spectrometric determination is acquired, and at least parts of the same microbe material is used for both acquisitions, especially after a single culture.
[0035] To differentiate between subspecies and varieties, it can be favorable to use only specific parts of the microbial cells, for example the cell walls with the proteins located on their outside, for the IR spectra, since these proteins determine the serotype and usually also the pathovar. A precondition here is again a prior, certain identification of the species and the existence of an appropriate database for IR spectra from these parts of the microbial cells. The preparation of the cultured microbes can thus comprise their simple sedimentation onto a sample support, but also the destruction of the cells and the selection of those cell components which are more favorable than the complete microorganism for determining the variation. The components can be separated by centrifugation or filtration, especially by liquid gradient centrifugation, possibly also after derivatization, coagulation or other modifications.
[0036] This method of operation requires the existence of species-specific libraries of IR spectra of the microbial subspecies or even of the cell components of the microbial subspecies. This sounds like a vast undertaking which cannot be mastered. It is, however, general experience that in microbiological routine laboratories, only a small number of microbe species account for over 80 percent of the identifications which have to be done on a daily basis. Only three or four of these may require a more detailed classification; in addition, a few of the rarer microbe species may be interesting for a more detailed classification. While these microbe species of most urgent interest may differ from laboratory to laboratory, depending on the particular business focus, their relatively small number makes it possible to compile libraries of IR spectra which are suitable for these microbes. It has, furthermore, become apparent that an exchange of spectral libraries between different laboratories is possible if the strict standardization is adhered to.
BRIEF DESCRIPTION OF THE FIGURES
[0037] FIG. 1 shows an example of a flow chart for the identification of subspecies and varieties of microbes according to a first embodiment. The method starts with the provision of an MS spectral library. Then, IR spectral libraries of the subspecies and varieties for individual microbe species, which were obtained by species-specific culture and preparation, are provided. Then, a microbial isolate from the sample is cultured. Then, mass spectrometric identification of the species follows. Then, the query is made of whether identification of the sub-species and varieties is necessary and possible. If no, the method ends here in this example. If yes, species-specific culture and preparation of microbes of the isolate for IR spectral acquisition ensues. Then, IR spectra are acquired. Finally, sub-species and variety are identified using the species-specific IR reference spectra.
[0038] The left-hand side of FIG. 2 shows a simple and schematic embodiment for determining the species of a microorganism. A mass spectrum of components typical of the microorganism is acquired, and these components are represented by a particular mass signal pattern in the mass spectrum. The signal pattern is compared with patterns from a library of reference spectra, here MS reference # 1 and # 2 . MS reference # 1 does not show sufficient agreement with the measured signal pattern; in contrast, there is a good match between MS reference # 2 and the measured signal pattern, so the species of the microorganism can be determined. The right-hand side of FIG. 2 illustrates a simple and schematic embodiment for determining the subspecies and variety by means of infrared absorption spectrometry. To this end, in a special embodiment, the microorganisms that have already been classified successfully by species using mass-spectrometric analysis are cultured, prepared and then measured by IR absorption spectrometry under specific, predetermined conditions. Characteristics of the infrared absorption spectrum (IR spectrum) thus obtained can then be elaborated and visualized, for example by applying a principal component analysis (PCA), within the species-specific reference IR spectra. The main components of the infrared absorption spectrum measured (represented in the diagram by stars ★) can then be entered on a “map”, which also contains clusters of subspecies or varieties of the known species of the microorganism, i.e. locations where the parameters for specific subspecies or varieties are positioned after comparable culture, preparation and IR measurement. In a first example, the parameter ★ is outside all the clusters and is therefore not identifiable. In a second example, the parameter ★ can be assigned to a cluster and is thus determined to be a subspecies or variety.
[0039] FIG. 3 shows an example of a flow chart for identifying subspecies and varieties of microbes according to a second embodiment. The method starts with a hypothetical assumption of a certain microbe species in the sample. Then, an MS spectral library and an IR spectral library of the subspecies and varieties of the assumed microbe species, which was obtained by species-specific cultivation and preparation, are provided. Then, a microbial isolate from the sample is cultured species-specifically. Then, the microbes of the isolate are prepared on an IR sample support for IR spectral acquisition. Then, an IR spectrum is (or IR spectra are) acquired. Then, the microbes are prepared on the IR sample support for MALDI ionization. Then, MS spectra are acquired. Then, mass spectrometric identification of the microbe species is performed. Then, a query is made of whether the assumption concerning the microbe species was correct. If no, the method ends here in this example. If yes, then subspecies and variety are identified with the aid of the already acquired IR spectrum and the species-specific IR reference spectra.
DETAILED DESCRIPTION
[0040] The mass spectrometric methods currently in use can usually identify only the species with certainty; in favorable cases the subspecies also; but in a few rare cases, only the genus of microbes. It should again be emphasized here that the invention is based on the finding that infrared spectrometry can currently penetrate to lower levels of taxonomic classification than mass spectrometric identification is able to. This only applies if the infrared spectra used in the mathematical classification analysis contain a small group of closely related microbes, for example of only one genus or only one species, or even one subspecies, and the microbes are preferably grown under standardized, genus-, species- or subspecies-specific conditions. If the reference library consists only of IR spectra of different pathovars and serovars of a single microbe species, then it is often possible to unequivocally determine the pathogenic type or serotype (or at least the pathovar or serovar group) of the microbes in a sample, provided that the sample microbes actually belong to this species. If the microbe spectrum does not belong to the species expected, an assignment is not possible.
[0041] In medical diagnostics, in particular, there are, however, cases where microbes from blood, nasal mucus, stool or urine are initially unknown to a large extent, but which must be characterized as precisely as possible down to the varieties such as biovars, serovars, phagovars, or pathovars, usually after determining the species. The term “pathovars” alone implies that not all varieties of the species are pathogenic, but in medical diagnostics it is mainly the pathogenicity which counts. Since this determination cannot usually be done by mass spectrometry alone, one of the methods according to the invention can be used in such cases.
[0042] The methods according to the invention for the taxonomic identification of microbes in a sample are essentially characterized by the fact that a mass-spectrometric determination of the species is supplemented by a determination of the subspecies and/or variety by means of infrared spectrometry. A species-specific library of reference IR spectra is used for the determination of subspecies and variety.
[0043] In a first embodiment of the method according to the invention, the mass spectrometric identification of the microbe species is followed by a reculture and preparation of the microbes for the purpose of determining the subspecies and variety. This reculture and preparation is performed according to precisely the same specifications under which the IR spectra of the species-specific IR library of reference spectra were obtained. The preparation of the microbes for the IR spectra may even comprise the selection and separation of individual cell components from which the IR spectra are acquired. For example, purified cell walls can be used to acquire the IR spectra. It is also possible to use any chosen fraction of the cell components obtained by gradient centrifugation. The cell components can also be derivatized in order to obtain informative IR spectra.
[0044] As can be seen in FIG. 1 , this first embodiment of the method according to the invention for the determination of the species, subspecies and/or variety of unknown microbes in a sample comprises the steps
a) provision of a library with reference mass spectra and libraries with reference IR spectra which were obtained specific to the species, b) culture of a microbial isolate from the sample, c) mass spectrometric determination of the species of the microbes, d) culture and preparation of microbes of the isolate according to the species-specific specifications under which microbes for the library of reference IR spectra for this species were obtained, e) acquisition of an infrared spectrum, f) determination of the subspecies and/or the variety by means of a mathematical-statistical classification method using the species-specific reference IR spectra.
[0051] The method can be terminated after Step c) if, after the mass spectrometric determination of the microbial species in Step c), it is ascertained that there is no need for a more detailed classification or that no database with reference IR spectra is available for such a classification.
[0052] Step d) of the culture and preparation of microbes according to the specifications for this species in the corresponding library of reference IR spectra already indicates that, for each species, there is a separate collection of reference spectra which were measured on microbes cultured according to standard methods, adapted precisely to this species. The standard methods can include stipulations relating to nutrient medium, duration and temperature of the culture, oxygen and moisture content above the nutrient medium, and also the type of sample preparation for the IR spectrometer, and finally even the weighting scheme for individual sections of the IR spectrum for the classification.
[0053] The preparation method can also require that certain cell components be selected if this is the only way to achieve a sufficiently good differentiation of varieties. Many serovars of bacteria, for example, are distinguished by the different types of lipopolysaccharides of the outer cell membrane (as surface antigens), and are then designated by O104:H4, for example, (this is the EHEC serovar of the most recent epidemic EHEC outbreak in 2011). The “O” here stands for “surface antigen”. The precise differentiation of the lipopolysaccharides requires the separation and purification of the cell walls, but without dissolving the outer layer of the cell membrane.
[0054] This first embodiment can therefore comprise a preparation method whereby the cells of the microbes are carefully destroyed and the components of the cells are separated from each other, before an IR spectrum from one of the components is acquired. The cell digestion by destroying the cell walls must not be carried out in such a way that important components such as coat proteins and lipopolysaccharides are lost or destroyed. While a cell digest is usually carried out using strong acids (70 percent formic acid or trifluoroacetic acid) in order to dissolve all proteins as far as possible, it can be expedient here to carry out the cell digest with the enzyme lysozyme. The digested cells are then separated into individual cell components, preferably using gradient centrifugation, and only certain components, such as the cell walls, are used for the IR spectral measurement.
[0055] Whereas with the first embodiment, the mass spectrum is acquired first, and only then the IR spectrum, in a second embodiment this order is reversed. This second embodiment is preferable if one has an idea of what species of microbe is present in the sample. A species-specific culture is grown on the basis of this assumption, and an isolate from a colony is prepared on an IR spectrometric sample support. IR-transparent materials such as plates of zinc selenide or silicon have been used successfully as IR sample supports. After the acquisition of an IR spectrum, the microbe sample is then prepared for MALDI ionization, i.e. the microbes are digested and the contents of the microbial cells are prepared in matrix crystals. This can take place on the sample support for the IR measurement itself, for example on the silicon plate. The mass spectrometric acquisition leads to the identification of the microbe species, which confirms or disproves the assumption about the species. If the correct microbe species is present, the subspecies and, if applicable, the variety can now be determined from the IR spectrum already acquired. If such a determination were to take place without mass spectrometric confirmation of the assumed species, this could result in dangerous false positives or false negatives.
[0056] This second embodiment is particularly attractive because the IR spectra and the mass spectra can be obtained from the same microbes and, in special embodiments, on the same sample support plate also. FIG. 3 shows an example of a flow chart for this second embodiment.
[0057] This second embodiment is particularly suitable for use with enterobacteria, i.e. with E. coli. in particular. A trained specialist is already able to correctly identify the colony on the gelatinous nutrient medium in a Petri dish as E. coli with a probability of around 90 percent, so this procedure has a high probability of success. With E. coli, there is an urgent need to identify the pathotype, such as EHEC. If, however, a mass spectrometric confirmation for E. coli is not found, for example because it is Citrobacter, the evaluation of the IR spectrum can lead to diagnostically dangerous false results.
[0058] The exemplary methods mentioned above require that species- or preparation-specific libraries of IR spectra exist. These can actually be created by specialists in microbiological laboratories themselves, although this initially sounds like a vast undertaking which cannot be mastered. However, it has become apparent that, firstly, the strict standardization makes it possible to exchange spectral libraries between different laboratories; and, secondly, in microbiological routine laboratories, only four to six species of microbe account for over 80 percent of the identifications which have to be carried out on a daily basis. Only three or four of these may require a more detailed classification (example: E. coli, salmonella, S. aureus ); in addition, a few of the rarer microbe species may be interesting for a more detailed classification. While these microbe species of most urgent interest may differ from laboratory to laboratory, depending on the particular business focus, they do allow individual laboratories to compile such libraries of IR spectra for these microbes over the course of time.
[0059] As has been briefly indicated above, in a few, but sometimes important, cases the mass spectrometric identification method cannot provide good and certain differentiation between two species (or even genera). For one microbe species, the mass spectrometric reference library usually contains between five and twenty reference spectra of different strains, these strains being selected in such a way that their reference spectra cover the variation in the mass spectra of this microbe species as broadly as possible. It can happen that the variations of the mass spectra of a certain species overlap with mass spectra of a different species, or even genus, in respect of their similarity. Such a case, which must be regarded as critical, is the problem of differentiating unequivocally between the E. coli species (which, apart from the above-described EHEC varieties, also has a variety which is a pathogen of the relatively harmless traveler's diarrhea) and the Shigella genus (four species; pathogens of shigellosis (bacillary dysentery), which requires medical treatment). The E. coli species has mass spectra with unusually great variation. They are thus occasionally extremely similar to the mass spectra of one or other of the four Shigella species ( Shigella boydii, Shigella dysentenae, Shigella flexneri and Shigella sonnei ), which can be easily distinguished from each other mass spectrometrically, and consequently a definite mass spectrometric identification is often not possible.
[0060] It should be mentioned at this point that the phylogenetic similarities lead some molecular biologists to believe that the four Shigella species do not form a distinct genus, but actually represent four subspecies of E. coli. Whether such a reclassification takes place in the future or not, the different therapeutic requirements mean that the problem of identifying this subspecies will remain.
[0061] A special embodiment of the method according to the invention described above provides assistance here, but in this case an IR reference library is used which contains microbes of the Shigella genus and the E. coli species. If the mass spectrometric identification of Shigella or E. coli is completely unequivocal, the procedure is successfully concluded. If it is not unequivocal, however, the IR spectrometric reference library is used which comprises the genus Shigella and the species E. coli, and it is preferable to culture the microbes according to the specification which was used to culture the microbes for the reference spectra of this IR spectrometric reference library. The IR spectra then allow a reliable determination of the species present. A small number of similar cases of this type require IR spectrometry for the final determination of the species, and for this, databases with reference IR spectra of all the species that cannot be differentiated by mass spectrometry are required.
[0062] To determine the subspecies and varieties of this species, a third step of the analysis may then be necessary, with special reference IR spectra for this species or with a special evaluation algorithm for the reference spectra of the genus, which are selected so as to be specific to the species. A definite identification of E. coli can thus be followed by a determination of the variety. E. coli is part of the normal intestinal flora and is harmless as such, but there are many pathogenic varieties. Apart from the already mentioned EHEC, which was first described in 1977 and comprises various serovars such as serovar O157, serovar O103 and serovar O26, there are further pathogenic E. coli: enteropathogenic E. coli (EPEC), enterotoxigenic E. coli (ETEC), enteroinvasive E. coli (EIEC), enteroaggregative E. coli (EAEC) and diffusely adherent E. coli (DAEC). Here too, it can be expedient to apply the fundamental method of destroying the microbial cells and separating the cell components from each other before acquiring an IR spectrum from one of the components. Only certain components, such as the cell walls, are used for the IR spectral measurement.
[0063] Of particular interest for any therapy is the resistance of a microbe to certain antibiotics, which still has to be determined with laborious analytical methods. It is possible that refined methods of IR spectral measurement will also enable specific resistance types to be determined. It is also to be expected that serovar types can correlate with resistances to antibiotics.
[0064] It is possible that the method according to the invention allows different types of resistance to antibiotics to be detected directly with IR spectrometry, possibly with only certain fractions of the microbes being used for the spectral measurement. These fractions can, for example, be obtained in essentially the known way after the cell walls have been destroyed by centrifugation, especially by density gradient centrifugation. Where applicable, components of the microbes can also be prepared by derivatization, coagulation or other biochemical modifications in such a way that the microbes with different resistances can be differentiated from each other by means of their IR spectra.
[0065] The invention has been described with reference to a number of different embodiments thereof It will be understood, however, that various aspects or details of the invention may be changed, or various aspects or details of different embodiments may be arbitrarily combined, if practicable, without departing from the technical teaching of the invention. Generally, the foregoing description is for the purpose of illustration only, and not for the purpose of limiting the invention which is defined solely by the appended claims.
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The invention relates to a method for identifying unknown microbes in a sample, wherein a mass spectrometric determination termination down to the taxonomic level of the genus or species is supplemented by a detailed determination of a lower taxonomic level or variety by means of infrared spectrometry, using restricted reference libraries of infrared spectra. These libraries can be genus-specific, containing only infrared spectra of microbes of one genus, or species-specific, containing only infrared spectra of microbes of one species. In so doing, a robust mass spectrometric identification of the species of unknown microbes is advantageously supplemented with a detailed analysis of the subspecies and varieties by means of infrared spectrometry, primarily in order to identify medically important varieties such as pathovars like EHEC and EPEC, and antibiotic-resistant microbes like MRSA.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. patent application Ser. No. 10/397,599, filed Mar. 26, 2003, now U.S. Pat. No. 6,983,920, which is a divisional application of U.S. patent application Ser. No. 09/470,791, filed Dec. 23, 1999 by DeLine for REAR VIEW MIRROR MOUNTING ASSEMBLY, now U.S. Pat. No. 6,540,193, the disclosures of which are hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
The present invention relates generally to a rearview mirror mounting assembly and, more particularly, to a rearview mirror mounting assembly which pivotally mounts an interior rearview mirror to a mounting base attached to the vehicle.
Mounting brackets for supporting rearview mirrors are well known in the art. Typically, a rearview mirror is mounted to a mounting base via one or more ball and socket connections or joints. The double jointed mounting bracket allows for further movement of the interior rearview mirror relative to the mounting base, which is typically secured to an interior surface of the windshield of the vehicle or to a headliner or console at an upper edge of the windshield. The bracket must tightly retain a ball within the socket of the ball and socket joint, while still allowing relative rotation or pivoting therebetween. If the joints are not tightly secured, the interior rearview mirror may experience excessive vibration when the vehicle is being driven. These vibrational concerns are further enhanced when the interior rearview mirror comprises multiple components and electronic circuitry, such as electrochromic reflectors, microphones, map reading lights, and/or other accessories, which may add to the weight of the interior rearview mirror. These accessories increase the weight of the mirrors, such that the mirrors are not stable with a conventional double ball and socket-mounting bracket.
It is known to implement larger sized ball and socket joints to provide increased friction and thus greater stability between the ball and socket members of the mounting bracket. The larger ball further allows for a larger neck on the mounting bracket to increase bending inertia of the bracket. At the same time, however, it is preferred to minimize the size of the bracket components to enhance the appearance of the mirror assembly.
In order to provide a tight grip on the ball member, a spring or other biasing member may be implemented within a support arm of the mounting assembly in order to increase the gripping or clamping of the ball by the socket portion of the assembly. The spring is typically mounted and secured within the arm such that the spring exerts a force on the socket portion, which causes the socket to partially compress about the ball. A raised portion or ridge on the socket portion is provided which extends partially within the center of the spring, in order to properly align the spring within the mounting arm. The spring thus has to have a sufficient diameter to receive the raised portion within the coils of the spring.
These operational aspects of rearview mirror supports illustrated a need for supporting higher weight, added feature rearview mirrors while minimizing vibration, and for reducing functional problems in mirror supports such as misaligned springs, all while maintaining a pleasing overall appearance.
SUMMARY OF THE INVENTION
The present invention is intended to provide a mirror mounting assembly which pivotally mounts an interior rearview mirror to a mounting base positioned on the vehicle. Preferably, the mirror is mounted or connected to the mounting base via a dual ball and socket joint, at least one of which comprises a ball receiving cavity which pivotally receives a ball member therein. The ball receiving cavity maintains a secure grip on the ball member via a biasing member which is aligned and contained within a sleeve of the mounting assembly. The present invention is preferably implemented with an interior rearview mirror which comprises one or more electrical accessories and is thus of a greater weight than a standard mirror. For example, the mirror may weigh approximately 300 grams and may even weigh greater than approximately 500 grams.
According to a first aspect of the present invention, a support bracket for pivotally securing an accessory to a vehicle comprises a mounting base and a mounting arm. The mounting base is adapted for mounting to the vehicle. The mounting arm is pivotally securable to at least one of the mounting base and the accessory. The mounting arm comprises at least one ball receiving socket, a biasing member, an alignment element for aligning the biasing member. The alignment element comprises an outer confinement member which engages at least a portion of an outer surface of the biasing member. Preferably, the mounting arm further comprises a sleeve which at least partially encases the ball receiving socket and the biasing member. The ball receiving socket pivotally receives a ball member of one of the mounting base and the accessory. The confinement member extends at least partially along the biasing member to align the biasing member within the sleeve such that the biasing member biases the ball receiving socket toward the ball member, thereby pivotally securing the ball member therein.
Preferably, the confinement member comprises an annular ring. Preferably, the alignment element further comprises a substantially planar surface at a base of the confinement member, whereby an end of said biasing member engages the planar surface. Preferably, the sleeve is narrowed at an end corresponding to the ball receiving socket. The narrowed end is operable to clamp the ball receiving socket about the ball member in response to the biasing member biasing the socket toward the narrowed end of the sleeve. Preferably, a second ball member is rigidly secured at an end of the sleeve opposite the narrowed end. A base portion of the second ball member comprises the alignment element to align the biasing member between the ball receiving socket and the second ball member.
In one form, the biasing member is a coil spring which engages a planar, recessed region in the ball receiving socket. In another form, the biasing member is unitarily formed with the ball receiving socket and compressibly engages a recessed region at one of a ball receiving socket of the mounting arm, a ball member of the mounting arm, and the mirror itself.
According to another aspect of the present invention, a support bracket pivotally secures an accessory to the vehicle. The accessory has at least one electronic component which is electrically connected to a vehicle wiring via an accessory wiring. The support bracket comprises a mounting base and a mounting arm. The mounting base is adapted for mounting to the vehicle and comprises a first ball receiving socket. The mounting arm pivotally secures to the mounting base and to the accessory. The mounting arm comprises a first ball member for pivotally engaging the first ball receiving socket and a second ball member for pivotally engaging a second ball receiving socket on the accessory. The first ball member is positioned at an opposite end of the mounting arm from the second ball member. The mounting arm further comprises an outer sleeve which at least partially encases the mounting arm and the accessory wiring.
Therefore, the present invention provides a support assembly which provides pivotable mounting of an accessory or mirror relative to a mounting base. The alignment of the biasing member is maintained via at least one confinement member, such as an annular guide which extends along the arm of the support assembly, which substantially precludes lateral movement of the biasing member relative to the support assembly. A second ball member of the support assembly may be rigidly secured to the sleeve to further reduce vibration of the mirror. The first and second ball members may comprise the same sized ball or may have different diameter ball members. For example, the second ball member of the support assembly may have a greater diameter than the first ball member of the mounting base.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view looking forwardly in a vehicle of a rearview mirror mounting assembly in accordance with the present invention;
FIG. 2 is a sectional side view of the mounting assembly of FIG. 1 ;
FIG. 3A is a perspective view of a ball receiving socket showing the ball receiving portion of the socket;
FIG. 3B is a perspective view of the opposite end of the socket of FIG. 3A , showing the alignment ring and surface for the biasing member;
FIG. 4 is a sectional side view of an alternate embodiment of the present invention;
FIG. 5 is a sectional end view of the mounting arm, taken along the line V-V in FIG. 4 ;
FIG. 6 is a sectional side view of another alternate embodiment of the present invention wherein the ball receiving socket further comprises the biasing member;
FIG. 7 is a perspective view of the ball receiving socket shown in FIG. 6 ;
FIG. 8 is a sectional side view of another alternate embodiment of the present invention, wherein the mounting arm is fixedly secured to the interior rearview mirror;
FIG. 9 is a perspective exploded view of another alternate embodiment of the present invention;
FIG. 10 is a sectional end view of a mounting arm and plastic cover, taken along the line X-X in FIG. 9 ; and
FIG. 11 is a side elevation of another embodiment of the bracket assembly of FIG. 9 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now specifically to the drawings, and the illustrative embodiments depicted therein, an accessory or interior rearview mirror 10 is pivotally mounted to a mounting assembly 12 , which comprises a mounting arm 14 , which is pivotally mounted to a mirror mount or mounting base 16 ( FIG. 1 ). Mounting arm 14 of mounting assembly 12 preferably comprises a ball receiving member 20 , a biasing member 22 , a second ball member 24 and a sleeve member 26 which at least partially encases ball receiver 20 , biasing member 22 , and second ball member 24 ( FIG. 2 ). Preferably, biasing member 22 is positioned and aligned between ball receiver 20 and second ball member 24 and functions to bias ball receiver 20 outwardly from second ball member 24 and biasing member 22 , such that ball receiver 20 grips ball member 16 b , as discussed in detail below. Biasing member 22 is aligned longitudinally along sleeve 26 between ball member 24 and ball receiver 20 via a confining member, such as a raised annular ring 20 f , which is preferably at least partially cylindrical in section, and/or a corresponding confining member or annular ring 24 d , which extend longitudinally from a respective base or generally planar surface 20 e and/or 24 f at either or both of ball receiver 20 and/or ball member 24 , respectively, as discussed below.
The interior rearview mirror 10 may be a conventional electrochromic or prismatic day/night interior mirror and may comprise additional electronic components, such as map reading lights, a speaker and/or microphone, which may be in the mirror or within a module attached to the mirror or mounting arm as disclosed in commonly assigned U.S. patent application, Ser. No. 09/382,720, filed Aug. 25, 1999, now U.S. Pat. No. 6,243,003, an indicator for the microphone of the type disclosed in commonly assigned U.S. patent application, Ser. No. 09/396,179, filed Sep. 14, 1999, now U.S. Pat. No. 6,278,377, displays, such as of the type disclosed in commonly assigned U.S. patent application, Ser. No. 09/448,700, filed Nov. 24, 1999 by Timothy G. Skiver, Joseph P. McCaw, John T. Uken, and Jonathan E. DeLine for REARVIEW MIRROR ASSEMBLY WITH ADDED FEATURE MODULAR DISPLAY, now U.S. Pat. No. 6,329,925, communication systems, which may comprise a processing system of the type disclosed in commonly assigned U.S. patent application, Ser. No. 09/466,010, filed Dec. 17, 1999 by Jonathan E. DeLine, Niall R. Lynam, Ralph A. Spooner and Philip A. March for INTERIOR REARVIEW MIRROR SOUND PROCESSING SYSTEM, now U.S. Pat. No. 6,420,975, and/or the like, all of the disclosures of which are hereby incorporated herein by reference. Additionally, the interior rearview mirror may comprise storage capabilities, such as disclosed in commonly assigned U.S. patent application, Ser. No. 09/449,121, filed Nov. 24, 1999, now U.S. Pat. No. 6,428,172, and/or a compartment for electrical accessories, such as disclosed in commonly assigned U.S. patent application, Ser. No. 09/433,467, filed Nov. 4, 1999, now U.S. Pat. No. 6,326,613, and/or the like, the disclosures of which are hereby incorporated herein by reference. Because the rearview mirror may comprise one or more electrical accessories and may function to store other items, the mirror may have a greater weight than a standard prismatic mirror. Preferably, support assembly 12 supports an interior rearview mirror 10 weighing at least approximately 300 grams. More preferably, support assembly 12 supports an interior rearview mirror 10 which weighs at least approximately 400 grams and most preferably, at least approximately 500 grams.
The mount 16 may be secured, such as by an adhesive, to an interior surface 18 a of a vehicle windshield 18 ( FIG. 2 ) and may be a conventional mounting button, channel mount, a base member of the type disclosed in commonly assigned U.S. Pat. No. 4,936,533, issued to Adams et al., the disclosure of which is hereby incorporated herein by reference, or a breakaway mount of the type disclosed in commonly assigned U.S. Pat. No. 5,820,097, issued to Spooner, or U.S. Pat. No. 5,100,095, issued to Haan, et al., the disclosures of which are hereby incorporated herein by reference.
Preferably, as shown in FIG. 2 , mounting base 16 of mounting assembly 12 is secured to a mounting plate 16 a (commonly referred to in the art as a mirror mounting button), which is secured to interior surface 18 a of the windshield 18 . Mounting plate 16 a may be secured to the interior surface of the windshield, such as by an adhesive, or may be secured to a headliner or console (not shown) at or adjacent to an upper edge of the windshield, without affecting the scope of the present invention. Mounting base 16 preferably comprises a ball member 16 b formed at an end of a neck portion 16 c extending outwardly and rearwardly from a base portion 16 d of the mount 16 . Ball member 16 b and neck 16 c are preferably integrally formed with base 16 d and may comprise a metal, such as aluminum, such as A-380 aluminum, which may be powder painted to color match mount 16 with the trim and/or mirror housing of the vehicle. However, it is further envisioned that ball member 16 b may comprise an engineering polymer, such as a filled polymer, such as glass or mineral filled Nylon or the like, without affecting the scope of the present invention. Ball member 16 b is a generally spherical shaped ball for pivotal engagement with a correspondingly formed receiving socket on mounting arm 14 , as discussed below. Preferably, the ball 16 b and neck portion 16 c are partially hollowed or cored to reduce the mass of the mounting assembly 12 . Although not critical to the present invention, the mount 16 may be secured to the base portion 16 a via a set screw 16 e , as shown in FIG. 2 , or via any other known mounting means, and may be a breakaway mount or any other mount secured to a headliner or console of the vehicle, without affecting the scope of the present invention.
As shown in FIGS. 1 and 2 , sleeve 26 is a generally cylindrical member which extends between mount 16 and interior rearview mirror 10 . Preferably, sleeve 26 comprises a metal tubing, such as an aluminum tubing, such as aluminum 6061T9, which may be powder coated to match the color of the mount 16 and/or interior rearview mirror 10 and/or a desired vehicle interior or trim. However, other materials, such as an engineering polymer, such as a filled polymer, such as glass or mineral filled Nylon or the like, may be implemented without affecting the scope of the present invention. Sleeve 26 is generally hollow and comprises a cylindrical side wall 26 d which defines an inner surface 26 f and encases ball receiver 20 , biasing member 22 , and a portion of second ball member 24 , as discussed below. Sleeve 26 is preferably tapered or narrowed toward a forward end 26 a and further comprises an inwardly curved end 26 b , which is generally longitudinally opposite from tapered end 26 a . Inwardly turned end 26 b is sharply curved radially inwardly to form a generally annular ridge or ring 26 c , which closes a portion of the rearward end 26 b , such that the end 26 b has a smaller diameter opening than the cylindrical side walls 26 d of sleeve 26 .
As shown in FIGS. 2 , 3 A, and 3 B, ball receiver 20 preferably comprises a base portion 20 a and a ball receiving portion 20 b . Ball receiving portion 20 b comprises a cylindrical side wall 20 c and a partially spherical inner surface 20 d . Cylindrical side wall 20 c extends longitudinally outwardly from spherical surface 20 d of base portion 20 a , and defines a ball receiving cavity or socket for pivotally receiving ball member 16 b of mount 16 . Cylindrical side wall 20 c and base portion 20 a slidably engage inner surface 26 f of sleeve 26 as ball receiver 20 is moved by biasing member 22 . Preferably, ball receiving socket 20 comprises an elastomeric material, such as polypropylene or the like, such that cylindrical wall 20 c may flex radially inwardly as ball receiver 20 is moved longitudinally toward tapered end 26 a of sleeve 26 . Preferably, as best shown in FIG. 3A , cylindrical side wall 20 c further comprises a plurality of notches 20 g which extend longitudinally from a forward end 20 h of ball receiver 20 . Notches 20 g facilitate substantially uniform compression of forward end 20 h of ball receiver 20 as forward end 20 h is compressed radially inwardly by tapered end 26 a of sleeve 26 , in response to a biasing force exerted on ball receiver 20 toward tapered end 26 a by biasing member 22 . A circumferential groove or channel 20 j may be formed around an outer circumferential edge of partially spherical surface 20 d and radially inwardly of cylindrical side walls 20 c , to further facilitate inward bending of cylindrical walls 20 c as the walls 20 c engage tapered end 26 a of sleeve 26 .
Base portion 20 a of ball receiver 20 defines partial spherical surface 20 d at one end and further defines the means or element for aligning and guiding biasing member 22 at an end opposite the partial spherical surface 20 d . Base portion 20 a of ball receiver 20 comprises a substantially planar center region 20 e and a raised or longitudinally extending annular, cylindrical outer region 20 f . Raised annular outer portions 20 f form a cylindrical side wall or guide around an outer circumferential edge of planar surface 20 e , thereby defining a recessed, biasing member receiving portion of receiver 20 . A forward end 22 a of biasing member 22 is then received by the recessed portion and thereby aligned and secured within sleeve 26 by guide walls 20 f.
Second ball member 24 comprises a spherical shaped ball portion 24 a , a base portion 24 b , and a neck region 24 c extending between base portion 24 b and ball 24 a . Ball portion 24 a is positioned at an outer or rearward end of neck 24 c , which extends from base portion 24 b , such that ball 24 a and neck 24 c extend outwardly from end 26 b of sleeve 26 in a direction generally rearwardly with respect to the vehicle. Preferably, ball 24 a , neck 24 c and base 24 b are unitarily constructed and may be hollowed or cored in either direction to hollow out ball 24 a and neck 24 c to reduce the weight of the assembly. Ball member 24 may be substantially hollowed or cored from the forward end, as shown in FIG. 2 , or may be cored from the rearward end of ball 24 a , as shown in FIG. 6 . Preferably, ball member 24 comprises a metal, such as aluminum, such as a die cast aluminum, which may be powder painted to match the color with sleeve 26 and/or mount 16 and/or the vehicle interior. However, it is further envisioned that other materials, such as an engineering polymer, such as a filled polymer, such as glass or mineral filled Nylon or the like, may be implemented without affecting the scope of the present in invention.
Base portion 24 b is preferably correspondingly formed with inwardly curved end 26 b of sleeve 26 and is positioned within sleeve 26 such that an outer shoulder 24 e of base portion 24 b engages annular ring 26 c of sleeve 26 , thereby substantially precluding second ball member 24 from moving longitudinally outwardly from sleeve 26 . Preferably, ball member 24 is rigidly secured within sleeve 26 , such as by welding the shoulder portion 24 e to curved end 26 b of sleeve 26 , or by any other known means for securing the two components together. Alternately, the second ball member 24 may be unitarily formed with sleeve 26 , without affecting the scope of the present invention. Base portion 24 b of ball member 24 further comprises an outer confining member or annular ring 24 d which extends longitudinally within sleeve 26 along the cylindrical side walls 26 d , in a direction generally opposite from neck 24 c . Annular ring or wall 24 d defines and encircles a generally planar, annular ring or surface 24 f formed at base portion 24 b , such that a rearward end 22 b of biasing member 22 engages surface 24 f and is received within the recess formed by ring 24 d and planar surface 24 f . Although shown as an annular, ring shaped surface, planar surface 24 f may otherwise be a substantially continuous surface if ball member 24 is not cored or hollowed, or if ball member 24 is cored from the opposite end, such as is shown in FIG. 6 .
Biasing member 22 is preferably a coil spring, such as a steel spring having a spring rate of approximately 650 N/mm, although other materials and/or spring rates may be implemented without affecting the scope of the present invention. Biasing member 22 extends longitudinally within sleeve 26 and between the planar surfaces 20 e and 24 f of ball receiver 20 and ball member 24 , respectively. Biasing member 22 is secured and aligned between the two components by the annular rings 20 f and 24 d , which extend longitudinally toward one another from the respective components 20 and 24 . The annular flanges or walls 20 f and 24 d function to align and laterally confine biasing member 22 , such that opposite ends 22 a and 22 b of biasing member 22 engage the substantially planar surfaces 20 e and 24 f of ball receiver 20 and ball member 24 , respectively. Lateral or radial movement of biasing member 22 is thus substantially precluded by rings or walls 20 f and 24 d engaging an outer surface 22 d of biasing member 22 .
Accordingly, ball receiver 20 receives ball member 16 b of mount 16 , such that arm 14 is pivotally secured to mount 16 . Second ball member 24 likewise engages a correspondingly formed ball receiver or socket (not shown) of interior rearview mirror 10 , such that interior rearview mirror 10 is also pivotally mounted to mounting arm 14 of mounting assembly 12 . Biasing member 22 is partially compressed when mounting arm 12 is assembled and engaged with ball member 16 b of mount 16 , such that biasing member 22 exerts a force longitudinally along sleeve 26 toward ball receiver 20 . Because second ball member 24 is substantially fixed relative to sleeve 26 , rearward end 22 b of biasing member 22 is also substantially fixed relative to sleeve 26 . Cylindrical side walls 20 c of ball receiving portion 20 b are then forced inwardly at tapered end 26 a of sleeve 26 , such that ball receiver 20 grips ball member 16 b on mount 16 in response to the biasing force exerted by biasing member 22 . Further longitudinal movement of ball receiver 20 is limited as outer end 20 h of cylindrical wall 20 c becomes wedged between sleeve 26 and ball 16 b , since the diameter of ball 16 b and cylindrical wall 20 c is greater than the narrowed opening of narrowed end 26 a of sleeve 26 . The desired level of gripping of ball 16 b by socket 20 b may be attained by selecting an appropriate spring rate for biasing member 22 or by altering the coefficient of friction of ball receiver 20 .
Because arm 14 comprises a ball-in (ball receiver 20 of arm 14 receives ball member 16 b ) and a ball-out (ball member 24 extends outwardly from arm 14 ) mounting arrangement, mounting arm 14 provides a shorter overall length, such that the pivot joints of the mounting assembly 12 are closer to the main support or mount 16 , thereby reducing vibration of the mirror mount assembly. Furthermore, because ball member 24 is rigidly secured to or formed with the sleeve 26 of arm 14 , there is less vibration in the mounting arm assembly. Ball 24 a of ball member 24 may be the same size as ball 16 b of mount 16 , or may be of a greater diameter to enhance gripping within the corresponding receiving socket of the mirror, which further reduces vibration of the rearview mirror. Preferably, ball 24 a has a greater diameter than ball 16 b . More preferably, ball 24 a has a diameter which is greater than approximately 20 mm, such as approximately 22.4 mm, while ball 16 b has a diameter which is less than approximately 20 mm, such as approximately 15 mm. Alternatively, however, the ball 24 a of ball member 24 may have a smaller diameter than the ball 16 b of mount 16 , without affecting the scope of the present invention.
Additionally, the present invention allows a smaller diameter spring to be implemented between the ball member 24 and ball receiver 20 , while still maintaining proper alignment therebetween, since the longitudinally extending cylindrical side walls of ball receiver 20 and ball member 24 substantially preclude radial or lateral movement of biasing member 22 with respect to sleeve 26 . A center ridge or bump on the ball receiver and/or the ball member to insert within the spring is not necessary to align the spring within the mounting arm. This approach further allows for ball member 24 to be cored out from its rearward end, as shown in FIG. 6 , or its forward end, as shown in FIGS. 2 and 4 , while still providing proper alignment of biasing member 22 , all of which reduces weight and vibration in the assembly.
Referring now to FIGS. 4 and 5 , an alternate support bracket assembly 112 is shown, which comprises a mount 16 and an arm 114 . Mount 16 is substantially identical to mount 16 discussed above with respect to support assembly 12 , such that a detailed discussion of mount 16 will not be repeated herein. Arm 114 is likewise substantially similar to arm 14 , discussed above, in that it comprises a sleeve 126 , which substantially encases a ball receiving portion 20 , a biasing member 22 , and a second ball member 24 . Ball receiving portion 20 , biasing member 22 , and second ball member 24 are also substantially similar to the components discussed above with respect to support assembly 12 . Sleeve 126 is a generally cylindrical and hollow sleeve, which comprises a tapered or narrowed end 126 a and an inwardly curved end 126 b , similar to sleeve 26 discussed above. Likewise, tapered end 126 a functions to force the cylindrical wall portions 20 a of ball receiver 20 inwardly around ball member 16 b of mount 16 in order to enhance gripping of ball 16 b by receiver 20 and arm 14 , such that arm 114 may pivot relative to ball member 16 b , while ball member 16 b is substantially precluded from being removed from socket 20 and sleeve 126 . Inwardly curved end 126 b comprises an annular ridge or lip 126 c which engages an outer shoulder 24 e of second ball member 24 to substantially preclude longitudinally outward movement of second ball member 24 relative to sleeve 126 , similar to sleeve 26 and second ball member 24 , discussed above.
Sleeve 126 preferably includes one or more dimples or indentations 126 d , which are crimped inwardly to form bumps or ridges 126 e along an inward surface 126 f of sleeve 126 . Ridges 126 e are positioned immediately longitudinally inwardly from an innermost portion 24 g of cylindrical guide walls 24 e of ball member 24 . As shown in FIG. 5 , sleeve 126 may comprise multiple dimples 126 d which are spaced circumferentially around sleeve 126 . However, a single circumferential groove or indentation may extend around sleeve 126 and engage innermost surface 24 g of ball member 24 along its entire circumference, without affecting the scope of the present invention. As discussed above with respect to sleeve 26 , sleeve 126 preferably comprises a metal tubing, such as aluminum tubing, and may be powder coated to color match sleeve 126 with mount 16 and ball member 24 and/or the interior rearview mirror and/or the vehicle interior. However, other materials may be implemented, similar to sleeve 26 . The dimples may be die cast in sleeve 126 or may be crimped or otherwise formed therein. The lip 126 c and ridges 126 e function to rigidly secure or retain ball member 24 within sleeve 26 , thereby substantially precluding movement or vibration of ball 24 relative to sleeve 126 in either longitudinal direction. By reducing the possibility of relative movement between ball 24 and sleeve 126 , overall vibration of arm 114 and support assembly 112 is reduced.
Referring now to FIGS. 6 and 7 , an alternate embodiment 212 of the mirror support assembly of the present invention is shown which comprises a mounting member 16 and an arm 214 . Mounting member 16 is substantially identical to the mount 16 discussed above with respect to support assembly 12 such that a detailed description will not be repeated herein. Arm 214 comprises an outer sleeve 26 which at least partially encases a ball receiving socket 220 and a base portion 224 b of a second ball member 224 . Sleeve 26 is also substantially similar to sleeve 26 discussed above with respect to support assembly 12 . Second ball member 224 is likewise similar to ball member 24 and comprises a partial spherical member 224 a , a base region 224 b and a neck region 224 c extending between base region 224 b and spherical portion 224 a . Spherical portion 224 a may be approximately the same size as ball 16 b on mount 16 or may have a greater diameter than ball 16 b , as discussed above with respect to ball 24 b and ball 16 b of support assembly 12 .
Ball member 224 may be cored or hollowed from either end to reduce the weight of the assembly, similar to ball 24 discussed above. Preferably, ball member 224 is cored from an outer or rearward end, as shown in FIG. 6 , such that base portion 224 b defines a continuous, substantially planar surface 224 f at its forward end. Base portion 224 b comprises a cylindrical side wall or annular guide 224 e which extends longitudinally inwardly along an inner surface 26 f of sleeve 26 . A substantially flat base surface 224 f is formed along an inner surface of base portion 224 b and is substantially encircled by cylindrical side walls 224 e . As discussed above with respect to ball member 24 and sleeve 26 of support assembly 12 , base portion 224 b is formed to engage an annular ring 26 c formed by inwardly curved portions 26 b of sleeve 26 , thereby substantially precluding longitudinal movement of ball 224 outwardly with respect to sleeve 26 . Outer shoulders 224 d of base portion 224 b may be welded to sleeve 26 , such as by a rough texture in die cast using a spin weld or lathe type process, or may be otherwise secured to inwardly turned portions 26 b of sleeve 26 .
Ball receiving member 220 comprises a ball receiving portion 220 b and a biasing member portion 222 . Ball receiving portion 220 b comprises cylindrical side walls 220 c , which may further comprise notches 220 g at an outer end 220 h thereof, and a base portion 220 a , which further defines a partially spherical surface 220 d within cylindrical walls 220 c . An annular groove or channel 220 j is formed around an outer edge of partially spherical surface 220 d and immediately radially inwardly of cylindrical side walls 220 c , to facilitate inwardly bending of cylindrical walls 220 c as the walls 220 c engage tapered end 26 a of sleeve 26 , similar to that discussed above with respect to support assembly 12 .
Biasing member 222 is preferably unitarily formed with ball receiving portion 220 b of ball receiver 220 and extends longitudinally from base portion 220 a such that a forward end 222 a of biasing member 222 is integrally formed with base portion 220 a of ball receiver 220 . Preferably, biasing member 222 is generally cylindrical and comprises an outer cylindrical wall 222 c and a substantially flat or planar end surface 222 b at an end of biasing member 222 opposite or rearwardly from base end 222 a . Preferably, ball receiver 220 , and thus biasing member 222 comprise an elastomer material which preferably has a spring rate of approximately 50 N/mm to 120 N/mm.
As assembled, ball receiver 220 is substantially encased by sleeve 26 , as shown in FIG. 6 . Biasing member 222 has a longitudinal length such that planar surface 222 b engages flat planar surface 224 f of ball member 224 within guide walls 224 e . As assembled, biasing member 222 of ball receiver 220 is compressed such that biasing member 222 exerts a longitudinal force against base portion 220 a . Tapered ends 26 a of sleeve 26 prevent further longitudinally outward movement of ball receiver 220 , since outer ends 220 h of cylindrical side walls 220 c become wedged between spherical ball member 16 b and tapered end 26 a of sleeve 26 . Annular guide 224 e engages outer cylindrical surface 222 c of biasing member 222 and functions to properly align and retain biasing member 222 , such that planar surface 222 b of biasing member 222 remains substantially centered on base surface 224 f of ball member 224 .
Referring now to FIG. 8 , an interior rearview mirror 310 comprises a mounting arm 314 which extends from a back surface 310 a of interior rearview mirror 310 in a direction generally forwardly with respect to the vehicle. Mounting arm 314 comprises a substantially cylindrical sleeve portion 326 extending from back surface 310 a of interior rearview mirror 310 . Sleeve portion 326 is preferably fixedly secured to back 310 a of interior rearview mirror 310 and may be unitarily formed with the mirror housing or casing. Sleeve portion 326 comprises an inwardly tapered or narrowed end 326 a at an outer end opposite interior rearview mirror 310 . A ball receiving socket 320 is positioned within sleeve 326 and is substantially similar to ball receiver 20 , discussed above with respect to support assembly 12 . A partial spherical surface 320 b and a cylindrical side wall 320 c receive a ball member 16 b of a mount 16 , which is substantially similar to mount 16 discussed above and is mounted to an interior surface 18 a of windshield 18 in a known manner. A circumferential notch or channel 320 j is formed between spherical surface 320 d and walls 320 c to facilitate radially inward flexing of walls 320 c relative to partial spherical surface 320 d . Tapered end 326 a of sleeve 326 functions to force an outer end 320 h of cylindrical wall 320 c inward around ball member 16 b , such that ball member 16 b is pivotally secured within ball receiver 320 and sleeve 326 . Mirror assembly 310 is thus pivotally mounted to mount 16 via a single pivot joint.
Ball receiver 320 further comprises a flat or planar surface 320 e on a base portion 320 a and generally opposite partial spherical surface 320 d . A cylindrical, annular wall or guide portion 320 f extends longitudinally inwardly toward interior rearview mirror 310 around a circumferential outer edge of planar surface 320 e . Mirror assembly 310 further comprises a cylindrical cavity or recess 310 b which extends inwardly into interior rearview mirror 310 or generally rearwardly with respect to the vehicle. Cylindrical cavity 310 b is defined by a cylindrical side wall 310 c and an inner, substantially flat or planar end surface 310 d within interior rearview mirror 310 . Cylindrical cavity 310 b is generally centered with respect to sleeve 326 , such that cylindrical cavity 310 b is generally aligned with annular guide portions 320 f of ball receiver 320 .
A biasing member 322 , such as a coiled spring or the like, is positionable between planar surface 320 e of ball receiver 320 and planar surface 310 d of interior rearview mirror 310 . Biasing member 322 is guided and aligned between ball receiver 320 and interior rearview mirror 310 via the cylindrical side walls 310 c of cavity 310 b and guide walls 320 f of ball receiver 320 . As discussed above with respect to biasing member 22 , biasing member 322 exerts a force on ball receiver 320 to press ball receiver 320 longitudinally along sleeve 326 such that cylindrical walls 320 c of ball receiver 320 are pressed radially inwardly around spherical member 16 b of mount 16 , as ball receiver 320 is moved toward and engages tapered end 326 a of sleeve 326 , thereby facilitating pivotal engagement of connecting arm 314 on mount 16 , while substantially precluding removal of ball 16 b from sleeve 326 . Although shown as a coil spring, biasing member may be any other known means for exerting a biasing force on socket 320 , and may be integrally formed therewith, similar to biasing member 222 and socket 220 , discussed above, without affecting the scope of the present invention. End 326 a may be formed into the tapered or narrowed end after insertion of biasing member 322 , ball receiving socket 320 , and ball member 16 b into cavity or recess 310 b.
Therefore, the present invention provides an interior rearview mirror support assembly which may be pivotally attached to a ball mount at a windshield or headliner or console of the vehicle. The support assembly may provide one or more pivotable ball and socket joints which facilitate pivotal movement of an accessory, such as an interior rearview mirror, relative to the substantially fixed ball mount on the window or headliner of the vehicle. A biasing member is positioned within a portion of the mounting assembly to maintain a tight grip on the ball member of the mount, while allowing rotational movement between the ball mount and a ball receiver within the support assembly. The biasing member is maintained in alignment with the ball receiver via at least one annular, cylindrical guide wall extending longitudinally along a portion of the support assembly. The guide wall substantially precludes lateral movement of the biasing member to maintain the biasing member in a proper orientation with respect to the ball receiver and support assembly, such that the force exerted by the biasing member on the ball receiver remains in substantially the same direction and is substantially constant to provide a substantially constant gripping force of the ball mount by the ball receiver. The present invention further provides reduced vibration in the interior rearview mirror due to the rigid connection of the mirror ball member with the arm or sleeve and the substantially uniform engagement of the ball mount via the aligned biasing member and the cylindrical walls of the ball receiver.
Referring now to FIGS. 9-11 , an alternate embodiment 400 is disclosed which comprises a mount 416 and a mounting arm 414 , which pivotally connects to the mount 416 at one end and to an interior rearview mirror at an opposite end. The interior rearview mirror may comprise one or more electronic components, such that a mirror wiring harness or the like (not shown) may be routed to the mirror to provide power and/or control of the electronic accessories via a vehicle wiring harness at the headliner of the vehicle. Mount 416 is preferably a breakaway mount, such as disclosed in commonly assigned U.S. Pat. No. 5,820,097, issued to Spooner, the disclosure of which is hereby incorporated herein by reference, but may be other button or channel mounts, without affecting the scope of the present invention.
Mount 416 preferably comprises a breakaway resilient retainer 416 a , which is adapted to engage a button (not shown) secured to the windshield. Retainer 416 a comprises a plurality of mounting flanges 416 b for removably securing the retainer to the button, and a ball receiving socket 416 c for pivotally receiving a ball member therein, as discussed below. Mount 416 further comprises a casing 416 d which is mountable on retainer 416 a to cover the retainer and provide a finished appearance to the mount 416 . Preferably the cover 416 d comprises a molded polymeric, plastic material, which may further include a channel 416 e for a mirror wiring (not shown) to be routed and secured therethrough.
Mounting arm 414 is preferably a double ball arm, which comprises a central shaft portion 414 a and opposite ball members 414 b and 414 c . Ball members 414 b and 414 c are attached to respective neck portions 414 d and 414 e at opposite ends of shaft portion 414 a . A first ball member 414 b is pivotally connectable to ball receiving socket 416 c of mount 416 , while the second ball member 414 c is pivotally secured within a ball receiving socket of the interior rearview mirror (not shown). A socket such as that shown in embodiment 310 would be suitable. Mounting arm 414 further comprises a cover member 415 , which substantially encases shaft portion 414 a of arm 414 . Preferably, as shown in FIG. 10 , cover member 415 is slotted along its entire length to facilitate expansion of the slot or opening 415 e for insertion of shaft 414 a therewithin. Cover member 415 is biased to return to its closed position to secure shaft 414 a within cover member 415 . Cover member 415 preferably comprises a plastic material, such as polypropylene, EPDM, or the like, and is preferably moldable in a desired color to match the interior rearview mirror or interior color scheme or trim of the vehicle. As shown in FIG. 10 , cover member 415 has a generally circular cross-section, which defines a generally circular passageway 415 a extending therealong. A channel or groove 415 b is also provided along passageway 415 a to provide a passageway for the mirror wiring harness between the wiring channel 416 e of mount 416 and the interior rearview mirror.
It is further envisioned that cover member 415 may further comprise a recess 415 c and a slotted cover plate 416 d which covers or encloses recess 415 c . Recess 415 c may contain scented inserts or the like, for providing an air freshener in the vehicle, which would not be visible to an occupant of the vehicle. Additionally, recess 415 c may be positioned substantially adjacent to wiring groove or channel 415 b , such that the scented inserts may be of the type whereby performance is enhanced through heating, with the heat being provided by the resistance in the wiring when one or more of accessories associated with mounting arm 414 is in use.
Referring now to FIG. 11 , an alternate embodiment of the invention comprises a mounting base 516 , a mounting arm 514 and an accessory such as an interior rearview mirror 510 . The interior rearview mirror may comprise one or more electronic accessories, such that a mirror wiring 511 is connectable between interior rearview mirror 510 and a vehicle wiring harness or wiring (not shown). Mount 516 is mountable to an interior surface of the windshield and comprises a mounting button or the like 516 a and a ball receiving mounting retainer 516 b , which is mountable to button 516 a to secure mount 516 to the windshield or the like. Retainer 516 b preferably comprises a ball receiving socket 516 c for receiving a ball member, as discussed below. Preferably, a wiring passageway 516 d is provided in retainer 516 b to facilitate routing of the mirror wiring through the retainer and into ball receiving socket 516 c . Preferably, retainer 516 b further comprises a cover to provide a finished appearance to the mount 516 . The cover preferably comprises a plastic material, which may be molded in color to match the color of the trim or accessories of the vehicle.
Mounting arm 514 is preferably a double ball mounting arm, which comprises a central shaft portion 514 a and a ball member 514 b and 514 c positioned at opposite ends of the shaft portion 514 a . A passageway 514 d is provided through mounting arm 514 , preferably through a center portion of ball members 514 b and 514 c and shaft portion 514 a , for receiving and routing the mirror wiring 511 from passageway 516 d of mount 516 to a corresponding passageway 510 a of interior rearview mirror 510 . Mirror assembly 510 comprises a ball receiving socket 510 b for receiving ball member 514 c of arm 514 and a wiring passageway 510 b for receiving the mirror wiring from passageway 514 d and arm 514 . Ball receiving socket 516 c of mount 516 likewise receives ball member 514 b of arm 514 , such that the wiring which is routed through passageway 516 d in mount 516 is further routed through passageway 514 d of arm 514 and into passageway 510 b of interior rearview mirror 510 . Preferably, passageway 514 d is flared outwardly at either end to facilitate movement of the mirror wiring as one or both ball members are pivoted within their respective sockets, thereby substantially reducing the possibility of cutting or damaging the wiring as the mirror and/or arm 514 are pivoted relative to the mount 516 .
Changes and modifications in the specifically described embodiments can be carried out without departing from the principles of the invention, which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law.
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An interior rearview mirror assembly for a vehicle includes a mirror head, a mounting base, a support arm and a cover element. The mirror head includes a reflective element and at least one electronic component which is electrically connected to a power source of the vehicle via wiring. The support arm has an elongated shaft portion, a first end and a second end opposite said first end. The mirror head is pivotable about the first end via a first ball and socket joint, and the second end is pivotable about the mounting base via a second ball and socket joint. The wiring is disposed between an outer surface of the shaft portion and the cover element. The cover element attaches to the shaft portion such that the wiring is routed at least partially along the outer surface and is at least partially hidden from view by the cover element.
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RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent App. Nos. 62/145,455 and 62/145,460, both filed Apr. 9, 2015, which are herein incorporated by reference for all purposes.
FIELD OF THE INVENTION
[0002] This invention relates generally to door latching assemblies, and more particularly, to door latching assemblies that use a motorized lock mechanism to lock a door handle and prevent it from rotating.
BACKGROUND
[0003] There are many factors and constraints that influence designs of lock and trim assemblies, including the number of lock functions supported, the strength of the lock, the ability of the lock to thwart an attack, and the cost of manufacture. Each design constraint compounds the complexity of such a design, because attempting to accommodate a given design constraint may restrict one's ability to accommodate a different design constraint. Because not all designs are equally effective or practical, and because changing circumstances continually give rise to new design constraints, there is always a need for innovation.
[0004] For example, lock and trim assemblies that utilize a door lever commonly engage the spindle directly to the door handle, relying on a stop mechanism to prevent the lever and spindle from rotating. In many such assemblies, it is possible to defeat the stop mechanism by applying a crowbar or long wrench to the lever, shearing off components of the stop mechanism. Therefore, it is advantageous for a lock and trim assembly to be designed in a manner that thwarts such an attack.
[0005] As another example, many lock mechanisms require a door handle to be in a neutral, non-latch-retracting position in order to lock the handle. It is therefore advantageous for the trim assembly to incorporate a return spring to bias the handle back to the neutral position and an escapement spring to engage the lock when the handle returns to the neutral position.
[0006] Moreover, when choosing a replacement trim assembly for a door, it is important to find a trim assembly that is compatible with the spindle and possibly other elements of the interior latching assembly, that matches the door function (e.g., is it an interior door or an exit door), that is compatible with the handedness of the door, that matches the physical dimensions and relative placement of the mortise and/or bore cylinder, and that matches the physical arrangement of trim mounting holes.
[0007] Most trim assemblies, however, are only suitable for a specific type or make of lock. It would be advantageous to have a universal trim assembly that, with minimal substitution or rearrangement of parts, accommodates a wide variety of types and makes of locks, as well as a wide variety of lock functions. However, the design of such an assembly is complicated by the typically tight spacing of trim assembly components. For example, a rearrangement of the trim mounting posts may require a rearrangement of other trim assembly components.
[0008] The present invention described below can be characterized in many different ways, not all of which are limited by its capacity to address the above-mentioned issues, needs or design constraints.
SUMMARY
[0009] The present invention is directed to a lock trim assembly that incorporates an electric motor and an escapement assembly to operate a lock. The door trim assembly comprises a driver assembly operated by the motor, an escapement assembly, comprising a control member and an escapement spring, operated by the driver assembly, and a coupling assembly for coupling a door handle to a latch-retracting spindle. The escapement assembly is movable between a locking position that blocks rotation of the spindle and an unlocking position that does not block rotation of the spindle. The coupling assembly alternates between a default orientation and a blocking orientation, wherein the default orientation allows the escapement assembly to move into the locking position and the blocking orientation blocks the escapement assembly from moving into the locking position. When the coupling assembly is in the default orientation, the motor is operable to move the escapement assembly between the unlocking position and the locking position. When the coupling assembly is in the blocking orientation, operation of the motor to drive the blocked escapement assembly into the locking position causes the escapement assembly to store energy in the escapement spring for forcing the escapement assembly into the locking position once the coupling assembly is reoriented back to the default orientation.
[0010] The lock trim assembly also preferably incorporates a handle-to-spindle coupling assembly designed to thwart a torque attack on a door lever. Furthermore, the motor and escapement assembly are preferably arranged in a trim assembly that is adaptable to a variety of different doors, latching assemblies, and trim preparations.
[0011] These and other aspects and advantages of the embodiments disclosed herein will become apparent in connection with the drawings and detailed disclosure that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an exploded view diagram of one embodiment of a trim assembly according to the present invention.
[0013] FIG. 2A is a perspective view of the trim assembly of FIG. 1 , in assembled form.
[0014] FIG. 2B is a perspective view of an alternative embodiment of an assembled trim assembly.
[0015] FIG. 2C is a perspective view of another alternative embodiment of an assembled trim assembly.
[0016] FIG. 2D is a perspective view of yet another alternative embodiment of an assembled trim assembly.
[0017] FIG. 3 is an exploded view diagram of the motorized lock and escapement mechanism of FIG. 1 .
[0018] FIG. 4 is a perspective view of the trim assembly of FIG. 2A , with portions of the back plate assembly removed to reveal the inner workings of the trim assembly when in a locked configuration.
[0019] FIG. 5 is like FIG. 4 , showing the trim assembly in an unlocked position.
[0020] FIG. 6 is a plan view of the trim assembly showing the trim assembly in a locked position.
[0021] FIG. 7 is a cross-section view of the trim assembly cut along line A-A of FIG. 6 , with the trim assembly in a locked position.
[0022] FIG. 8 is another cross-section view of the trim assembly cut along line A-A of FIG. 6 , with the trim assembly in an unlocked position.
[0023] FIG. 9 is a perspective view, from a left side, spindle aspect viewpoint, of the inner workings of the trim assembly when in a locked position.
[0024] FIG. 10 is a perspective view, from a right side, spindle aspect viewpoint, of the inner workings of the trim assembly when in a locked position.
[0025] FIG. 11 is a perspective view, from a left side, handle aspect viewpoint, of the inner workings of the trim assembly when in a locked position.
[0026] FIG. 12 is a perspective view, from a left side, spindle aspect viewpoint, of the inner workings of the trim assembly when in an unlocked position.
[0027] FIG. 13 is a perspective view, from a left side, spindle aspect viewpoint, of the inner workings of the trim assembly when in an unlocked position.
[0028] FIG. 14 is a perspective view, from a left side, handle aspect viewpoint, of the inner workings of the trim assembly when in an unlocked position.
[0029] FIG. 15 is a perspective view, from a left side, spindle aspect viewpoint, of the inner workings of the trim assembly when in an escapement condition.
[0030] FIG. 16 is a perspective view, from a left side, spindle aspect viewpoint, of the inner workings of the trim assembly when in an escapement condition.
[0031] FIG. 17 is a perspective view, from a left side, handle aspect viewpoint, of the inner workings of the trim assembly when in an escapement condition.
[0032] FIG. 18 is a perspective view of the trim assembly when in an escapement condition, with the control member marked in dashed lines to reveal the spread-apart legs of the escapement spring.
[0033] FIG. 19 is a plan view of an alternative embodiment of the trim assembly, with portions of the back plate assembly removed to reveal the inner workings of the trim assembly when in a locked configuration.
[0034] FIG. 20 is another plan view of the alternative embodiment of FIG. 19 , showing the trim assembly in an unlocked configuration.
[0035] FIG. 21 is another plan view of the alternative embodiment of FIG. 19 , showing the trim assembly in an escapement condition.
[0036] These and other aspects and advantages of the embodiments disclosed herein will become apparent in connection with the drawings and detailed disclosure that follows.
DETAILED DESCRIPTION
[0037] FIGS. 1-21 illustrate various embodiments of a trim assembly 10 . In describing preferred and alternate embodiments of the technology described herein, as illustrated in FIGS. 1-21 , specific terminology is employed for the sake of clarity. The invention is not intended to be limited to the specific terminology so selected, but rather to be construed liberally in the context of this specification. The invention described herein, moreover, should be understood to incorporate all technical equivalents that operate in a similar manner to accomplish similar functions.
[0038] The trim assembly 10 comprises a coupling assembly 25 —for example, a handle coupler 20 and spindle driver 30 —that transfers load from a door handle 18 to a spindle 36 . The trim assembly 10 also comprises a return spring 19 and a stopper or locking dog 50 operative to selectively lock the coupling assembly 25 , preventing it from rotating to retract the door latch (not shown). The trim assembly 10 also comprises a motor 11 , a transmission or driver assembly 60 , and an escapement assembly 70 that together operate the stopper 50 . The spindle 36 extends into a door cavity that houses a latch assembly (not shown), for example, a cylindrical trim assembly or a mortise trim assembly. Rotation of the spindle 36 is operative to retract the latch (not shown).
[0039] The trim assembly 10 also comprises an escutcheon 14 and a back plate assembly 15 that is mounted to the face of the door. The motor 11 , driver assembly 60 , escapement assembly 70 , handle coupler 20 , and most of the spindle driver 30 are contained between the escutcheon 14 and the back plate assembly 15 . The handle coupler 20 is configured to be coupled to and rotated with a door handle/lever 18 . A return spring 19 biases the handle 18 toward a neutral, non-latch retracting orientation. In one embodiment, the handle 18 can be operated in either direction from the neutral, non-latch retracting orientation to retract the latch. The trim assembly 10 may also provide collars or flanged parts 94 and 95 to adapt the trim assembly 10 to particular door widths.
[0040] As best illustrated in FIG. 3 , the handle coupler 20 comprises a disk or flange 22 mounted for coaxial rotation with the handle 18 , a slot 24 for receiving a stopper 50 , and fins 28 on either side of the slot 24 . The handle coupler 20 further comprises bent-up tabs 26 that fit into corresponding notches 38 of the spindle driver 30 to detachably couple the handle coupler 20 to the spindle driver 30 . The handle coupler 20 also comprises a bridge 23 that fits into the broach 17 of the handle 18 . The spindle 36 does not go into the broach 17 . Therefore, subjecting the handle 18 to an overtorquing attack shears the bridge 23 without turning the spindle 36 .
[0041] The handle coupler 20 also comprises a spring leg bracket 21 for mounting opposite legs of a return spring 19 . Rotation of the handle coupler 20 pulls and/or pushes the legs of the return spring 19 apart, biasing the handle 18 back toward a neutral, non-latch-retracting position.
[0042] Like the handle coupler 20 , the spindle driver 30 also has a slot 34 for receiving a stopper 50 , although in alternative embodiments, only one of the handle coupler 20 and spindle driver 30 have a slot 24 or 34 for receiving a stopper 50 .
[0043] Advantageously, the use of the spindle driver 30 in conjunction with the handle coupler 20 not only thwarts overtorquing attacks, but also enables the trim assembly 10 to be adapted to a variety of different spindles with minimal substitution of parts. The spindle driver 30 's eight-pronged opening 39 accommodates both spindles 36 that are square and spindles 36 that are diagonally oriented (as shown, for example, by the Corbin spindle in FIG. 2C ) when in the neutral, non-latch-retracting position. If the internal latching assembly has a larger or smaller spindle diameter, the trim assembly 10 can be adapted to the spindle 36 simply by swapping out the spindle driver 36 for one with an appropriate-sized spindle aperture.
[0044] The motor 11 is mounted to the escutcheon 14 and includes an upper face or bracket 12 and a shaft 13 . The shaft 13 is oriented perpendicular to the spindle 36 . The driver assembly 60 is mounted on the motor 11 and operative to rotate an eccentrically-positioned offset pin 79 (or, alternatively, a cam) between an engage-lock position and a disengage-lock position.
[0045] The driver assembly 60 comprises a slip clutch 62 mounted on the motor 11 and a carousel 76 mounted on the slip clutch 62 for rotational movement with the shaft 13 . The carousel 76 rotates the eccentrically-located offset pin 79 .
[0046] The escapement assembly 70 comprises a control member 85 and an escapement spring 72 . In FIGS. 1-18 , the control member 85 is a pivot arm mounted to the escutcheon 14 to pivot about an axis 86 parallel to a spindle axis between locking and unlocking positions. In FIGS. 19-21 , the control member 85 is a slider that slides vertically between locking and unlocking positions. (Note that for clarity, structure constraining the slider's movement is not shown in FIGS. 19-21 ).
[0047] The control member 85 either has a pivot member or post 84 ( FIGS. 19-21 ) upon which the coiled core 75 of the escapement spring 72 is mounted, or an aperture 91 ( FIGS. 1-18 ) for receiving a spring pivot (not shown). The coiled core 75 of the escapement spring 72 is mounted to the control member 85 via the post 84 or inserted spring pivot. The control member 85 also has a spring leg anchor or abutment 87 . The legs 73 , 74 of the escapement spring 72 straddle the spring leg anchor 87 . In FIGS. 1-18 , the spring anchor 87 is configured as a wedge 87 that has a lower face 88 and a ramped upper face 89 with a wedge angle that matches the angle between the first and second spring legs 73 , 74 ( FIG. 17 ). In FIGS. 19-21 , the spring anchor 87 is configured as a post. In both embodiments, the first and second spring legs 73 , 74 straddle and grasp a wedge-shaped abutment 87 of the control member 85 . And in FIGS. 1-18 , the spring leg anchor 87 also provides an abutment that acts as a stop to constrain rotation of the offset pin 79 between two rotational limits.
[0048] The escapement spring 72 is a helical torsion spring with a coiled core 75 , an axis 86 parallel to the spindle's axis, and two legs 73 , 74 . Each leg has an elongated radially extending portion 73 a, 74 a and an axially extending portion 73 b, 74 b ( FIG. 3 ). In FIGS. 1-18 , the spring 72 is mounted to the control member 85 by forcing the legs 73 , 74 to intersect each other and straddle the spring leg anchor 87 . In FIGS. 19-21 , the legs of the escapement spring 72 do not intersect.
[0049] The axially extending portions 73 b, 74 b of the first and second spring legs 73 , 74 extend beyond the spring leg anchor 87 into positions above and below the offset pin 79 . If non-alignment of the spindle driver slot 34 and/or handle coupler slot 24 blocks the stopper 50 from engaging the spindle driver slot 34 and/or handle coupler slot 24 , rotation of the offset pin 79 into an engage-lock position forces the lower spring leg 73 downward and away from the lower face or edge 88 of the spring leg anchor 87 , as illustrated in FIGS. 15-18 and 21 . This spreads the spring legs 73 , 74 apart, winding the coiled core of the escapement spring 72 and storing energy. (Note that in the non-intersecting spring leg embodiment of FIGS. 19-21 , the spring is wound oppositely of the embodiment of FIGS. 1-18 ). Assuming that the carousel 76 is maintained in the same position, realignment of the spindle driver 30 and handle coupler 20 allows the spring 72 to release the stored energy by driving the upper spring leg 74 and control member 85 in a downward direction, until the stopper 50 is engaged with the spindle driver slot 34 , as illustrated in FIGS. 9-11 .
[0050] In FIGS. 1-18 , a hanger 86 projects out from the control member 85 . The hanger is configured to fit in a slot 51 of the stopper 50 in order to carry the stopper 50 between locked and unlocked positions. In FIGS. 19-21 , the stopper 50 is rigidly coupled to, or simply an extension of, the control member 85 . In both embodiments, the stopper 50 is operative for radial movement between a locked configuration that blocks the spindle driver 30 and/or handle coupler 20 from rotating and an unlocked configuration in which the spindle driver 30 and handle coupler 20 are free to rotate. In a locked configuration, the stopper 50 engages the spindle driver slot 34 and/or handle coupler slot 24 , blocking the spindle driver 30 from rotating.
[0051] The offset pin 76 , control member 85 , and escapement spring 72 are respectively arranged so that rotation of the offset pin 79 between its rotational limits biases the control member 85 to travel between its locking position ( FIGS. 9-11, 19 ) and its unlocking position ( FIGS. 12-14, 20 ). They are also arranged so that the offset pin 79 is in contact with and operative to push the second leg 73 of the escapement spring 72 away from the first leg 74 of the spring 72 , thereby biasing the control member 85 toward the locking position. If the spindle driver slot 34 and/or handle coupler slot 24 are not aligned with the stopper 50 , then one of the fins 28 of the handle coupler 20 blocks the stopper 50 from descending into a locking position. Rotating the offset pin 79 into the engage-lock position results in a first escapement condition, described further below, in which the offset pin 79 pushes the second leg 73 of the escapement spring 72 away from the first leg 73 , as shown in FIGS. 15-18 and 21 . The stored energy of the spring 72 biases the control member 85 toward the locking position. If the spindle driver 30 rotates from a position in which the slot 24 and/or 34 is/are not aligned with the stopper 50 to a position in which the slot 24 and/or 34 is/are aligned with the stopper 30 , the biasing of the escapement spring 72 pushes the stopper 50 into the slot 24 and/or 34 .
[0052] The escapement assembly 70 is operative under a non-escapement condition and at least a first escapement condition. The first escapement condition is characterized by an attempt to lock the door when the stopper 50 is not aligned with the spindle driver slot 34 and/or handle coupler slot 24 . Until alignment is restored, the stopper 50 is blocked from extending into the slot 24 and/or 34 .
[0053] Movement of the handle 18 and handle coupler 20 into a neutral, non-latch-retracting position lines the stopper 50 up with the handle coupler slot 24 . Once aligned, the stored energy of the escapement spring 72 rotates the control member 85 down, extending the stopper 50 into the slot 24 and/or 34 , thus locking the handle 18 in a non-latch-retracting position.
[0054] A second escapement condition is characterized by an attempt to unlock the door while the locked lever arm 18 is being pushed on. The asymmetry of the load exerted on the stopper 50 may have a binding effect, preventing the stopper 50 from retracting out of the slot 24 and/or 34 . Under this condition, rotation of the offset pin 79 into a disengage-lock position will push the upper leg 74 of the escapement spring 72 upward and away from the ramped upper surface 89 of the spring anchor 87 , again winding up and storing energy in the spring 72 . Once pressure is released from the lever arm 18 , thereby removing the binding effect, the spring 72 forces the control member 85 up, retracting the stopper 50 away from the slot 24 and/or 34 .
[0055] In the non-escapement condition, by contrast, the spring anchor 87 stays in substantial alignment with the offset pin 79 as the offset pin 79 rotates between engage-lock and disengage-lock positions.
[0056] In either escapement condition, the control member 85 is blocked from rotating, thereby impeding movement of one of the legs 73 , 74 of the escapement spring 72 . Operation of the motor 11 in either escapement condition causes the pin 79 to spread the axially extending portions 73 b, 74 b of the legs 73 , 74 apart, winding up and storing energy in the escapement spring 72 . Once the stopper 50 is free to travel between locked and unlocked positions, the stored-up energy of the wound-up escapement spring 72 is released into control member 85 , causing the control member 85 to rotate until the spring legs 73 and 74 reach their minimum-energy condition, in which they are once again grasping the spring anchor 87 .
[0057] The driver assembly 60 optionally comprises a slip clutch 62 mounted to the motor 11 . The slip clutch 62 —which, in one embodiment, comprises an over-torque clutch—comprises a keyhole for receiving the motor shaft 13 , a stationary portion mounted to the motor bracket 12 , and a carousel 65 driven within torque limits by the motor shaft 13 . Carousel couplers 66 couple the carousel 65 to the pin carrier 76 for synchronized rotation therewith. In another embodiment, the motor 11 is directly connected to the pin carrier 76 .
[0058] Advantageously, the back plate assembly 15 allows trim mounting posts 99 to be mounted to the trim assembly 10 in a variety of arrangements, to accommodate a variety of existing borehole and trim mounting hole arrangements, without interfering with the motor 11 , driver assembly 60 , and escapement assembly 70 . In the embodiment shown, the back plate assembly 15 comprises an upper plate or deadbolt plate 96 , a mid plate 93 positioned over the motor 11 , driver assembly 60 , and escapement assembly 70 , and a bottom plate or spindle plate 97 . Posts 99 can be mounted to the plates 93 , 96 , and 97 wherever necessary to adapt the trim assembly to any of a variety of configurations of trim mounting holes on an existing door. In FIG. 2A , for example, two posts 99 are positioned at relative 4:30 and 10:30 o'clock positions on the spindle plate 97 . In FIG. 2B , two posts 99 are positioned at relative 1:30 and 7:30 o'clock positions on the spindle plate 97 . And in FIG. 2D , which depicts a trim assembly 10 for an exit door, a single post 99 is positioned at the 6:00 o'clock position on the spindle plate 97 . Also, the deadbolt plate 96 provides an elongated aperture 69 for receiving a deadbolt assembly. This accommodates variable spacing that may exist in existing doors between the deadbolt borehole and the spindle 36 .
[0059] Also advantageously, the trim assembly 10 is configured and arranged in a manner that shares much in common with the trim assembly described and depicted in my co-pending U.S. Patent Application No. ______, filed the same day as the instant application, and entitled “Door Trim Assembly with Clutch Mechanism,” which application is herein incorporated by reference for all purposes. Many of the components are the same or substantially the same. The back plate assembly 15 and spindle driver 30 , for example, are the same. The same handle 14 may be used. The escutcheon 14 , for example, is the same except for a few stamped parts. The commonalities between the locks reduce the cost of manufacture and allow for a more uniform set of instructions in assembling either trim assembly to a door.
[0060] Several different types of motors 11 are suitable for use with the present invention. In one embodiment, a stepper motor is used. In another embodiment, gear motor is used in conjunction with an over torque clutch 62 .
[0061] It should be noted that the embodiments illustrated and described in detail herein are exemplary only, and that various other alternatives, adaptations, and modifications may be made within the scope of the present invention. Accordingly, the present invention is not limited to the specific embodiments illustrated herein, but is limited only by the following claims.
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A lock trim assembly incorporates an escapement assembly comprising a control member and an escapement spring. The escapement assembly is movable between a locking position that blocks rotation of the spindle and an unlocking position that does not block rotation of the spindle. A coupling assembly that couples the handle to the spindle rotates between a default orientation and a blocking orientation. The default orientation allows the escapement assembly to move into the locking position. The blocking orientation blocks the escapement assembly from moving into the locking position. When the coupling assembly is in the blocking orientation, operation of the motor to drive the blocked escapement assembly into the locking position causes the escapement assembly to store energy in the escapement spring for forcing the escapement assembly into the locking position once the coupling assembly is reoriented back to the default orientation.
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BACKGROUND OF THE INVENTION
[0001] 1) Field of the Invention
[0002] The present invention relates to variable sweep aircraft and, more particularly, to a pivoting aircraft wing capable of varying the sweep angle of an aircraft, as well as an associated system and method.
[0003] 2) Description of Related Art
[0004] It is well known that wing design plays an instrumental role in optimizing lift and drag during flight in response to various conditions. Wing design becomes especially important depending on whether the wing is subjected to subsonic, transonic, or supersonic speeds. Decreasing drag involves balancing several different parameters, including, for example, speed, altitude, angle of attack, wing dimensions, and the profile of the airfoil.
[0005] Wings having a high span are preferred for takeoff and landing where drag is substantially lower than wings having a low span. Because the aspect ratio is defined as the ratio of the wing span to the average chord length, longer and narrower wings will have better lift than shorter and wider wings. However, swept wings are preferred over high aspect ratio unswept wings at transonic and supersonic speeds because drag is significantly reduced. Even though swept wings can also maintain the required lift at these higher speeds, swept wings do not perform well at subsonic speeds. Therefore, swept wing aircraft are generally required to have lower sweep angles than would typically be required for transonic and supersonic speeds in order to make takeoff and landing feasible.
[0006] Therefore, variable sweep aircraft wings have been developed that are able to balance the tradeoffs of using either a high aspect ratio, unswept wing, or a lower aspect ratio, swept wing. Aircraft with variable sweep wings can modify the wing configuration from a high span during takeoff, subsonic cruise, or landing, to an increased sweep during supersonic speeds. Advantageously, aircraft with variable sweep wings are able to decrease weight due to an increase in fuel efficiency and may require smaller engines to accelerate the aircraft to supersonic speed, in addition to being capable of operating over a wide range of speeds, decreasing noise due to decreased drag, and shortening takeoff and landing field lengths.
[0007] For example, U.S. Pat. No. 4,212,441 to Ascani, Jr. et al (“Ascani”) discloses a wing pivot assembly for a variable sweep aircraft. Ascani discloses a pivot assembly located at the end of each wing adjacent to the fuselage. The pivot assembly includes a pivot pin that utilizes a “pin within a pin” design, where either pin can carry the load limit. A pair of outboard lugs, i.e., plates, located between the wing and the pivot pin acts to carry the wing bending moment loads into the pin, while a second pair of inboard lugs located between the pivot pin and a carry-through structure carry the wing bending moment loads into the carry-through structure. In addition, two bearing assemblies connecting to the outboard lugs facilitate rotating of the pivot pin and also transmit wing bending moment loads from the outboard lugs into the pivot pin. Ascani also employs a shear bearing and the “truss concept,” which includes canting the inboard and outboard lugs at an angle, to counter axial shear loading.
[0008] However, previous variable sweep aircraft, such as that discussed above, have inherent disadvantages, namely increased weight, which counteracts any advantages associated with varying the sweep of the wings. In addition, the pivot pin design and excess weight offer a poor mechanical advantage and offset load paths. The support structure surrounding the pivot pin may extend quite far out into the outboard wing box in order to direct the loads away from a wide wing box geometry and toward the pin in a way that does not exceed material strength limits. The same is true of the inboard bearing support structure. Therefore, in addition to a potentially large and heavy pivot pin, the supporting structures add even more weight in transferring loading from the wings to the pivot pin and further inboard to a carry-through structure. Furthermore, the thickness of the wing is required to be at least as thick as the pivot pin, and even wider to accommodate the surrounding support structures, which also increases weight and drag, especially for supersonic aircraft.
[0009] It would therefore be advantageous to provide a lighter weight pivoting aircraft wing that can vary the wing sweep angle of an aircraft. In addition, it would be advantageous to provide a pivoting aircraft wing that can vary the sweep angle without sacrificing lift and drag. Finally, it would be advantageous to provide a pivoting aircraft wing that enables an aircraft to travel at supersonic speeds without increasing drag.
BRIEF SUMMARY OF THE INVENTION
[0010] The invention addresses the above needs and achieves other advantages by providing a variable sweep aircraft that is able to change the orientation of its wings from an unswept position at low speeds, takeoff, and landing to a swept position at higher speeds. Thus, the variable sweep aircraft is able to pivot its wings about a virtual axis of rotation to any number of sweep angles depending on the speed and other circumstances to reduce drag. The pivoting aircraft wing of the present invention is able to reduce the weight of the variable sweep aircraft relative to conventional variable sweep aircraft, which consequently reduces drag.
[0011] In one embodiment, the pivoting aircraft wing includes a wing member, a carry-through structure, and a spar box assembly pivotally connected to the carry-through structure. The spar box assembly extends longitudinally within the wing member. The spar box assembly includes a spar box and at least one bearing support structure attached to the spar box. In one variation of the present invention, one end of the spar box tapers to a point proximate to the third bearing and defines a generally triangular shape. The aircraft wing further includes a plurality of bearings disposed within a plurality of bearing races defined by the bearing support structure and carry-through structure. The plurality of bearing races advantageously define an arcuate path of rotation such that the wing member is capable of rotating about a virtual axis of rotation. In variations of the present invention, the aircraft wing is capable of pivoting from an unswept position having about 10 degrees of sweep to a swept position having at least 70 degrees of sweep. An actuator connected to the spar box may be employed to pivot the wing member to various sweep angles.
[0012] The plurality of bearings may include first, second, and third bearings. The first and second bearings may be attached to the carry-through structure, while the third bearing may be attached to an end of the spar box proximate to the carry-through structure. The spar box assembly may comprise at least a pair of bearing support structures that define respective bearing races in which the first and second bearings are disposed such that the spar box assembly is capable of pivoting about the first and second bearings. Also, a bearing support structure may be attached to the carry-through structure and define at least one bearing race such that the third bearing may be disposed and pivoted within the bearing race. The spar box assembly may advantageously pivot about the plurality of bearings and bearing races to vary the sweep angle of the wing member.
[0013] In another embodiment of the present invention, a pivoting aircraft wing system includes a pair of wing members, a fuselage member, and a carry-through structure carried by the fuselage member. The aircraft wing system also includes a pair of spar box assemblies that pivotally connect to the carry-through structure and extend longitudinally within each of the wing members. Each spar box assembly includes a spar box and at least one bearing support structure attached to the spar box. Furthermore, the aircraft wing system includes a plurality of bearings disposed within a plurality of bearing races defined by each of the bearing support structures and carry-through structure. The plurality of bearing races defines an arcuate path of rotation such that each of the wing members is capable of rotating about a respective virtual axis of rotation.
[0014] The present invention further provides a method of pivoting a pair of aircraft wings on a variable sweep aircraft. The method includes first providing a fuselage member, a carry-through structure carried by the fuselage member, and a pair of spar boxes. Each of the spar boxes are pivotally connected to the carry-through structure and extend longitudinally within each of a pair of wing members such that each of the wing members are coupled to each of the spar boxes. The method further includes pivoting each of the wing members about a virtual axis of rotation to predetermined sweep angles.
[0015] Optionally, the method includes pivoting the wing members about a virtual axis of rotation defined by a plurality of bearings disposed within a plurality of bearing races defined between the carry-through structure and each of the spar boxes. Each of the wing members may be pivoted simultaneously with a respective actuator to predetermined sweep angles, such as a sweep angle of at least 70 degrees.
[0016] The present invention therefore provides variable sweep aircraft wings that are capable of being oriented at various sweep angles to reduce drag at different speeds. The combination of varying the aspect ratio and reducing the weight of the variable sweep aircraft wings facilitates a decrease in drag. Weight is reduced by maintaining the bending, torsional, and axial loads in the wing spar box structure, rather than focusing the loading through a single small pivot on each wing. Spreading the loading over a larger area results in a reduction in the structural gauges of the wing, which directly results in weight reduction. Reducing drag, in turn, may reduce noise and fuel consumption because of the smaller engine required, and may decrease the runway length needed for takeoff and landing.
[0017] In addition, the variable sweep aircraft wing of the present invention may decrease the effects of sonic booms on commercial flights, as well as facilitate over-land supersonic commercial flights. Commercial flights traveling at supersonic speeds have been generally limited to flights over water due to the effects of sonic booms on humans; however, the configuration of the variable sweep aircraft wing of the present invention may make low-boom flight more achievable. This feature is due to the unswept and swept positions the aircraft wing may obtain, which permits the aircraft to takeoff and land at low speeds with reasonable field lengths, as well as pivot to a more swept position during higher speeds than fixed wing supersonic aircraft can achieve because of their low speed requirements.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0018] 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:
[0019] FIG. 1 is a top view of a variable sweep aircraft according to one embodiment of the present invention, illustrating the wings in an unswept position;
[0020] FIG. 1A is another top view of the variable sweep aircraft of FIG. 1 , illustrating the wings in a swept position.
[0021] FIG. 2 is an enlarged section view taken through line 2 - 2 illustrating the virtual axis of rotation of the variable sweep aircraft shown in FIG. 1 ;
[0022] FIG. 3 is an enlarged exploded view of one end of a spar box assembly shown in FIG. 1 ;
[0023] FIG. 3A is an enlarged cross-sectional view of a bearing race shown in FIG. 3 ;
[0024] FIG. 4 is an enlarged perspective view of a spar box, bearing support structures, and bearings according to another embodiment of the present invention;
[0025] FIG. 5 is a cross-sectional view of the spar box shown in FIG. 4 , with the section taken through bearings A, B, and the view facing inboard; and
[0026] FIG. 6 is another cross-sectional view of the spar box shown in FIG. 4 in an unswept position, with the section taken through bearing C, and the view facing aft.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, this invention 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.
[0028] Referring now to the drawings and, in particular to FIG. 1 , there is shown a variable sweep aircraft 10 . The term “variable sweep aircraft” is not meant to be limiting and may be any aircraft capable of varying the sweep angle of the wings such that the aspect ratio may be increased and decreased depending on the flight speed and other desired parameters. Thus, variable sweep aircraft could be a variable geometry aircraft, or any aircraft that includes wings that may pivot, rotate, swivel, or otherwise change the orientation of the wings to various sweep angles. As a result, the variable sweep aircraft 10 is capable of flying from subsonic to supersonic speeds with improved lift and drag properties over a wide range of speeds.
[0029] In one embodiment of the present invention FIG. 1 illustrates a variable sweep aircraft 10 including a fuselage 11 and a pair of wings 12 extending in opposite directions from the fuselage. Each of the wings 12 is carried by, or otherwise attached to, a structural spar box 14 . The spar boxes 14 are pivotally attached to a carry-through structure 16 . Bearings, generally indicated at 18 , and races, generally indicated at 19 , are located between each of the spar boxes 14 and the carry-through structure 16 and define a virtual axis of rotation 20 , as will be explained more fully below. Each of the wings 12 rotates about a respective virtual axis of rotation 20 . As shown in FIG. 1A , actuators 22 are connected to each of the spar boxes 14 and are operable to rotate the wings about the virtual axis of rotation 20 to various sweep angles 0 .
[0030] The actuators 22 could be any hydraulic, pneumatic, or similar mechanism that is capable of providing sufficient force to pivot each of the wings 12 . Thus, the actuators 22 could be electrically, mechanically, or electro-mechanically controlled, and are capable of closely controlling the sweep angles θ to pivot the wings 12 to predetermined sweep angles. Preferably the actuators 22 are capable of pivoting each of the wings 12 simultaneously to maintain the stability of the variable sweep aircraft 10 during flight.
[0031] As shown in the embodiment of FIG. 2 , an engine inlet 24 is located below each of the wings 12 to'direct air into the engine to thrust the variable sweep aircraft 10 . In one embodiment of the present invention, a turbojet engine with air inlets on both sides of the fuselage 11 could be incorporated with the variable sweep aircraft 10 to provide the aircraft with adequate thrust to reach supersonic speed. In addition, a wing strake 26 extends approximately orthogonal to the fuselage 10 and aft towards each of the wings 12 and carry-through structure 16 . Thus, the strake 26 is aligned in the direction of airflow and is generally aligned with each of the wings 12 when the wings 12 are fully swept, as shown in FIG. 1A .
[0032] The structural spar boxes 14 , as known to those skilled in the art, include a front spar 28 and a rear spar 30 , both of which extend vertically within each of the wings 12 . The front 28 and rear 30 spars are connected by a pair of horizontal members to form a hollow “box.” The spar boxes 14 extend substantially along the length of each of the wings 12 to provide the main structural support for the wings 12 and to increase the torsional rigidity of the wings. At one end of the spar boxes 14 , the spar boxes include a tapered end 44 having a generally triangular shape, as shown in FIG. 3 . Thus, each of the front 28 and rear 30 spars converge and intersect at bearing C. Because each of the spar boxes 14 are connected to the respective wings 12 , as the spar boxes are rotated each of the wings are also rotated to vary the sweep angle θ. As a result, the wings 12 follow an arcuate path of rotation about their respective virtual axis of rotation 20 .
[0033] Generally, an upper skin 32 and a lower skin 34 are carried, or otherwise attached to, each of the spar boxes 14 , as shown in FIG. 2 . Internal skin stiffeners, stringers, and ribs are typically arranged between the upper 32 and lower 34 skins and along the wings 12 for reinforcement and to define the contour of the airfoil, as known to those skilled in the art. Generally, the stiffeners and stringers extend spanwise within the wings 12 , while the ribs extend chordwise. It is understood that any arrangement of spars, skin stiffeners, stringers, or ribs could be used within each of the wings 12 to provide varying amounts of support, wing shapes, or airfoils. For example, the spar boxes 14 could also include a middle spar located between the front 28 and rear 30 spars. Similarly, the spar box 14 could have a shape other than triangular at the end proximate to bearing C, such as a semi-circular or even rectangular.
[0034] The carry-through structure 16 , as known to those skilled in the art, bridges between the wings 12 and attaches to, or is integral with, the fuselage 11 . Thus, the carry-through structure 16 is a major structural element that transfers loading from the wings 12 and spar boxes 14 to, or across, the fuselage 11 . The carry-through structure 16 is shown in FIG. 1 as having a curvature that conforms to each virtual axis of rotation 20 , and also lies adjacent to the upper 32 and lower 34 skins, as shown in FIG. 2 . FIG. 1 also illustrates that the carry-through structure 16 is generally aligned spanwise with the leading edge of the wings 12 when in an unswept position. It is understood that the carry-through structure 16 could be any shape or size to accommodate different sized fuselages 11 , wings 12 , or spar boxes 14 , as well as conform to a variety of virtual axes of rotation.
[0035] Referring now to FIGS. 1-3 , one advantageous embodiment of the present invention is shown and is described in detail for purposes of example and not of limitation. The variable sweep aircraft 10 of this embodiment is about 155 feet in length, and has a span of approximately 120 feet in an unswept position. The front 28 and rear 30 spars are spaced about 6 feet apart. Also, the variable sweep aircraft 10 has a sweep angle θ of about 10 degrees when unswept, and may rotate to a sweep angle of about 70 degrees.
[0036] It should be noted that the aforementioned features of the exemplary embodiment of the variable sweep aircraft 10 may change as they depend on many factors. For example, the fuselage 11 could be various cross sections and sizes depending on the type of aircraft desired. Additionally, the profile of the airfoil could be any suitable airfoil, symmetric or asymmetric, having any number of chord lengths, leading edge radii, trailing edge angles, and thicknesses, as known to those skilled in the art, depending on the drag and lift properties desired. Although it is preferred that the wings 14 assume a sweep angle θ ranging from about 10 to 70 degrees, it is understood that any specified angle could be employed with the variable sweep aircraft 10 in alternative embodiments of the present invention to achieve a desired drag coefficient.
[0037] The bearings 18 and bearing races 19 advantageously define a virtual axis of rotation 20 for each of the wings 12 . As illustrated in the embodiment shown in FIG. 3 , bearing support structure 36 is attached to the vertical face of the front spar 28 , while bearing support structure 38 is attached to the vertical face of the rear spar 30 . Each of the bearing support structures 36 , 38 defines a race 42 in its outer surface, i.e., the surface facing away from the spar box 14 , as shown in FIGS. 2, 3A , that engages a respective one of bearings A, B. Bearing A is a single ball attached to the carry-through structure 16 that fits within the bearing race 42 defined in bearing support structure 36 such that each of the spar boxes 14 may pivot when rotated to a specified sweep angle θ. Similarly, bearing B is a ball that is attached to the carry-through structure 16 that allows the spar boxes 14 to pivot along the races within the bearing race 42 defined in bearing support structure 38 . Thus, the bearing support structures 36 , 38 provide a smooth radial path in which each of the bearings A, B ride when the spar box is rotated. It should be noted that bearings A, B and bearing support structure 38 are shown on FIG. 2 in dashed lines for illustrative purposes only, as the view of section 2 - 2 would not otherwise depict bearings A, B and bearing support structure 38 . Bearings A, B could be attached to the carry-through structure 16 , and bearing support structures 36 , 38 attached to the spar boxes 14 , by any suitable means, such as by welding, fastening, riveting, and the like, that is capable of withstanding the loads endured during flight.
[0038] Bearing C is shown in FIGS. 2-3 as having two adjacent balls that are attached to the tapered end 44 of the spar boxes 14 . A bearing support structure 48 is attached to the carry-through structure 16 , and bearing C may be positioned with a ball in each of a pair of races 40 defined by the bearing support structure such that bearing C may pivot within the pair of races when the spar boxes 14 are rotated. Bearing C pivots to position C, while in a fully swept position, and thus follows an arcuate path of rotation, as shown in dashed lines on FIG. 1A . Bearing C could be attached to the spar boxes 14 , and bearing support structure 48 attached to the carry-through structure 16 , by any suitable means, such as by welding, fastening, riveting, and the like, that is capable of withstanding the loads endured during flight.
[0039] Thus, the bearings 18 and bearing races 19 define a virtual axis of rotation 20 for each of the wings 12 in one advantageous embodiment of the present invention. The term “virtual” axis of rotation 20 is used because there is no actual bearing, bearing race, or other device at the specific point about which the wings 12 pivot. However, each of the wings 12 pivots about its respective virtual axis of rotation 20 , which acts to distribute loading away from a single pivot point.
[0040] FIGS. 4-6 illustrate another embodiment of the present invention. Each of the spar boxes 14 includes a bearing C that is integrally formed with the spar box. Bearing C includes several teeth 46 that extend outwardly and engage bearing races 40 defined in a bearing support structure 48 . The bearing support structure 48 is attached to the carry-through structure 16 . As shown in FIG. 4 , bearing C is located proximate to a tapered end 44 , wherein the tapered end extends from the end of the spar box 14 to bearing C. Bearing support structures 36 , 38 are attached to the spar box 14 and also include several bearing races 42 that may engage the teeth 52 extending from bearings A, B. As before, bearings A, B are attached directly to the carry-through structure 16 , as shown in FIG. 5 . As a result, the bearing support structures 36 , 38 , 48 define respective bearing races 40 , 42 that are arranged in an arc so that the teeth 46 , 52 of each of the respective bearings may slide within the bearing races to rotate the spar boxes 14 about a respective virtual axis of rotation 20 .
[0041] The wings 12 generally experience shear, torsional, and bending loading during flight. Bearings A, B, C transfer loading to the carry-through structure 16 and fuselage 11 and vice versa. Specifically, bearings A, B transfer shear loading due to drag and lift, as well as torsional loading due to the wing pitching moment. The lever arm of the torsional load in the unswept and swept positions would be equivalent to the distance between bearings A, B in approximately a chordwise direction. Bearing C transfers the bending moment caused by lift and the lift distribution along each of the wings 12 . The bending moment arm would be reacted over the spanwise distance from a line between bearings A and B to bearing C when the wings 12 are in an unswept position, while the moment arm would be reacted over a longer arm from position C 1 to bearing B in a swept position. The bending moment in bearing C is generally much higher than the loading experienced at bearings A, B. The configuration of bearings A, B, C distributes the loading so that no single bearing or pivot point experiences all of the loading at any given instant.
[0042] The wings 12 could be any suitable material, but is preferably a lightweight yet high strength aluminum or composite suitable for aircraft wings. Similarly, the spar boxes 14 , carry-through structure 16 , bearings 18 , and bearing races 19 are preferably all lightweight and manufactured from a composite, ceramic, or metallic material. The composite material could be any suitable particle-reinforced, sandwiched, laminated composite, or fiber-reinforced material, such as a carbon-fiber reinforced plastic. In one embodiment, the bearings 18 include a metallic or ceramic backing and have a Teflon™ material (commercially available from E.I. du Pont de Nemours and Company) surface where the bearings engage the bearing races 19 . However, it is understood that various composites, including metals and their alloys, could be incorporated in additional embodiments of the present invention.
[0043] Although the wings 12 are illustrated in one embodiment of the present invention as having three pivot points about bearings A, B, C to define the virtual axis of rotation 20 , it is understood that alternative configurations could be employed and still be within the scope of the present invention. For example, any number of bearings 18 , bearing races 19 , and bearing support structures 36 , 38 , 48 could be used to define the virtual axis of rotation 20 . In addition, the bearings 18 , bearing races 19 , and bearing support structures 36 , 38 , 48 could be arranged such that the virtual axis of rotation 20 may be located in any desirable location between the spar box 14 and carry-through structure 16 .
[0044] Although various elements, such as the bearings 18 and bearing supports structures 36 , 38 , 48 , are described as being “attached” in various embodiments, it is understood that the bearings 18 , bearing races 19 , and bearing support structures 36 , 38 , 48 could be integrally molded, machined, or otherwise formed as discrete elements, in either or both of the spar boxes 14 and carry-through structure 16 , and still be “attached” for purposes of the present invention and still be capable of withstanding the loading imposed on the variable sweep aircraft 10 during flight. For example, the bearing support structures 36 , 38 could be integral with the spar boxes 14 , or bearings A, B could be integral with the carry-through structure 16 . Additionally, it is understood that in alternative embodiments the spar box 14 could carry all of the bearings 18 , while the carry-through structure could define all of the bearing races 19 , and vice versa.
[0045] Furthermore, although the bearings 18 are shown in FIGS. 1-3 as being spherical, the bearings could be any type or dimension of bearing, such as tapered, cylindrical, or the like, that enable the spar boxes 14 and wings 12 to pivot. It is also understood that the bearings 18 illustrated in FIGS. 4-6 could include any number and dimension of respective teeth 46 , 52 to accommodate any number of respective bearing races 19 defined in the respective bearing support structures 36 , 38 , 48 . Similarly, the bearing races 19 could be any type or dimension to accommodate each of the corresponding bearings 18 , and could be lubricated in alternative embodiments. It is also understood that each of the bearings 18 and corresponding bearing races 19 could also be different, so that at least one bearing and corresponding bearing race are different than the others.
[0046] Advantageously, the configuration of the bearings 18 and bearing races 19 act to distribute the loading about a virtual axis of rotation 20 for each of the wings. This distribution ensures that the weight of the carry-through structure 16 and spar box 14 can be reduced. In addition, because the loading is distributed, the thickness of the wing may also be reduced, which allows for small thickness-to-chord ratios to be employed. For example, in one embodiment of the present invention, the thickness-to-chord ratio is about 0.08 in an unswept position and about 0.025 at about 70 degrees of sweep, which are typical values for aircraft traveling at supersonic speeds. Furthermore, the variable sweep aircraft 10 of the present invention is also capable of traveling at supersonic speeds, and the decreased weight and drag would improve all aspects of performance and make a low-boom configuration more achievable.
[0047] Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
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A pivoting aircraft wing and associated system and method are provided. The pivoting aircraft wing includes a wing member, a carry-through structure, and a spar box assembly pivotally connected to the carry-through structure. The spar box assembly extends longitudinally within the wing member. The spar box assembly comprises a spar box and a bearing support structure attached to the spar box. The aircraft wing further includes a plurality of bearings disposed within a plurality of bearing races defined by the bearing support structure and carry-through structure. The plurality of bearing races advantageously define an arcuate path of rotation such that the wing member is capable of rotating about a virtual axis of rotation.
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TECHNICAL FIELD
The present invention relates generally to a bracket or clip for supporting shelves in cabinets and the like. More particularly, this invention concerns an interchangeable shelf support bracket for securing either one of two different thicknesses of shelves against tipping in a shelf assembly, although it can be used with any thickness shelf.
BACKGROUND ART
Cabinets, bookcases and the like generally include a number of shelves supported between a pair of side walls. The shelves can be supported in either fixed or adjustable positions. Adjustability, of course, is desireable because it allows the user to vary spacing between the shelves in accordance with the height of the items stored thereon. This is typically accomplished with brackets or clips, two of which are generally provided at each end of each shelf, for insertion into holes or sockets in the side walls.
Various types of such shelf support brackets or clips have been available heretofore. In their simplest form, they comprise posts or pins which protrude outwardly from the side wall beneath the edge of the shelf. Such shelf supports provide no locking or retention of the shelves against upward or outward separation from the side walls.
Various forms of shelf supports or brackets having a locking or retention function have also been available heretofore. For example, U.S. Pat. No. 3,759,191 to Freeman shows a reversible cabinet shelf bracket which is rotatable 180° between an up/locked position wherein a vertical pin on the end of a flange is received by a socket in the underside of the shelf, and a down/unlocked position wherein the pin is out of engagement with the shelf. This bracket retains the shelf against outward movement from the side walls, but not against upward movement or tipping.
Shelf supports with a vertical retention function have also been available heretofore. For example, U.S. Pat. No. 3,870,266 to MacDonald shows a self-locking shelf support comprising an L-shaped bracket with a retractable spring pin at the upper end thereof. U.S. Pat. Nos. 3,471,111 and 3,471,112 to MacDonald show shelf support brackets having resilient fingers which engage the top surface of the shelves. U.S. Pat. Nos. 4,666,117 to Taft; 4,432,523 to Follows; and 4,037,813 to Loui are also representive of the prior art in this regard. While these brackets constrain the shelves against vertical separation, they are only adapted for use with one shelf thickness.
A need has thus arisen for an improved shelf support bracket which can be used with either one of two predetermined thicknesses of shelves, while providing retention against both vertical and outward separation from the side walls.
SUMMARY OF THE INVENTION
The present invention comprises an improved shelf support bracket which overcomes the foregoing and other disadvantages associated with prior art. In accordance with the invention, there is provided a shelf bracket comprising an upright back portion with at least one pin but preferably two pins, extending from one side thereof for receipt in vertically spaced apart openings in a wall of a bookcase, cabinet or the like. A lateral portion extends outwardly from the other side of the back portion for supporting the lower edge of a shelf thereon. The back portion also includes a H-shaped notch with opposing aligned resilient tabs therein, both of which can move out of their normal positions to permit passage of the edge of a shelf. Both tabs include protruding lips on their free ends for constraining either one of two different thicknesses of shelves therein against vertical separation from the bracket. The lateral portion preferably includes a notch for receiving a protrusion on the underside of the shelf in order to constrain the shelf against outward separation therefrom as well.
BRIEF DESCRIPTION OF DRAWINGS
A better understanding of the invention can be had by reference to the following Detailed Description in conjunction with the accompanying Drawings, wherein:
FIG. 1 is a perspective view of the interchangeable shelf support bracket incorporating the invention;
FIG. 2 is a front view of the shelf bracket herein;
FIG. 3 is a top view of the shelf bracket herein;
FIG. 4 is a partial sectional view of the shelf bracket herein supporting the edge of a shelf on a side wall in a bookcase, cabinet or the like; and
FIG. 5 is a partial sectional view similar to FIG. 4, but showing a relatively thicker shelf supported therein.
DETAILED DESCRIPTION
Referring now to the Drawings, wherein like reference numerals designate like or corresponding elements throughout the views, there is shown a shelf support bracket 10 incorporating the invention. The bracket 10 can be used in cabinets, bookcases and the like for adjustably supporting the shelves therein. Typically, two such brackets 10 would be used at each end of each shelf. As will be explained more fully hereinafter, the bracket 10 can be used with either one of two different predetermined thicknesses of shelves for supporting the shelf on a side wall and securing it against both vertical and outward movement therefrom.
The bracket 10 includes an upright back or side plate 12. The side plate 12 is preferably rectangular such as about 2.25" by 0.75", although any suitable shape can be used.
A pair of vertically spaced apart lugs or pins 14 are provided on one side of the side plate 12. In accordance with the preferred construction, two such pins 14 are utilized, although only one can be used if desired. As illustrated, the pins 14 are spaced about 1.25" apart, although any suitable spacing can be used. Each pin 14 extends laterally in a direction generally transverse to the side plate 12, and is of generally cylindrical shape. In accordance with the preferred construction, each pin 14 is "roundish" or slightly out of round, such as about 0.193" by 0.178", by about 0.38" long, in order to provide a better fitting tolerance with complementary holes drilled into the side wall (not shown) of a cabinet.
An edge plate or flange 16 is provided on the opposite side of the side plate 12 for supporting the lower edge of a shelf. A pair of gussets 18 are provided between the underside of the edge plate 16 and the adjoining surface of the side plate 12 for reinforcement. As illustrated, two such spaced apart gussets 18 are utilized, although a single gusset can be used instead, if desired.
The bracket 10 also includes a dual thickness shelf retention means 20. The shelf retention means 20 comprises a pair of opposing spring tabs 22 and 24 located within a H-shaped notch 25 in the side plate 12. A lip 26 is provided on the lower, free end of the upper tab 22. Similarly, a lip 28 is provided adjacent the upper free end of the lower tab 24. Each of the lips 26 and 28 includes an inclined upper surface for permitting passage of the end of a shelf thereby, and a flat lower surface for retaining the edge of the shelf thereunder after passage. It will be noted that the tabs 22 and 24 are not as thick as the surrounding portions of the side plate 12, for flexibility and in order to provide clearance for flexing.
FIGS. 4 and 5 show bracket 10 supporting shelves on the side wall 30 of a typical cabinet assembly. As shown in FIG. 4 the lower spring tab 24 serves to retain the edge of a shelf 32 of one predetermined thickness, such as about 0.75 inch, while the upper spring tab 22 serves to retain the edge of a relatively thicker shelf 34, such as about 1.0 inch thick, as shown in FIG. 5.
In accordance with the preferred construction, the edge plate 16 includes a notch 36 therein for receiving a protrusion 38 on the underside of a shelf in order to retain the shelf against outward movement from the side wall. If desired, a raised rib 40 can also be provided on the back plate 12 adjacent flange 16 to avoid sticking between the shelf and bracket 10.
The bracket 10 is preferably of integral molded construction, and can be made from suitable plastic such as reinforced polyester alloy.
From the foregoing, it will thus be apparent that the present invention comprises an improved shelf support bracket having several advantages over the prior art. The primary advantage is that the same bracket can be utilized to support and retain either one of two shelf thicknesses without any modification or adjustment whatsoever. This in turn leads to time and cost savings. Other advantages will be evident to those skilled in the art.
Although particular embodiments of the invention have been illustrated in the accompanying drawing and described in the foregoing Detailed Description, it will be understood that the invention is not limited only to the embodiments disclosed, but is intended to embrace any alternatives, equivalents, and/or modifications or rearrangements of elements falling within the scope of the invention as defined by the following claims.
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An interchangeable shelf support bracket (10) particularly for use with either one of two different thicknesses of shelves includes a side plate (12), mounting pins (14), edge flange (16), and pair of opposing retainer tabs (22, 24) each of which includes a lip (b 26, 28) adapted to receive the edge of one of the two shelves.
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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates generally to techniques for enabling a Web site origin server to obtain content delivery services from a third party service provider on an as-needed basis.
[0003] 2. Description of the Related Art
[0004] Today's Web sites are a double-edged sword. They present enterprises with the opportunity for both resounding success and costly, dramatic failure. The possibility for either scenario to occur is chiefly due to the Internet's open design. Indeed, the ability to reach a global community of customers and partners via the Web comes with many risks. The open design means that enterprises must expose themselves by opening a public entry-point to get the global reach they need. Couple that with the inherent weaknesses of centralized infrastructure and there is a recipe for failure. Indeed, a growing number of threats can bring a site down daily. These threats include hacker attacks, viruses, Internet worms, content tampering and Denial of Service (DoS) attacks. Moreover, the site's popularity itself can generate “flash crowds” that overload the capabilities of the site's origin server(s). Any one of these events can produce unpredictable site disruptions that impede revenue operations, dilute brand investments, hamper productivity and reduce goodwill and reputation.
[0005] A content provider can ameliorate these problems by outsourcing its content delivery requirements to a content delivery network (a “CDN”). A content delivery network is a collection of content servers and associated control mechanisms that offload work from Web site origin servers by delivering content on their behalf to end users. A well-managed CDN achieves this goal by serving some or all of the contents of a site's Web pages, thereby reducing the customer's infrastructure costs while enhancing an end user's browsing experience from the site. In operation, the CDN uses a request routing mechanism to locate a CDN content server close to the client to serve each request directed to the CDN, where the notion of “close” is based, in part, on evaluating results of network traffic tests.
[0006] While content delivery networks provide significant advantages, some content providers prefer to maintain primary control over their Web site infrastructure or may not wish to pay for the cost of fully-provisioned CDN services. As a result, the site remains exposed to the myriad of potential security and flash crowds that may bring the site down at any time.
[0007] It would be highly desirable to provide a content provider the ability to receive “on demand” use of a CDN to provide an additional layer of protection to ensure business continuity of an enterprise Web site. The present invention addresses this need.
BRIEF SUMMARY OF THE INVENTION
[0008] It is a primary object of the present invention to provide an infrastructure “insurance” mechanism that enables an origin server to selectively use or fail over to a content delivery network (CDN) upon a given occurrence at the site. Upon such occurrence, at least some portion of the site's content is served from the CDN so that end users that desire the content can still get it, even if the content is not then available from the origin site.
[0009] It is another primary object of the invention is to provide origin server “insurance” to render server content accessible even if access to the origin server is inhibited in some way.
[0010] It is another more specific object of the present invention to provide a mechanism that enables a Web site origin server to use a content delivery network for insurance purposes on an as-needed basis. Preferably, this operation occurs in a seamless and automatic manner, and it is maintained for a given time period, e.g., for as long as the need continues.
[0011] According to an illustrative embodiment, the technical advantages of the present invention are achieved by monitoring an origin server for a given occurrence and, upon that occurrence, providing failover of the site to a CDN. Preferably, this is accomplished by re-directing DNS queries (to the origin server) to the CDN service provider's request routing mechanism. In this fashion, DNS queries for content are resolved by the CDN DNS mechanism as opposed to the site's usual DNS. The CDN DNS mechanism then maps each DNS request to an optimal server in the CDN in a known manner to enable the requesting end user to obtain the desired content, even if the origin server is unavailable. As a consequence of this site insurance, given content on the origin server is always available.
[0012] The site insurance may be triggered upon a given occurrence—the scope of which is quite variable. Representative occurrences include, without limitation, a flash crowd at the site, a site failure, excess traffic to the site originating from certain geographies or networks, excess demand for certain content on the site such as high resolution streaming content, excess latency or slowdown at the site as perceived by network downloading agents deployed throughout the CDN or elsewhere, or a site attack such as a Denial of Service (DoS) attack at or adjacent the site. Generally, the present invention selectively moves traffic from the origin to the CDN when there is excessive load on the origin or the origin is unreachable. These examples, however, are merely illustrative.
[0013] The site insurance functionality may operate in a standalone manner or be integrated with other CDN services, such as global traffic management.
[0014] The foregoing has outlined some of the more pertinent features of the present invention. These features should be construed to be merely illustrative. Many other beneficial results can be attained by applying the disclosed invention in a different manner or by modifying the invention as will be described.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a block diagram of a known content delivery network in which the present invention may be implemented;
[0016] [0016]FIG. 2 is a simplified block diagram illustrating how site insurance functionality is provided according to the present invention;
[0017] [0017]FIG. 3 is a flowchart illustrating how the site insurance is triggered upon determination of a given event at the origin server; and
[0018] [0018]FIG. 4 illustrates a global traffic management system in which the site insurance functionality may be integrated according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] By way of background, it is known in the prior art to deliver digital content (e.g., HTTP content, streaming media and applications) using an Internet content delivery network (CDN). A CDN is a network of geographically-distributed content delivery nodes that are arranged for efficient delivery of content on behalf of third party content providers. Typically, a CDN is implemented as a combination of a content delivery infrastructure, a request-routing mechanism, and a distribution infrastructure. The content delivery infrastructure usually comprises a set of “surrogate” origin servers that are located at strategic locations (e.g., Internet network access points, Internet Points of Presence, and the like) for delivering content to requesting end users. The request-routing mechanism allocates servers in the content delivery infrastructure to requesting clients in a way that, for web content delivery, minimizes a given client's response time and, for streaming media delivery, provides for the highest quality. The distribution infrastructure consists of on-demand or push-based mechanisms that move content from the origin server to the surrogates. An effective CDN serves frequently-accessed content from a surrogate that is optimal for a given requesting client. In a typical CDN, a single service provider operates the request-routers, the surrogates, and the content distributors. In addition, that service provider establishes business relationships with content publishers and acts on behalf of their origin server sites to provide a distributed delivery system.
[0020] As seen in FIG. 1, an Internet content delivery infrastructure usually comprises a set of “surrogate” origin servers 102 that are located at strategic locations (e.g., Internet network access points, and the like) for delivering copies of content to requesting end users 119 . A surrogate origin server is defined, for example, in IETF Internet Draft titled “Requirements for Surrogates in the HTTP” dated Aug. 9, 2000, which is incorporated herein by reference. The request-routing mechanism 104 allocates servers 102 in the content delivery infrastructure to requesting clients. The distribution infrastructure consists of on-demand or push-based mechanisms that move content from the origin server to the surrogates. A CDN service provider (CDNSP) may organize sets of surrogate origin servers as a group or so-called “region.” In this type of arrangement, a CDN region 106 typically comprises a set of one or more content servers that share a common back-end network, e.g., a LAN, and that are located at or near an Internet access point. Thus, for example, a typical CDN region may be co-located within an Internet Service Provider (ISP) Point of Presence (PoP) 108 . A representative CDN content server is a Pentium-based caching appliance running an operating system (e.g., Linux, Windows NT, Windows 2000) and having suitable RAM and disk storage for CDN applications and content delivery network content (e.g., HTTP content, streaming media and applications). Such content servers are sometimes referred to as “edge” servers as they are located at or near the so-called outer reach or “edge” of the Internet. The CDN typically also includes network agents 109 that monitor the network as well as the server loads. These network agents are typically co-located at third party data centers or other locations. Mapmaker software 107 receives data generated from the network agents and periodically creates maps that dynamically associate IP addresses (e.g., the IP addresses of client-side local name servers) with the CDN regions.
[0021] Content may be identified for delivery from the CDN using a content migrator or rewrite tool 106 operated, for example, at a participating content provider server. Tool 106 rewrites embedded object URLs to point to the CDNSP domain. A request for such content is resolved through a CDNSP-managed DNS to identify a “best” region, and then to identify an edge server within the region that is not overloaded and that is likely to host the requested content. Instead of using content provider-side migration (e.g., using the tool 106 ), a participating content provider may simply direct the CDNSP to serve an entire domain (or subdomain) by a DNS directive (e.g., a CNAME). In either case, the CDNSP may provide object-specific metadata to the CDN content servers to determine how the CDN content servers will handle a request for an object being served by the CDN. Metadata, as used herein, refers to a set of control options and parameters for the object (e.g., coherence information, origin server identity information, load balancing information, customer code, other control codes, etc.), and such information may be provided to the CDN content servers via a configuration file, in HTTP headers, or in other ways. The Uniform Resource Locator (URL) of an object that is served from the CDN in this manner does not need to be modified by the content provider. When a request for the object is made, for example, by having an end user navigate to a site and select the URL, a customer's DNS system directs the name query (for whatever domain is in the URL) to the CDNSP DNS request routing mechanism. A representative CDN DNS request routing mechanism is described, for example, in U.S. Pat. No. 6,108,703, the disclosure of which is incorporated herein by reference. Once an edge server is identified, the browser passes the object request to the server, which applies the metadata supplied from a configuration file or HTTP response headers to determine how the object will be handled.
[0022] As also seen in FIG. 1, the CDNSP may operate a metadata transmission system 116 comprising a set of one or more servers to enable metadata to be provided to the CDNSP content servers. The system 116 may comprise at least one control server 118 , and one or more staging servers 120 a - n , each of which is typically an HTTP server (e.g., Apache). Metadata is provided to the control server 118 by the CDNSP or the content provider (e.g., using a secure extranet application) and periodically delivered to the staging servers 120 a - n . The staging servers deliver the metadata to the CDN content servers as necessary.
[0023] The above described content delivery network is merely illustrative. The present invention may leverage any content delivery infrastructure in which a service provider operates any type of DNS-based request routing mechanism.
[0024] According to the present invention, a content provider's origin server(s) provide the Web site's content in the usual manner that would occur in the absence of a content delivery network (CDN). The origin server(s) may be located at a content provider location or a third party hosting site. Thus, conventionally, an end user running a client machine would launch his or her Web browser to a URL identifying the content provider Web site. Through conventional DNS, the end user's browser would be connected to the origin server to fetch the content. That well-known operation is augmented according to the present invention to provide so-called “site insurance,” which is a technique to provide “on-demand” use of the CDN in given circumstances. The CDN service provider preferably makes the site insurance functionality available to one or more content provider customers as a managed service, which is available on an as-needed basis. Thus, according to the invention, Web site traffic is handled by the origin server(s) in the usual manner (i.e., without the CDN) and is triggered upon a given occurrence at the origin server. Representative occurrences include, without limitation, a flash crowd at the site, a site failure, excess traffic to the site originating from certain geographies or networks, excess demand for certain content on the site such as high resolution streaming content, excess latency or slowdown at the site as perceived by network downloading agents deployed throughout the CDN or elsewhere, a Denial of Service (DoS) attack at or adjacent the site, a DoS attack that indirectly impacts the site, or the like. Of course, the above examples are merely illustrative.
[0025] [0025]FIG. 2 is a simplified block diagram of how site insurance is provided to a particular origin server 200 by the service provider operating a CDN 202 . Origin server 200 has a name service 204 (e.g., running DNS software such as BIND) associated therewith. According to the invention, the name service 204 is modified to include a control mechanism 206 that monitors the server for one or more given occurrences that trigger the site insurance. Alternatively, control mechanism 206 operates in association with the CDN name service. In an illustrative embodiment, the control mechanism is implemented in software executable on a processor and implements a dynamic modification of a local DNS record (e.g., a DNS A record) upon determining that the given occurrence has taken place. Thus, the local DNS record may be modified so that a given content provider domain is directed to a CDN-specific domain, i.e., a domain that cues the CDN's request routing mechanism 208 to handle the given request. Illustratively, assume that the normal content provider domain is www.cp.com and that this is the domain that is used by a given end user browser to fetch content from the origin server. According to the invention, when the control mechanism 206 identifies the given condition at the site that triggers the site insurance server, that mechanism rewrites the DNS record in the name service 204 so that www.cp.com points to a CDN request routing mechanism. Thus, for example, if the CDN domain is g.cdnsp.net, the domain www.cp.com is pointed to g.cdnsp.net. A convenient way to do this is to insert a DNS CNAME into the A record for www.cp.com. Any other convenient aliasing technique, such as domain delegation, can be used. As a result of this modification, requests for content associated with the www.cp.com domain are selectively handled by the CDN.
[0026] [0026]FIG. 3 is a flowchart of the process for a particular event that triggers the site insurance. Step 300 assumes the default operation wherein the origin server is operating without assistance from the CDN. At step 302 , a test is made to determine whether a given event triggering the site “insurance policy” has occurred. If not, the routine cycles. As noted above, there may be many diverse types of events that could trigger the insurance. When the given event occurs, as indicated by a positive outcome of the test at step 302 , the routine continues at step 304 wherein the control mechanism rewrites the local DNS record as described above. This redirects DNS queries, which were originally intended for the content provider domain, to the CDN domain. At step 306 , this rewrite cues the CDNSP's DNS request routing mechanism to resolve the query. As a consequence, the query (and thus the content request) is managed by the CDN, thereby relieving the origin server of having to handle the request. At step 308 , a test is made to determine whether the given event that has triggered the insurance has ended. If not, the routine cycles and the site insurance is maintained. If, however, the outcome of the test at step 308 indicates that the given event that triggered the insurance has ended, the routine continues at step 310 to rewrite the local DNS record (e.g., by removing the CNAME). This returns the site back to its default operation, wherein the content is delivered without reference to the CDN. Steps 308 and 310 are not required, as the given site insurance may simply be removed after a given timeout, at a given time, or upon some other condition.
[0027] The content delivery network service provider may provide the site insurance functionality as a standalone product or managed service (as described above) or integrated with a global traffic management (GTM) product or service. An illustrative GTM system is known commercially as FirstPoint SM and is available from Akamai Technologies of Cambridge, Mass. This technique is described in commonly-owned, copending application Ser. No. 09/866,897, filed May 29, 2001, titled Global Load Balancing Across Mirrored Data Centers, which application is incorporated herein by reference. Other commercial available products include Cisco Global Director, global load balancers from F 5 , and the like. Any product/system/managed service that has the ability to direct a client request to one of a set of mirrored sites based on network traffic conditions, server load, and the like, may be used as the GTM system.
[0028] In this embodiment, the content provider purchases the GTM and the site insurance services from the CDN service provider. The content provider's origin server may or may not be mirrored, but typically it will be. Accordingly, the GTM directs end user requests to the origin server, or to one of the mirrored origin servers, in the usual manner. Upon occurrence of a given event triggering the insurance policy, however, the GTM, as modified to include the site insurance mechanism, automatically and seamlessly moves traffic away from the origin servers and onto the CDN.
[0029] Integrating GTM and site insurance functionality in this manner provides significant advantages. In low demand situations, the GTM simply directs end users to the origin servers in the normal manner. As the demand increases, however, the GTM automatically senses the load changes and directs it to the CDN, where it can be more effectively managed by the distributed CDN infrastructure.
[0030] [0030]FIG. 4 illustrates how a customer Web site is integrated into the traffic redirection system to take advantage of the site insurance. It is assumed that the customer has a distributed web site of at least two (2) or more mirrored origin servers. Typically, the GTM system operates to load balance multiple subdomains/properties provided they are in the same data centers. As described in Ser. No. 09/866,897, integration simply requires that the customer set its authoritative name server 400 to return a CNAME to the GTM name servers 408 , which, thereafter, are used to resolve DNS queries to the mirrored customer site. Recursion is also disabled at the customer's authoritative name server. In operation of the GTM system, an end user 402 makes a request to the mirrored site using a conventional web browser or the like. The end user's local name server 404 issues a request to the authoritative name server 400 (or to a root server if needed, which returns data identifying the authoritative name server). The authoritative name server then returns the name of a name server 408 in the managed service. The local name server then queries the name server 408 for an IP address. In response, the name server 408 responds with a set containing one or more IP addresses that are “optimal” for that given local name server and, thus, for the requesting end user. As described in Ser. No. 09/866,897, the optimal set of IP addresses may be generated based on network maps created by testing the performance of representative common points on the network. The local name server selects an IP address from the “optimal” IP address list and returns this IP address to the requesting end user client browser. The browser then connects to that IP address to retrieve the desired content, e.g., the home page of the requested site. The above-described operation is augmented according to the present invention to include the site insurance functionality. The control mechanism 405 is illustrated in the drawing. Control mechanism 405 monitors for occurrence of the one or more triggering events to provide the site insurance functionality. This can be accomplished in a seamless manner by having authoritative name server 400 , upon occurrence of the event, simply return the name of whatever lower level CDN name server will manage the request. The CDN service provider may operate separate name server mechanisms for the GTM service and for the site insurance, or these functions can be integrated into the same CDNSP-managed DNS. When the triggering event occurs, the end user browser's local name server 404 is handed back the name of a CDN name server from which the local name server 404 obtains the IP address of a CDN edge server. This redirection occurs automatically and without user involvement or knowledge.
[0031] Representative machines on which the present invention is operated may be Intel Pentium-based computers running a Linux or Linux-variant operating system and one or more applications to carry out the described functionality. One or more of the processes described above are implemented as computer programs, namely, as a set of computer instructions, for performing the functionality described.
[0032] Having described our invention, what we claim is as follows.
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An infrastructure “insurance” mechanism enables a Web site to fail over to a content delivery network (CDN) upon a given occurrence at the site. Upon such occurrence, at least some portion of the site's content is served preferentially from the CDN so that end users that desire the content can still get it, even if the content is not then available from the origin site. In operation, content requests are serviced from the site in the usual manner, e.g., by resolving DNS queries to the site's IP address, until detection of the given occurrence. Thereafter, DNS queries are managed by a CDN dynamic DNS-based request routing mechanism so that such queries are resolved to optimal CDN edge servers. After the event that caused the occurrence has passed, control of the site's DNS may be returned from the CDN back to the origin server's DNS mechanism.
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FIELD OF THE INVENTION
The present invention relates to a device for denaturing articles of value of the type comprising at least one reservoir filled with a fluid designed to soil the said articles and a pyrotechnic charge associated with the said reservoir for opening the latter with a view to releasing the said fluid over the said articles.
BACKGROUND OF THE INVENTION
A device of this kind is described in document EP-B-0,188,155.
This device is used in a container for transporting valuables such as banknotes. It comprises a deformable reservoir filled with ink and equipped with a longitudinal line of weakness. A pyrotechnic cord is placed along this line of weakness. Furthermore, a metallic casing of triangular section is inserted between the pyrotechnic cord and the line of weakness.
When the pyrotechnic cord is ignited, this cord throws the metallic casing on to the line of weakness, which breaks. Under the action of the reverberation of the shock wave against the deformable wall of the reservoir in which vibration occurs, the ink contained in this reservoir is ejected through the opening formed along the line of weakness.
After the device has been triggered, and when most of the ink has been thrown over the articles to be denatured, the reservoir is still in one piece, only the longitudinal line of weakness having been broken to form an opening through which the ink is released.
The effectiveness of such a device is unsatisfactory and the use of a cutting cord is not always sufficient to open any paper envelope or metal wrapper in which the articles to be denatured may be contained. Furthermore, as the ink is thrown over the articles only after the shock wave has reverberated and bounced back from the part of the reservoir opposite its opening, the ink thrown out has a low speed, which means that its dispersion throughout the container is poor.
SUMMARY OF THE INVENTION
The object of the invention is to provide a solution to the problem mentioned earlier, and in particular to provide a device for denaturing articles which is effective irrespective of the distribution of the articles in the container, even if these articles are wrapped.
To this end, the subject of the invention is a device for denaturing articles of value of the aforementioned type, characterized in that the or each reservoir is essentially delimited by a wall made of a material which fragments in an appropriate way so that, under the action of the pyrotechnic charge, a multitude of disjointed elemental fragments is produced.
According to particular embodiments, the device may have one or more of the following features:
the said fragmentation material is a borosilicate glass;
the said material is a hardened glass;
the pyrotechnic charge is a detonating cutting cord;
the or each reservoir and the pyrotechnic charge are placed side by side in a deflector that diverges towards its outlet opening, which opening is intended to face towards the said articles;
the or each reservoir has an elongate shape and the pyrotechnic charge extends along the length of the reservoir on the outside of this reservoir;
the deflector has the shape of a channel and is delimited by two side walls that diverge towards the outlet opening and extend along the length of the or of each reservoir;
the pyrotechnic charge is placed inside the reservoir; and
the reservoir has an elongate shape and the pyrotechnic charge extends over most of the length of the reservoir.
Another subject of the invention is a container comprising a chamber for protecting articles of value and a device for denaturing the valuables, which is connected to a triggering unit, characterized in that the denaturing device is a device as defined hereinabove.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood from reading the description which will follow, given merely by way of example and made with reference to the drawings in which:
FIG. 1 is a view in perspective of an open suitcase for transporting monies, comprising a denaturing device according to the invention;
FIG. 2 is a part view in perspective of the denaturing device of FIG. 1; and
FIG. 3 is a view in perspective of an alternative form of the denaturing device according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
The suitcase 10 depicted in FIG. 1 comprises two half-shells 12 , 14 articulated together. This suitcase forms a security container delimiting a chambers 16 for receiving articles of value to be transported such as banknotes, computer data media, or electronic components.
The chamber 16 is equipped with an opening in its upper part. This access opening can be blocked by the upper half-shell 14 that forms a lid.
Fixed along the entire length of the interior face of the lid 14 is a device 18 for denaturing the articles contained in the suitcase. This device is connected to a triggering unit 20 . The latter is designed to fire the pyrotechnic means of the denaturing device in response to a predetermined item of information, in particular an attempted break-in, detected by a sensor borne by the suitcase. This triggering unit comprises, for example, a detonator, ref 4301 , from the company Davey Bickford.
As depicted in FIG. 2, the device 18 comprises two identical rigid reservoirs 22 in the shape of cylinders of revolution containing a fluid designed to soil the articles contained in the suitcase. The fluid is, for example, indelible ink.
The device further comprises a single pyrotechnic charge 24 formed by a detonating cutting cord, for example of the type HA 54 05.01 marketed in France by the company PYROMECA. This cord has a triangular cross-section, the length of one side being 4 or 5 mm.
According to the invention, the wall delimiting the reservoirs 22 is made essentially of a material that fragments and which, under the action of the pyrotechnic charge, is smashed into a multitude of disjointed elemental fragments more or less the same as each other.
The reservoirs are thus formed, for example, from ampoules made of borosilicate glass, or of a hardened glass.
The reservoirs 22 and the pyrotechnic charge 24 are supported by a deflector 26 extending along the entire length of the lid 14 and having the overall shape of a channel.
The deflector is delimited by a bottom 28 equipped with slots 29 for the passage of screws for attaching to the interior face of the lid, and by two side walls 30 which diverge towards the outlet opening of the deflector. This opening faces towards the inside of the suitcase when the suitcase is closed, and in particular faces towards the articles contained therein. The internal angle formed by the side walls 30 with the bottom 28 is, for example, approximately 120°.
Fixed along the longitudinal mid-plane of the deflector is a middle wall 32 supporting the detonating cutting cord 24 . The reservoirs 22 are thus placed in the two compartments delimited in the deflector on each side of the wall 32 . They are held slightly away from the bottom 28 and from the side walls 30 .
The wall 32 comprises a stand 34 , formed by a portion bent at right angles and welded to the bottom 28 of the deflector. The free edge of the middle wall 32 has uniformly spaced cuts which delimit tabs 36 . These tabs are deformed alternately towards one then the other of the two reservoirs 22 .
As depicted in FIG. 2, the detonating cord 24 is trapped and held by bonding between the deformed tabs 36 . It thus simultaneously faces both reservoirs along successive portions separated by the tabs 36 .
It will be understood that with such an arrangement, when the pyrotechnic charge 24 is fired, the explosion produced smashes the two reservoirs 22 in such a way that, under the effect of the blast, the numerous fragments produced are thrown towards the articles contained in the suitcase. In particular, they are guided by the deflector 26 . Under the effect of the shock of the fragments, any wrapper that may surround the articles becomes torn. The ink contained in the reservoirs is simultaneously propelled by the effect of the blast and is thus thrown over the articles whose cover has been lacerated by the fragments of the reservoir.
The direct action of the blast both on the fragments from the wall of the reservoirs and on the fluid allows the fragments and the fluid to be thrown at high speed over the articles. Furthermore, the presence of the deflector guides the fragments and the fluid directly towards the articles so that their dispersion is low.
The use of a detonating cutting cord advantageously produces a direct effect of lacerating the articles in the region where the cord is attached.
FIG. 3 depicts another alternative form of a denaturing device according to the invention.
This device comprises a cylindrical reservoir 40 formed by a glass ampoule. The wall of the ampoule is made of a material that fragments, such as borosilicate glass or hardened glass. This reservoir is filled with indelible ink or some other fluid intended to soil the articles. A pyrotechnic charge 42 placed directly in contact with the ink and extending along the axis of the cylinder passes axially right through it. This charge is formed, for example, of a detonating cord consisting of an explosive charge surrounded by a lead sleeve with a total thickness of approximately 1.5 mm.
The charge 42 is connected by a fuze 44 provided at one of its ends, to a triggering unit.
It will be understood that as before, the firing of the pyrotechnic charge 42 smashes the reservoir 40 which fragments into a collection of elemental fragments which are thrown towards the articles to be denatured. At the same time, the ink contained in the reservoir is dispatched over the articles under the effect of the blast.
In an alternative form, not depicted, the pyrotechnic charge 42 is bonded directly along the tube 40 on the outside of this tube.
With such an arrangement, the articles can be arranged anyhow inside the container. This is because the explosion produces a blast which is applied to the reservoir directly. The structure of the wall of this reservoir thus, in addition to the ink, plays a part in denaturing the articles by a laceration effect.
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The invention concerns a device for altering the appearance of valuable articles comprising at least a reservoir ( 22 ) filled with a fluid adapted to soil said articles and a pyrotechnic charge ( 24 ) associated with said reservoir ( 22 ) for opening the latter to release said fluid on said articles. The (each) reservoir ( 22 ) is substantially defined by a wall made of a fragmentation material adapted, by the effect of the pyrotechnic charge ( 24 ), to produce a multitude of scattered elementary splinters. The invention is applicable to suitcases for the transport of funds.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of and takes priority under 35 U.S.C. §119 to U.S. Patent Application No. 61/279,704 filed on Oct. 26, 2009.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to a dynamic traction element, and more particularly to a dynamic traction element construction wherein a flexible elastomeric traction arm element is designed and configured to yield an improved dynamic traction element providing for a faster rate of deformation return following compression.
[0004] 2. Description of the Related Prior Art
[0005] Prior dynamic traction element constructions include dynamic traction elements having pivoted or articulated sections joined together in a central hub area; these flexible traction elements are composed of a singular material, typically a resilient thermoplastic urethane dynamic element configuration.
[0006] There are three forces or stresses that may act on a material, all of which are intermolecular: sheer or tensile, compression, and torque. Sheer or tensile stress represents a force acting on an object, which is being pulled apart. Compression stress represents a force acting on an object that is being pushed together. Lastly, torque represents a rotational or twisting stress on an object.
[0007] The instant invention primarily deals with both sheer and compression stresses on a material; additionally these effects on the material may also be influenced by water and its associated contaminants, as along with ultra violet radiation.
[0008] Polyurethane comprises a series of urethane molecules linked together by hydrogen bonds. In contrast, water which may be found on the golf course for instance, would not be considered pure water, rather there may be additional compounds dissolved in the water, such as hydrocarbons which themselves are a series of long carbon chains with hydrogen atoms attached around the outside of the chain. Therefore, moisture from a golf course will wick up into the polyurethane (water will wick up into nylon as well, but nylon is not as reactive as urethane to hydrocarbons). As the water evaporates, the hydrogen atoms from the hydrocarbons will release from the chain forming free-floating hydrogen radicals. Since the hydrogen bonds holding the urethane molecules together require a lot of energy to maintain, the tendency will be for the urethane molecules to release the hydrogen bond linking it to the next urethane molecule and substitute in its place a free floating hydrogen atom, which in its free-floating nature requires less energy. As a result, the bond between the hydrogen atoms requires less energy to maintain than the bond between the hydrogen and urethane molecules; as such the energy difference favors the direction the polyurethane molecules ultimately undertake. The result on a golf cleat is that over time, more and more intermolecular bonds will break, thereby will lose a cleat's resiliency to quickly return to a cleat's original position, and instead will remain in a compressed set.
SUMMARY OF THE INVENTION
[0009] The instant invention, as illustrated herein, is clearly not anticipated, rendered obvious, or even present in any of the prior art mechanisms, either alone or in any combination thereof.
[0010] The instant invention comprises a dynamic golf cleat having a plurality of composite dynamic traction elements; the elements preferably assume an angle with respect to the plane of the shoe sole, to allow room for deflection toward the shoe sole under pressure load. Each dynamic traction element is preferably formed of an elastomeric material including, but not limited to thermoplastic urethane. A series of embedded thin tensile members are disposed to be oriented and integrally formed within each flexible traction element, and are preferably molded within each dynamic traction element. Each individual tensile member is centrally located within each corresponding dynamic traction element. This orientation allows for the creation within each dynamic traction element of distinct upper and lower surface areas. As such, these sections of the dynamic traction elements possess facing surfaces which are joined by the thin tensile member sections.
[0011] According to one embodiment of the instant invention, two elastomeric sections separated by a thin tensile member define a dynamic traction element, and within these dynamic traction elements are areas defined as stress concentration zones, or stress lenses. These stress lenses are preferably comprised of ridges and/or grooves oriented and disposed to be integrally formed within each dynamic traction elements. The ridges or grooves are designed to concentrate or focus the stresses caused by deformation from broad areas of the elastomeric dynamic traction elements into smaller concentrated areas of the elastomeric elements. As a result, this concentration of stresses, such as compression stress or tensile stress require more energy to deform the material, than if the stresses were more broadly dispersed within its molecular structure. Therefore, the faster deformation return in this embodiment may be attributed to the embedded and integrally molded tensile member surface conforming to the curved sections of a plurality of traction teeth and which is disposed to be substantially bendable and able to conform to straight teeth sections.
[0012] It is known in the art that when two materials with two different flex modulus values are surface bonded, they create a material that has a higher flex modulus than the simple sum of the independent flex modulus of the two materials. Therefore, the return speed of a material from deformation (for example under pressure load) to its original pre-deformation position of the composite dynamic traction element (i.e. the dynamic traction element with the bonded core, is about six times the speed of the non-composite dynamic traction element).
[0013] The increased recovery speed for a material may desired in any activity, but possesses increased significance when a plurality of traction elements are flexing under pressure loads typically encountered during sports that require any type of running by a player. The recovery rate on a non-composite or “simple” dynamic traction element is does not allow the dynamic traction element to its original position following deformation prior to each new stride a running player undertakes. Therefore once a player starts running, a simple dynamic traction element will not be able to fully recover its shape until the player stops running and the load is removed for a sufficient time interval, such as the time the shoe is of the ground during a typical walking stride of a golfer for example.
[0014] Finally, the premature aging of the elastomeric material due to wicking contaminated water, such as dew-covered grass with petroleum based pesticides added would be delayed by the addition of the core member and its inherent improved performance characteristics, as well as the tendency of the core material to be significantly less sensitive to the effects of any petroleum based pesticides. Ultraviolet radiation, another aging enhancer will also have less effect on the composite dynamic traction elements, again because the core material is less sensitive to begin with but also because it is protected to a degree by the outer covering of the elastomeric material.
[0015] Therefore, to summarize, in a dynamic cleat whereby the flexible element is made from a single material of a single durometer or flex modulus, an individual is required to rely on a very slow process in order for each flexible dynamic element to return to their original pre-stressed position. This process is known as entropy and encompasses the universal law that all things will eventually return to their lowest energy state. Thus, for a deformed flexible element, once the deforming stress is removed, the lowest energy state for the molecules of the flexible element would be defined as their original locations. In one embodiment, this state may be described as the location and shape of each flexible element upon reaching a solid state.
[0016] The molecules of each flexible element may be comprised of long chains of carbon atoms surrounded primarily by hydrogen atoms with the occasional nitrogen, oxygen or sulfur atoms forming right angles, thereby allowing the molecule to become a more rigid building block upon bonding with other molecules. Typically, these atoms are held together as a result of not possessing the correct amount of neutral electric charge to assume a state of rest.
[0017] As such, once a force pushes the flexible material and deforms it, the electrons closest to the deformed areas require more energy to stay locked together. However, sometimes the force is too great and the electron bonds fail and the parts subsequently break apart. Returning now to the deformed dynamic element; the force applied and the distance the deformation takes place is low enough that the parts keep their electron bonds and simply want to go back to the un-deformed shape where they can reach their lowest energy state.
[0018] Since the molecular chains do not have a chance to all get in line before they cooled and solidified, the process of returning to its original shape is not completely uniform. As some electrons pull together, they often times need to push other electrons apart momentarily in order to get back into shape. This process, entropy is therefore slow and itself not very energetic. Two weak electron bonds battling each other to get back in line, momentarily creating an opposing force situation can reduce the energy component of that particular movement to near zero, making it agonizingly slow.
[0019] Therefore, by introducing a tensile member embedded into the dynamic traction material will alter the chemical and mechanical properties of the instant invention. The tensile member that would be embedded would optimally and preferably match as close as possible the material characteristics as the over-molded elastomeric material. Since the tensile member is made of a much denser, stronger, more rigid material, it may be quite thin. Additionally, close to the thickness it would need merely to hold itself up in position in order to hold its shape prior to the injection of the elastomeric material, likely only several thousands of an inch thick.
[0020] Moreover, the tensile member is preferably put in place to put more order into the stresses that will occur once the dynamic element is deformed by being pushed into the shoe sole surface. For the most part, all the molecules above the tensile member will go into a tensile stress load condition and the molecules below the tensile member will go into a compression stress load condition. This alone increases the organization level of stress load on the material dramatically. Add to this organized state the fact that the molecules attached to both the top and bottom of the tensile member stay attached as the tensile member deforms as it bends. This puts a organized concentrated motion of forces pulling apart (Tensile stress) of the elastomeric material above the tensile member and pushing together (Compression stress) the elastomeric material below the tensile member.
[0021] Not only have the forces involved been separated and located, the tensile stresses above the member and the compression stresses below the member but we further concentrate the larger stronger stresses within each side closest to the member itself. More organization of forces at work means more concentrated energies at work when it is time for the dynamic traction element to return to its uncompress, pre-stressed shape.
[0022] Using similar approaches to concentrating the force loads, the longitudinal ridges along the top surface of the traction element and the lateral grooves on the bottom surface are additional methods that generally act as stress organizers as well, further concentrating the forces involved in the deformation of the traction element. Therefore they act to help speed the return to shape though typically not as effectively as the embedded tensile member does.
[0023] There has thus been outlined, rather broadly, the more important features of the a dynamic traction election in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
[0024] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0025] These together with other objects of the invention, along with the various features of novelty, which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a plan view of a typical prior art dynamic cleat.
[0027] FIG. 2 is a sectioned, longitudinal side elevation view of a dynamic traction element taken along section line 2 - 2 of FIG. 1 .
[0028] FIG. 3 is a sectioned, lateral elevation view of a dynamic traction element taken along section line 3 - 3 of FIG. 1 .
[0029] FIG. 4 is a plan view of the present invention dynamic cleat.
[0030] FIG. 5 is a sectioned, longitudinal side elevation view of a dynamic traction element taken along section line 5 - 5 of FIG. 4
[0031] FIG. 6 is a sectioned, lateral elevation view of a dynamic traction element taken along section line 6 - 6 of FIG. 4 .
[0032] FIG. 7 is a top view of the threaded base shown in FIG. 4 .
[0033] FIG. 8 illustrates a second embodiment of the threaded base shown in FIG. 4 and is a top view of the embedded tensile members and their threaded base.
[0034] FIG. 9 illustrates a third embodiment of the threaded base shown in FIG. 4 and is a top view of the embedded tensile members and their threaded base.
[0035] FIG. 10A is a sectioned, longitudinal side elevation view of a dynamic traction element taken along section line 2 - 2 of FIG. 1 and is similar to the figure as shown in FIG. 2 .
[0036] FIG. 10B is a sectioned, longitudinal side elevation view of a dynamic traction element taken along section line 2 - 2 of FIG. 1 and is shown when flattened by a force is acting on dynamic traction elements.
[0037] FIG. 11A is a sectioned, longitudinal side elevation view of a composite dynamic traction element taken along section line 5 - 5 of FIG. 4 and is similar to the figure as shown in FIG. 2 .
[0038] FIG. 11B is a sectioned, longitudinal side elevation view of a composite dynamic traction element taken along section line 5 - 5 of FIG. 4 and is shown when flattened by a force acting on the dynamic traction elements.
[0039] FIG. 11C is a sectioned, longitudinal side elevation view of a composite dynamic traction element taken along section line 5 - 5 of FIG. 4 and is shown when flattened by a force acting on the dynamic traction elements.
[0040] FIG. 12A is a sectioned, lateral elevation view of a dynamic traction element taken along section line 6 - 6 of FIG. 4 .
[0041] FIG. 12B is a sectioned, lateral elevation view of a dynamic traction element taken along section line 6 - 6 of FIG. 4 also showing color coded stress concentrations correlated to the color key shown.
[0042] FIG. 13A is a sectioned, lateral elevation view of a dynamic traction element taken along section line 3 - 3 of FIG. 1 .
[0043] FIG. 13B is a sectioned, lateral elevation view of a dynamic traction element taken along section line 3 - 3 of FIG. 1 also showing color coded stress concentrations correlated to the color key shown.
[0044] FIG. 14 shows an alternate embodiment with three dynamic elements and three tensile members.
[0045] FIG. 15A shows the embedded tensile member of FIG. 14 .
[0046] FIG. 15B is a cross section of one of the dynamic elements shown in FIG. 15A and taken along section line 15 A- 15 A.
[0047] FIG. 16 shows still another alternate embodiment with six dynamic elements and three tensile members.
[0048] FIG. 17A shows the embedded tensile member of FIG. 16 .
[0049] FIG. 17B is a cross section of one of the dynamic elements shown in FIG. 15A and taken along section line 17 A- 17 A.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0050] FIG. 1 illustrates a plan view of a typical prior art dynamic cleat 12 comprised of a central hub 14 having a central wear area 18 . The prior art dynamic cleat 12 is also comprised of a plurality of dynamic traction elements, in this example 16a trough 16 e . Each dynamic traction element is further comprised of raised traction teeth portions 20 for providing enhanced traction.
[0051] FIG. 2 illustrates a sectioned, longitudinal side elevation view of a dynamic traction element taken along section line 2 - 2 and shows the simple non-composite dynamic traction element 16 a with its traction tooth area 20 along with central hub 14 having and the convex central wear area 18 . The convex central wear area 18 being of a high durometer provides a compression limit of the spikes on hard surfaces such as a paved area, thus helping extend wear damage characteristics of the spike.
[0052] FIG. 3 illustrates a sectioned, lateral elevation view of a dynamic traction element taken along section line 3 - 3 and shows the simple non-composite dynamic traction element 16 a.
[0053] FIG. 4 illustrates a plan view of the present invention dynamic cleat 22 along with the central hub 24 having a central wear area 28 . As part of the central hub portion 28 , a plurality of tensile members 32 a through 32 e are shown in dotted lines and preferably embedded within a plurality of dynamic traction elements 26 a through 26 e respectively. Each dynamic traction element 26 is further comprised of a raised traction teeth portion 30 preferably for providing enhanced traction.
[0054] FIG. 5 illustrates a sectioned, longitudinal side elevation view of a dynamic traction element 26 taken along section line 5 - 5 and shows the composite dynamic traction element 26 a with a corresponding traction tooth area 30 , along with the central hub portion 24 having a convex central wear area 28 . The convex central wear area 28 is preferably of a high durometer to provide a compression limit of the spikes on hard surfaces such as a paved area, thus helping extend wear damage characteristics of the spike. Furthermore, as discussed in FIG. 5 , each dynamic traction element 26 includes a substantially embedded tensile member 32 having a raised end ridge 34 . Each embedded tensile member 32 is preferably chemically bonded to an associated surface 44 and 46 of the elastomeric material of the dynamic traction element 26 a . To further provide bonding strength the raised end ridge 34 may provide an added mechanical bonding function. Also shown on composite dynamic traction element 26 a is a longitudinal ridge 38 b on the top tension side of the tensile member 32 and lateral notches 36 on the compression side of the tensile member, which will be explained in more detail when describing FIGS. 11A-11C .
[0055] FIG. 6 illustrates a sectioned, lateral elevation view of a dynamic traction element taken 26 along section line 6 - 6 and shows more clearly the longitudinal ridges 38 a and 38 b on the top tension side of the tensile member 32 preferably embedded within the composite dynamic traction element 26 a.
[0056] FIG. 7 is a top view of the embedded tensile members 32 and their threaded base 24 . The wings that extend away from the center are the integral molded tensile members 32 a through 32 e . Shown on the ends of the tensile members are integrally molded ridges 34 a through 34 e that are disposed to create the mechanical bonds that exist on the ends. These mechanical bonds will assist the chemical bonds that will occur between the urethane and the nylon material on their contacting upper and lower surfaces in maintaining structural integrity.
[0057] FIG. 8 illustrates a second embodiment and is a top view of the embedded tensile members 32 and their threaded base 48 . The wings that extend away from the center are the integral molded tensile members 50 a through 50 e . Shown on the surface of the tensile members are the integrally molded holes 52 a through 52 e that create the mechanical bonds that exist between the tensile members and their associated dynamic traction members. These mechanical bonds will assist the chemical bonds that will occur between the urethane and the nylon material on their contacting upper and lower surfaces in maintaining structural integrity.
[0058] FIG. 9 illustrates a third embodiment and is a top view of the embedded tensile members and their threaded base 54 . The wings that extend away from the center are the integral molded tensile members 56 a through 56 e . Shown on the ends of the tensile members are the integrally molded ridges 34 a through 34 e along with the integrally molded holes 52 a through 52 e both of which will create the mechanical bonds that exist between the tensile members and their associated dynamic traction members. These mechanical bonds will assist the chemical bonds that will occur between the urethane and the nylon material on their contacting upper and lower surfaces in maintaining structural integrity.
[0059] FIG. 10A is a sectioned, longitudinal side elevation view of a dynamic traction element taken along section line 2 - 2 and shows the simple non-composite dynamic traction element 16 a with its traction tooth area 20 along with a central hub portion 14 having a convex central wear area 18 , the same position as shown in FIG. 2 . In this figure, the dynamic traction element 16 a is in an uncompressed relaxed state.
[0060] FIG. 10B is a sectioned, longitudinal side elevation view of a dynamic traction element 16 a taken along section line 2 - 2 and shows the simple non-composite dynamic traction element 16 a with its traction tooth area 20 along with a central hub 14 having a convex central wear area 18 , the same position as shown in FIG. 2 . Note the dynamic traction element is in the compressed stressed state. As the urethane molecules in the wings of the cleat cure, their relaxed state is at an upward angle as shown in FIG. 10A . When flattened a force is acting on these wings causing a tensile stress as shown in FIG. 10B . The stress is at the molecular level between the bonds holding the urethane molecules together. It is an undefined relaxed stress that puts all of the molecules under some tensile sheer. There exists little energy to reduce the molecules to their original upward angled position. Thus when the force is removed the return will be very gradual.
[0061] FIG. 11A is a sectioned, longitudinal side elevation view of a dynamic traction element taken along section line 5 - 5 and shows the composite dynamic traction element 26 a with a corresponding traction tooth area 30 along with a central hub portion 24 having a convex central wear area 28 . The convex central wear area 28 being of a high durometer provides a compression limit of the spikes on hard surfaces such as a paved area, thus helping extend wear damage characteristics of the spike. Also shown in FIG. 5 are an embedded tensile member 32 and the raised end ridge 34 . The embedded tensile member 32 is chemically bonded to the associated surfaces 44 and 46 of the elastomeric material of the dynamic traction element 26 a . To further provide bonding strength, the raised end ridge 34 provides an added mechanical bonding function. Also shown on composite dynamic traction element 26 a is longitudinal ridge 38 b on the top tension side of the tensile member 32 and lateral notches 36 on the compression side of the tensile member.
[0062] FIG. 11B is a sectioned, longitudinal side elevation view of a dynamic traction element taken along section line 5 - 5 and shows the composite dynamic traction element 26 a with its traction tooth area 30 along with a central hub portion 24 . Note the dynamic traction element is in the compressed stressed state. FIG. 11B further shows the tensile member 32 compressed with the force being separated into two different stresses, each acting on the tensile member 32 in a different manner. Above the tensile member 32 the stresses experienced within the elastomeric material consists of primarily tension (i.e. the molecules have a pressure applied that wants the shear them apart). The tensile member 32 itself sets up this separation of stress forces.
[0063] Because the elastomeric material is essentially chemically and mechanically fused to the tensile member itself, it creates a setting whereby the elastic material above the tensile member is primarily under tension and the elastomeric material below the tensile member is primarily under compression stress. In short, tensile stress exists above the embedded tensile member and compression stress exists below. When a general broad tensile stress is separated, making one side compression and one side tension, the stress is concentrated which gives the stress more energy resulting in the elastomeric material. Thus, in this case the polyurethane will have more energy to spring back into shape. The lateral notches on the compression side of the tensile member help focus the stress even, more making it more concentrated. Although not shown, the stresses and dynamics that are occurring to the urethane are also occurring to the embedded nylon tensile member and since nylon has a much more dense molecular structure its tendency to return to its original shape is even greater.
[0064] FIG. 11B shows in a rough manner the directions and types of stresses taking place within the elastomeric material itself. Broadly speaking above the tensile member when the dynamic element is deformed downward and the material is put under shear stress, what is happening is the molecules are stress in such a way as they want to shear apart. It is simply the covalent bonds of the electrons holding together that prevent the breakdown and separation of the material and ultimately failure of the part. That force to pull the molecules apart is a tensile shear. Tensile meaning stretching force and shear meaning ultimately slide by after bond failure. Ironically compression forces under the tensile member though a force pushing the parts together is still ultimately a shearing action. Under a compression failure the covalent bonds fail and the molecules simple slide by in the opposite direction appearing to compress but in essence it is still considered a shearing event, which is why in the drawings the force is denoted a compression shearing action.
[0065] FIG. 11C is again a sectioned, longitudinal side elevation view of a dynamic traction element taken along section line 5 - 5 and shows the composite dynamic traction element 26 a with its traction tooth area 30 along with a central hub portion 24 ; it is included in order to more clearly define the localized shearing action specifically in relation to the ridges and grooves designed to focus and concentrate the shearing forces into more compact areas, thus increasing the stress on the localized molecules resulting in more localized strain and therefore more localized recovery, which results in faster more robust molecular recovery.
[0066] FIG. 12A is a sectioned, lateral elevation view of a dynamic traction element taken along section line 6 - 6 and shows more clearly the longitudinal ridges 38 a and 38 b on the top tension side the tensile member composite dynamic traction element 26 a . This is the same view used as FIG. 6 earlier. FIG. 12B show the cross sections of the preferred embodiment that were originally shown in FIG. 12A and FIG. 6 , with the addition of coding to show the concentration levels of stress forces while under load conditions; the color gradations on FIG. 12B shows the distribution of stress levels on the dynamic traction elements; using the key, the concentration of highest stress, will be near the surface of the embedded tensile members or in the ridges; the high stress levels at the chemical bonded surfaces, are where the tensile members 32 are bonded to the elastomeric material of dynamic traction element 26 . The top surface 40 of each tensile member 32 , deals with a tensile force applied by the tensile forces within the area 44 of the dynamic element 26 that is bonded to the surface of each dynamic traction element 26 . Meanwhile the bottom surface 42 of each tensile member 32 , deals with a compression force applied by the compression forces within the area 46 of the dynamic element 26 that is bonded to the surface of dynamic traction element 26 . A further concentration of forces is achieved by the addition of longitudinal ridges 38 a and 38 b running along the top surface of dynamic traction element 26 . These ridges although designed to concentrate a force that is below its deformation threshold, now are disposed to apply a larger force to the elastomeric material which in turn applies a larger opposite force to recover from the deformation, thus adding to the faster recovery rate, or return rate of the overall compression cycle time.
[0067] FIG. 13A is a sectioned, lateral elevation view of a prior art dynamic traction element taken along section line 3 - 3 and shows the simple non-composite dynamic traction element 16 . The lack of an embedded tensile member and top surface ridges is evident.
[0068] FIG. 13B is a sectioned, lateral elevation view of a prior art dynamic traction element taken along section line 3 - 3 and shows the simple non-composite dynamic traction element 16 with the addition of color coding to show the concentration levels of stress forces while under load conditions. The color gradations on FIG. 12B show where the stress will be highest and lowest. Using the key, the concentration of highest stress, is only the tensile stresses which occur broadly throughout the elastomeric material but is more concentrated closest to the top outside surface, where tensile stress levels are at there highest. The lack of an embedded tensile member and top surface ridges is evident in the lack of opposing stress forces and concentration areas. The result is a sluggish return speed from compression forces and an overall slow cycle time.
[0069] FIG. 14 illustrates a plan view of an alternate embodiment dynamic cleat 60 with an elastomeric flexible dynamic traction portion 62 having three dynamic element 68 a 68 b and 68 c over-molded onto three embedded tensile members, 70 a through 70 c , each of which includes dual independent embedded tensile members units 72 a and 72 b that are embedded into corresponding dynamic element 68 a , 68 b and 68 c . Also as part of the elastomeric overlay is a plurality of molded soft but static traction elements 78 . In this embodiment the design calls for three, but the actual number would be determined but such design factors as aesthetics and/or actual additional traction needs. Each dual embedded tensile member 70 a through 70 c has a centrally positioned perpendicularly convex angled tensile ridge 74 . The perpendicular curve is perpendicular to the typical curved tensile members shown in the primary embodiment FIG. 4 . The two, perpendicular, associated curved surfaces create what is considered a compound curved surface, which in turn adds more structural strength and even faster return from deforming forces than a single curved embedded tensile member would typically exhibit.
[0070] FIG. 15A illustrates a top view of the embedded tensile member unit 64 of the alternate embodiment dynamic cleat 60 shown in FIG. 14 . The three wings that extend away from the center are the integral molded tensile members 72 a through 72 c . Shown along the surfaces of the tensile members is a plurality of integrally molded holes 76 , in this embodiment one hole per corresponding dynamic traction element. The holes 76 replace the ridges 34 of the primary embodiment and perform essentially the same function; that of providing an additional mechanical bond to the already existed chemical bond created during the over-molding process. These mechanical bonds will assist the chemical bonds that will occur between the urethane and the nylon material on their contacting upper and lower surfaces.
[0071] FIG. 15B illustrates a cross section of one of the dynamic elements 70 showing that the surface may be domed. The domed shape in area 74 , which creates the compound curved surfaces that give the nylon portion a lot more energy to return to its original shape and also requires a lot more energy to deform, thus the dynamic element will spring up quickly. This type of cleat along with the cleat shown in FIG. 16 may be used for sports where the time interval between compressions is quicker than in walking i.e. sports where there is running such as soccer and football. This alternate embodiment allows the spike to be in its original position before every foot strike, which is virtually impossible with the return cycle time of current spikes.
[0072] FIG. 16 illustrates a plan view of an alternate embodiment dynamic cleat 80 with an elastomeric flexible dynamic traction portion 82 having three dynamic element 88 a , 88 b and 88 c over-molded onto three embedded tensile members, 90 a through 90 c , each of which, having dual, independent embedded tensile members units 92 a and 92 b that are embedded into corresponding dynamic element 88 a , 88 b and 88 c . Also as part of the elastomeric overlay is a plurality of molded soft but static traction elements 98 . In this embodiment the design calls for three, but the actual number would be determined but such design factors as aesthetics and/or actual additional traction needs. Each dual embedded tensile member 90 a through 90 c has a preferably centrally positioned perpendicularly concaved curved tensile ridge 94 . The perpendicular curve is perpendicular to the typical curved tensile members shown in the primary embodiment of FIG. FIG. 4 . The two, perpendicular associated curved surfaces, create what is considered a compound curved surface, which in turn adds more structural strength and even faster return from deforming forces than a single curved embedded tensile member would typically exhibit.
[0073] FIG. 17A illustrates a top view of the embedded tensile member unit 94 of the alternate embodiment dynamic cleat 80 shown in FIG. 14 . The three wings that extend away from the center are the integral molded tensile members 92 a through 92 c . Shown along the surfaces of the tensile members is a plurality of integrally molded holes 76 , in this case one hole per dynamic traction element. The holes 76 replace the ridges 34 of the primary embodiment and perform essentially the same function; that of providing an additional mechanical bond to the already existed chemical bond created during the over-molding process. These mechanical bonds will assist the chemical bonds that will occur between the urethane and the nylon material on their contacting upper and lower surfaces.
[0074] FIG. 17B illustrates a cross section of one of the dynamic elements 90 showing that the surface is of a convex domed shape. The convex domed shape in area 94 , which creates the compound curved surfaces that give the nylon portion a lot more energy to return to its original shape and also requires a lot more energy to deform, thus the dynamic element will spring up quickly. This type of cleat and the cleat shown in FIG. 16 may be used for sports where the time interval between compressions is quicker than in walking i.e. sports where there is running such as soccer and football. This alternate embodiment allows the spike to be in its original position before every foot strike, which is virtually impossible with the return cycle time of current spikes.
[0075] In another embodiment, there is a single longitudinally flexible ridge area located longitudinally on the top surface of each flexible traction element, acting in the role of a tensile stress lens area. In a third embodiment, in the middle portion of each thin tensile member is a thickened end portion circular cutout hole running through the thin tensile member. The circular cutout hole adds additional bonding strength to help keep the embedded thin tensile member bonded in place, by adding mechanical strength in addition the chemical bonds created between the thin tensile member and the flexible traction element during the molding process. In a forth embodiment, both lateral raised ridges and circular cutout hole are used for added mechanical strength.
[0000] In another embodiment, the thermoplastic urethane may have a Shore A hardness of from about 55-A to 95-A, with about 85-A being a preferred hardness. The dynamic elastomeric cleat elements are integrally molded to and project in a radial manner outward from, a central hub portion. The central hub portion is formed of a rigid plastic material such as nylon 6/6 typically, having a Shore D hardness of from about 45-D to 80-D, with about 70-D being a preferred hardness. On the end of each thin tensile member is a thickened end portion running laterally across the thin tensile member end. The thickened portion adds additional bonding strength to help keep the embedded thin tensile member bonded in place, by adding mechanical strength in addition the chemical bonds created between the thin tensile member and the flexible traction element during the molding process. In one embodiment, there are two flexible ridge areas acting in the role of a tensile stress lens sections. These tensile stress lens sections are longitudinal in shape and are located on the upper surface area of the dynamic traction element. A single or plurality of lateral cutout areas act in the role of a compression stress lens sections on the lower surface area of the dynamic traction element.
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A dynamic golf cleat having a plurality of composite dynamic traction elements, the wherein the elements preferably assume an angle with respect to the plane of the shoe sole, to allow room for deflection toward the shoe sole under load. The dynamic traction element is preferably formed of an elastomeric material such as thermoplastic urethane. A hub portion having a threaded attachment means is preferably oriented perpendicular to the plane of the shoe sole. Extending outwardly in a radial manner from the hub portion is a plurality of embedded thin tensile members oriented to be integrally formed within each flexible traction element. Each individual tensile member is centrally located within each dynamic traction element creating a distinct upper surface area and a lower surface area, within each dynamic traction element. Said sections of the dynamic traction elements have facing surfaces joined by a thin tensile member sections. These thin tensile member sections are molded integral with the two flexible traction element, an upper surface area and a lower surface area.
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BACKGROUND OF THE INVENTION
This invention relates to the measurement of total iron binding capacity in serum.
Iron is carried in the blood plasma by a specific carrier protein called transferrin. This is a protein of molecular weight 76,000-80,000, which has two sites each capable of binding one iron atom. The total amount of transferrin present determines the total iron binding capacity (T.I.B.C.) of the serum.
The estimation of the T.I.B.C. is an important clinical procedure, with an established role in the diagnosis of such conditions as iron deficiency anaemia and haemochromatosis, and in the monitoring of therapeutic procedures. In iron deficiency states, T.I.B.C. is elevated: in iron overload conditions T.I.B.C. is depressed.
Techniques which are currently used for determination of T.I.B.C. rely on the saturation of transferrin and removal of excess iron from the serum with an adsorbent such as magnesium carbonate (Ramsay, W. N. M.: Clin. Chim. Acta 2 221 (1957)) or an ion exchange resin (Peters, T., Giovanello T. J., Apt, L. and Ross, J. R.; J. Lab. Clin. Med. 48 274 (1956)). Other methods employ direct measurement of the excess iron after saturation, and calculation of unsaturated iron-binding capacity (Williams, H. L., and Conrad, M. E.; J. Lab. Clin. Med. 67 171 (1966); O'Malley, J. A., Hassan, A., Shiley, J., and Traynor, H.; Clin. Chemistry 16 92 (1970)). The most commonly used magnesium carbonate method is subject to error owing to the inclusion of non-transferrin bound iron in the supernatant solution (Ramsay, W. N. M.; J. Clin. Pathol. 26 691 (1973)).
An improved method using an alumina column, which was faster and simpler than the magnesium carbonate method while offering improved accuracy, was previously disclosed by the present inventor (Clin. Chemistry 26 156 (1980)).
SUMMARY AND OBJECTS OF THE INVENTION
The object of the present invention is to provide improvements in the measurement of T.I.B.C.
There is provided in accordance with the invention a tube closed at one end, having a removable closure, the tube containing a measured quantity of a dried iron-saturating substance, which is adhered to the inner surface of the base of the tube, and a measured quantity of dried alumina (aluminum oxide, Al 2 O 3 ).
Preferably the tube and closure are made of plastics.
Preferably the neck of the plastic tube is threaded to receive a plastics screw cap. The screw cap is most preferably large enough to contain the quantity of alumina.
Preferably the tube is made of polystyrene, most preferably of transparent polystyrene.
Preferably the cap is made of polyethylene.
The dried iron-saturating substance is preferably a complex salt of ferric iron.
The alumina is preferably basic chromatographic grade alumina, most preferably Brockmann grade II.
Preferably the tube is designed to fit sample carriers of automatic analysers such that their sample probes will sample from above the level occupied by alumina in the tube.
According to a further aspect of the invention, there is provided a method of performing the measurement of T.I.B.C. using the apparatus described hereinabove comprising pouring alumina out of the tube into the cap, adding a solvent, for example water, to the tube to dissolve the iron-saturating substance, and adding the sample of serum to the tube; then after a brief period of incubation to allow the iron to bind to transferrin in the serum sample, replacing the alumina in the tube, mixing the tube to allow binding of the unbound iron to the alumina, and after allowing the alumina to settle, measuring the iron content of the supernatant by any suitable means, for example by automatic continuous flow analyser or by atomic absorption spectroscopy.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWING
Preferred embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which:
FIG. 1 represents an exploded view of a free-standing sample tube having a screw cap, containing a measured amount of alumina powder, and having a measured amount of an iron-saturating substance bonded to the interior surface of the tube;
FIG. 2 represents an exploded view of free-standing sample tube as in FIG. 1 but having a slidably fitting cap; and
FIG. 3 represents an exploded view of a free-standing sample tube as in FIG. 1, but having a screw cap with a solid central projection extending to a hollow opening, to the interior surface of which is bonded a measured amount of an iron-saturating substance.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to one embodiment of the invention there is provided a free-standing sample tube as shown in FIG. 1 comprising a polyethylene cap 1 which is adapted to screw onto the threaded neck 2 of a polystyrene tube 3 which is closed at one end, and has a rim 4 forming a base which enables the tube to be free-standing. The tube contains a measured amount of washed and dried chromatographic-grade alumina powder 5, and a measured amount of an iron-saturating substance 6 bonded to the base of the interior surface of the tube 3.
According to one preferred embodiment there is provided a free-standing sample tube, comprising a polyethylene cap 1 which is adapted to fit snugly within the neck 2 of a polystyrene tube 3 which is closed at one end, and has a rim 4 forming a base which enables the tube to be free-standing. The tube contains a measured amount of washed and dried chromatographic-grade alumina powder 5, and a measured amount of an iron-saturating substance 6 bonded to the base of the interior surface of the tube 3.
The polyethylene cap defines a hemispherical enclosure large enough to contain the alumina and constructed so that the internal diameter of the cap is identical to that of the base. The cap is designed to fit into the base such that there is a continuous, unbroken internal surface.
The tube preferably is 44 mm high (not including the cap), has an outside diameter of 15 mm at the top and 12.5 mm at the base, and has a working capacity of 2 ml. More preferably the tube is 40 mm high.
Preferably 0.4 g of alumina is used.
In a preferred embodiment, the iron-saturating substance is attached to the base of the tube 3 by adding 10 ul of a solution of FeCl 3 at a concentration of 500 mg Fe 3+ /l in 0.1 mole/l citric acid containing 0.2% sodium azide and heating the tube in an oven at 70° until dry (approximately 3 hours).
In a specific example, the test is performed as follows:
1. Invert the tube and remove the cap so that the alumina is retained in the cap.
2. Add 1 ml. of water to the tube and wait two minutes or longer to dissolve the dried iron saturating substance which is attached to the bottom of the tube.
3. Add 0.5 ml. of specimen (serum) and stand three minutes or longer to allow the iron to bind to the carrier protein transferrin.
4. Pour the alumina back into the tube and then replace the cap.
5. Place the capped tube onto a laboratory rotator and mix by constant inversion for ten minutes or longer.
6. Remove the tube from the rotator and stand 1/2 minute or longer and either transfer a portion of the supernatant to another sample container or use the tube itself as a sample container. (The tube may be used as the sample container on some automatic instruments e.g. the Technicon auto-analysers commonly used in hospitals.
7. Measure the iron content of the supernatant.
According to another preferred embodiment, there is provided a free standing sample tube as shown in FIG. 3, comprising a polyethylene cap 1 which is adapted to screw onto the threaded neck 2 of a polystyrene tube 3 which is closed at one end and has a rim 4 forming a base which enables the tube to be free standing. The tube contains a measured amount of washed and dried chromatographic-grade alumina powder 5.
The cap 1 contains a solid central projection which extends to a hollow opening, which may for example be hemispherical. A measured amount of an iron-saturating substance 6 is bonded to the interior surface of the opening.
This cap design allows the test to be performed without decanting the alumina. The central projection to which the iron-saturating substance is bonded restricts contact of alumina with the iron-saturating substance, thereby allowing iron to dissolve and bind to transferrin before it is bound to alumina.
The tube preferably is 44 mm high (not including the cap), has an outside diameter of 15 mm at the top and 12.5 mm at the base and has a working capacity of 2 ml. The central projection has an external diameter of 7 mm and extends 11 mm into the tube when the cap is screwed on. The hollow opening of the projection is able to contain 10 ul of solution.
The iron-saturating substance is attached to the interior of the hollow opening by adding 10 ul of a solution of FeCl 3 at a concentration of 500 mg Fe 3+ /l in 0.45 mole/l citric acid containing 1% glycerol to the inverted caps and heating at 70° C. in an oven until dry (approximately three hours). The concentration of citric acid (0.45 mole/l) is chosen to promote optimum binding or iron to transferrin in the presence of alumina. The glycerol is added to enhance bonding of the iron-saturating substance to polyethylene.
Preferably 0.4 g of alumina is used.
In a specific example the test is performed as follows:
1. Remove the cap containing the iron-saturating substance.
2. To the tube containing the alumina add 1 ml of water followed by 0.5 mls of serum.
3. Replace cap and proceed with steps 5 to 7 as before.
The present invention represents a considerable improvement compared to the prior art with respect to the cost of materials, stability of reagents, speed and convenience of carrying out the procedure, and reliability of results. The cost of materials for the present invention is less than one third the cost for the column technique. The prepared tubes are stable for at least six months at room temperature, compared to the stability of the stock FeCl 3 solution of the present inventor's earlier publication (Clin. Chemistry 26 156 (1980)) which was three months at 4° C. The working solution in that case was stable for one week only. The procedure of the present invention can be performed in one minute (excluding the incubation period), compared to 11/2 minutes for the earlier procedure.
Furthermore, a considerable amount of labour is avoided by the provision of the reagents in pre-packaged form, eliminating the need for washing and drying and weighing or dispensing of alumina and preparation and dispensing of iron solution for the column method.
Quality control for the procedure can be enhanced by the pre-testing of batches of alumina before addition to the tubes. This overcomes the problem of the occasional batch of alumina which binds iron inconsistently, leading to errors and further expense.
Thus the use of the "one-tube" technique of the present invention results in cost savings in both materials and labour.
The procedure of the present invention is not subject to error resulting from lipaemic, icteric or haemolysed serum samples. Preliminary studies indicate that the procedure is applicable to plasma samples as well as to serum samples.
It will be clearly understood that the invention in its general aspects is not limited to the specific details referred to hereinabove.
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An apparatus for use in the measurement of total iron binding capacity of blood serum or plasma comprises a container having a removable closure and containing a measured quantity of dried iron-saturating substance, which is adhered to the inner surface of the container or of the closure and a measured quantity of dried alumina. The invention further provides a simple, rapid and inexpensive method for measurement of total iron binding capacity using the apparatus.
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BACKGROUND OF THE INVENTION
This invention relates to cultivators of the type which include a plurality of tools that engage and till the soil.
The prior art includes a wide variety of cultivating implements designed for both pre-planting use and for cultivating at various stages of crop growth. Many prior art implements, commonly called "rotary hoes", were designed to cover large areas of a field with closely spaced rotary tools. The prior art also discloses a variety of cultivating implements having multiple rotary tools, each of which may be angled with respect to the line of draft of the implement.
One such example of a prior art implement is shown in U.S. Pat. No. 1,249,008 to W. P. Bonds, Jr. The implement shown in the Bonds patent has a plurality of laterally spaced rotary ground engaging tools suspended from a transverse bar with means for simultaneously raising all of the tools away from the ground and a spring assembly for individually urging each of the tools down into the ground. Bonds also discloses structure which enables the tools to be selectively angled with respect to the line of draft of the implement by means of a collar and shaft arrangement for each rotary tool and a set screw which extends through the collar and can be brought into engagement with the shaft.
The disadvantages of most of the prior art adjustable implements include the necessity for using a wrench or other hand tool when adjusting the angle of draft of each ground engaging tool, that the rotary tools are raised or lowered from the ground in unison, that a visual aid such as a protractor is required for accurately setting the angle of draft of the rotary tool, that some type of external measuring device is required for accurate placement of various tools along the length of a tool bar when assembling the implement, and that certain ones of the tools already mounted on a tool bar must be removed from the tool bar when it is desired that certain portions of the width of the implement be free from ground engaging tools as when cultivating about growing crops, etc.
SUMMARY OF THE INVENTION
Briefly described, the invention disclosed herein comprises a cultivator which includes a plurality of ground engaging tools, with each tool preferably including a rotary spider that rotatably engages the ground for the purpose of cultivating the soil prior to and after a crop emergence. The spider of each tool is anglable with respect to the draft of the implement so that the spider may run straight through the soil or comb through the soil and throw dirt to one side or the other of the tool. Each tool is individually mounted on the tool bar, and each tool may float in the ground or be raised up from the ground and locked in its up position. The implement is constructed so that the angling of the spiders and the raising of the tools to their inactive positions can be accomplished without the use of hand tools, and the spiders can be placed at various predetermined angles with respect to the line of draft of the implement.
A second small tool bar is rigidly fixed to a larger conventional tool bar in such a manner that a clamp of one of the ground engaging mounts on the second tool bar and is slidable along the length thereof without encountering any obstruction. The tool bar assembly on which the tools are mounted has a variety of distinct indicia disposed along its length for indicating the proper location of tools relative to drill lines of the crops for use with crops of various row spacings. The indicia include symbols corresponding to a particular row spacing and indicate at what locations along the tool bar the tools should be located for particular crop row spacing. The location of a plurality of these symbols along the bar allows the user to set up and use the implement for various row spacing for different crops without resorting to external measuring means.
The present invention also includes a clamp assembly for each ground engaging tool which is constructed to be attached to the second, smaller tool bar. The combination of the clamp and the improved tool bar assembly allows the tool support arm of each ground engaging tool to be mounted directly to the smaller tool bar without sliding the tool onto the tool bar from the end of the tool bar. Furthermore when the jaws of the clamp are opened for placing them over the smaller tool bar, the clamp assembly maintains its integrity and the clamp assembly does not have to be disassembled in order to mount and dismount the ground engaging tool to the tool bar.
The tool support arm of each ground engaging tool may be individually locked in raised position by means of a leaf spring having an opening therein which automatically engages a locking post of the clamp assembly when the tool support arm is raised to a predetermined position. To lower the tool support arm, the operator lifts the free end of the tool support arm and disengages the leaf spring from the locking post. This allows each tool to be raised to and lowered from a locked position without the use of wrenches or other hand tools. When changing from one cultivating operation to another, the combination of the simple means for holding the individual tools up away from the ground in a locked position and the row indicia on the tool bar allow the user quickly to determine which tool should be raised to the locked position and to raise them by hand.
Each ground engaging tool may be individually angled by the novel angling means of the present invention. The axles of the individual rotary tools are supported at the lower ends of a pair of shank members and the shank members are attached at their upper ends to a pair of upper and lower parallel quadrant plates. The quadrant plates fit over a box-like member mounted on the tool support arm and a pivot shaft extends vertically through at least one quadrant plate and a box member. A plurality of notches is provided in the upper and lower quadrant plates. The notches are disposed on the edges of the plates facing away from said pivot shaft. The box member is fitted with a movable detent or tongue member and a spring urges said tongue member toward the pivot shaft and the notches of the quadrant plate, thus locking the shank members, and hence the rotary spider at the lower ends of the shank members, at a predetermined angle to the forward direction of travel of the implement. Thus, the operator of the implement may change the angle of each tool in the field merely by pulling back on the tongue member and rotating the rotary spider about a vertical axis until the spider is disposed at one of the predetermined angles with respect to the line of draft of the implement. By releasing the tongue member for engagement of the notch at that angle the parts are locked in selected position. Therefore the present invention provides a means of adjusting the angle of each tool with respect to the line of draft of the implement without the use of tools.
It is an object of this invention to provide an improved tool bar and indicia means which simplify and expedite the location of cultivator tools on the tool bar.
It is also an object of this invention to provide an improved mounting means for mounting cultivating tools to a tool bar of a farm implement.
It is a further object of this invention to provide an improved support structure for ground engaging tools of a cultivator which permits the tools to engage the ground with a floating action for cultivating crops or which permits the tools to be raised up and locked away from engagement with the ground.
It is a further object of this invention to provide a rotary cultivator with a plurality of rotatable ground engaging tools and with an improved means for expediently setting each ground engaging tool at any of several predetermined angles with respect to the line of draft of the implement without the necessity of visual alignment aids and without the use of hand tools such as wrenches.
Another object of this invention is to provide a cultivating implement which includes a plurality of rotatable ground engaging tools which independently swing about an axis transverse to the direction of movement of the implement and which includes means for expediently raising and locking the tools and means for expediently angling the tools with respect to the direction of movement of the implement.
These and other objects and improvements over the prior art provided by the present invention will be understood from the description of the preferred embodiment which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the cultivating implement.
FIG. 2 is a partial perspective view of the present invention, showing one of the cultivating tools in its raised and locked position.
FIG. 3 is a side view of the tool support arm with a portion broken away, the box member showing the locking means, and the jaw members of the tool bar clamp.
FIG. 4 is an exploded side view of the clamp assembly which hold each tool support arm to the tool bar.
FIG. 5 is a top view of the angling means.
FIG. 6 is a perspective view of the angling means.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring in more detail to the drawings, in which like numerals refer to like parts throughout the several views, FIG. 1 illustrates the cultivating implement 9 which includes a tool bar assembly 10 which is attached to the rear of a tractor 13 with a conventional three point hitch 18. The tool bar assembly 10 extends transversely to the normal direction of travel of the tractor 13. Tool bar assembly 10 comprises a conventional horizontal tool bar 11 and a second, smaller tool bar 12 rigidly attached thereto in spaced, parallel relationship behind the tool bar 11. A coulter 16 is mounted on tool bar 11 by hitch 17 and extends rearwardly behind the tractor 13 and cultivator implement 9 for the purpose of stabilizing the implement as the tractor pulls the implement through the field. Gauge wheels 23, mounted on the tool bar 11, hold the implement 9 at a predetermined height above the ground surface.
As illustrated in FIGS. 2 and 3, tool bar assembly 10 includes second tool bar 12 which is hexagonal in cross section, having a cross sectional area substantially smaller than that of larger tool bar 11. Second tool bar is fixedly connected to tool bar 11 by means of a plurality of braces 15 welded at intervals along the lengths of the tool bars. There is a plurality of cultivating tools 14 distributed along the tool bar assembly 10, and each cultivating tool 14 includes a clamp assembly 21, a tool support arm 20, and a pair of shank members 59 which extend down adjacent the free end of the tool support arm. A spider or other type rotary ground engaging tool 69 is rotatably mounted at the lower ends of the shank members.
The clamp assembly 21 of each cultivating tool 14 is approximately C-shaped and is slidable along the length of second tool bar 12 without being obstructed by any of the braces 15 which mount the second tool bar 12 to the larger tool bar 11. Thus, it can be seen that the tool bar assembly 10 allows clamp assembly 21 to be moved along the entire length of the bar without regard to location of hitches such as tractor hitch 18 or coulter hitch 17 which extend only about tool bar 11.
As illustrated in FIG. 4, clamp assembly 21 includes upper jaw member 26, lower jaw member 27 and pivot pin 28. The upper and lower jaw members are of identical construction and include clamp surfaces 38a and 38b which correspond in size and shape to the size and shape of tool bar 12, holes 32a and 32b for receiving hook post 30, semi-cylindrical pin surfaces 33 for projecting about pivot pin 28, and holes 37a and 37b for accepting the bolt 35. A tool support is provided with spaced, forwardly extending plates 20a having pivot openings 29 near the forward ends thereof for accepting pivot pin 28. Hook post 30 extends through holes 32a and 32b and hook post 30 is secured to pivot pin 28 by cotter pin 31. The lower end of post 30 is provided with a hook 34 the opening of which is forwardly directed. Jaw member 27 is assembled on the post 30. By inserting pivot pin 28 through openings 29 of support arm 20 and then attaching hook post 30 to pin 28 with cotter pin 31, the combination of the tool support arm 20, pivot pin 28, and hook post 30 become a working unit.
After the jaw member has been inserted onto the hook post, bolt 35 is passed through holes 37a and 37b and a nut 36 is screwed down the bolt until the semi-cylindrical pin surfaces 33 of the jaw members clamp about pivot pin 28. This assembles the entire clamp assembly comprising jaw members 26 and 27, pivot pin 28, cotter pin 31, and hook post 30 into an operable unit. Also, when the jaw members are placed about the tool bar 12 and nut 36 run down on bolt 35, clamp assembly 21 is rigidly secured to the tool bar 12, holding pin 28 parallel to tool bar 12. When the nut 36 is loosened, the clamp assembly may be moved along the length of tool bar 12. Bolt 35 is of such a length that nut 36 may remain on the threaded portion thereof while permitting jaw members 36 and 27 to separate enough that they may be slipped over tool bar 12, thus permitting assembly without dismantling the clamp assembly. Bolt 35 and its nut 36 thus serve as adjustable closing means for jaw members 26 and 27.
As illustrated in FIG. 3, jaw members 26 and 27 of each clamp assembly 21 include pads 39 adjacent their clamp surfaces 38a and 38b which protrude from both sides of the jaw members. As will be recalled, tool support arm 20, which is preferably a hollow tube of square cross section, is pivotally mounted to the clamp assembly 21 by pivot pin 28 so that it swings about an axis parallel to tool bar 12. The ends of plates 20a have beveled end surfaces 40 disposed to engage the side protrusions 39 of lower jaw member 27 as the tool arm swings about pivot pin 28 a predetermined distance downwardly toward the ground. Moreover, the angle of the beveled ends 40 is such that the tool support arm 20 to be swung upwardly more than 90° before the beveled surfaces 40 engage the pad 30 of the upper jaw member 26. Thus, the pads 39 of the upper and lower jaw members 26 and 27 function as stop members with respect to tool support arm 20 so that the tool arm can be moved to its up, locked position (as is explained hereinbelow), or can float upwardly to follow the contour of the ground and to clear normally encountered obstructions on the ground. However, when the tool bar assembly 10 is lifted by the tractor, the tool support arms swing downwardly with respect to the tool bar assembly through only a short arc before the stop surfaces limit further downward movement, whereby the cultivating tools 14 are suspended rearwardly from the tool bar assembly 10. Thus, each cultivating tool 14 floats freely about tool bar 12 when the cultivating tools attached thereto engage the ground, but the cultivating tools can be raised and locked in a position away from the ground for transporting the implement over areas in which cultivation is not desired, such as over a roadway.
As illustrated in FIGS. 3 and 4, each tool support arm 20 has a leaf spring 42 fixedly secured to the upper surface thereof. A hole 45 is formed in the spring 42. The configuration of the leaf spring 42 is such that when the tool arm pivots upwardly to the position of FIG. 2, the spring engages and rides up on the uppermost protruding end 41 of hook post 30, until the hole 45 registers with the upper protruding end 41. In this position the leaf spring snaps down about the upper end of the hook post 30, holding the arm in raised position.
To disengage the spring latching means, the tool carrying end of arm 20 is raised slightly, and the free end of leaf spring 42, which forms a handle 46, is pulled upwardly disengaging the spring from the upper end 41 of hook post 30. The cultivating tool 14 then falls by gravity to its normal ground engaging position.
While we show as a preferred ground working implement a slicer tine spider 69 of the type described in U.S. Pat. No. 3,766,988 to Whitsides, various other rotary ground engaging tools such as discs, notched discs, or rotary hoes may be used. Non-rotating tools such as sweeps and shovels may be substituted for the rotary tools.
As illustrated in FIGS. 3, 5 and 6, the rear end of each tool support arm 20 carries a box member 48 which includes upper and lower parallel plates 49 and 50, respectively. As best illustrated in FIG. 6, upper and lower parallel plates 49 and 50 are provided with elongated slots 51a and 51b respectively. A tongue member 52 of a length greater than the distance between upper and lower parallel plates 49 and 50 extends through both slots 51a and 51b. Member 52 has notches 55a and 55b therein. Member 52 is urged toward the forward end of box member 48 by spring 56.
Fitted over box member 48 is an assembly comprising upper quadrant plate 57, lower quadrant plate 58, and a pair of tool shank members 59 rigidly attached to the opposite edges of the quadrant plates. Upper and lower quadrant plates 57 and 58 are parallel to each other and are parallel to the upper and lower plates 49 and 50 of box member 48. Shank members 59 extend downwardly from the quadrant plates the proper distance to support the spider 69. The spider 69 or other ground engaging tool is mounted on an axle 61 extending between the lower ends of members 59. The forward end portion 58a of lower quadrant plate 58 extends beyond box member 48, and hole 58b is formed in the extension. Tension spring 54 is connected at its ends to the hole 58b of lower quadrant plate 58 and to the tension adjusting chain 54a which is connected to hook 34 of hook post 30, thus to bias the cultivator tool 14 down into the soil.
Vertically aligned openings 63 are formed in quadrant plates 57 and 58. Similar aligned openings 64 are formed in upper and lower parallel plates 49 and 50 of box member 48. Extending through these openings is a pivot pin 62, thus mounting the quadrant plates 57 and 58 and shank members 59 for rotation with respect to box member 48. Since box member 48 is rigidly secured to tool support arm 29, it can be seen that this arrangement allows the angling of shank members 59 and hence the angling of the cultivating tool 69 with respect to the longitudinal axis of tool support arm 20 and therefore with respect to the line of draft of the implement.
As illustrated in FIGS. 5 and 6, a series of spaced upper notches 65 is formed in the rear edge of upper quadrant plate 57. Similarly a series of spaced lower notches 66 is formed in the rear edge of lower quadrant plate 58. Both sets of notches extend radially from the center of pivot pin 62. The set of upper notches 65 lie at different angles to the longitudinal axis of tool support arm 20 than do lower notches 66, so that the upper notches 57 are angularly offset from lower notches 58. Thus, with the use of two quadrant plates 57 and 58 instead of one, the number of useable notches in quadrant plates 57 and 58 is increased while the width of metal lying between adjacent notches is such that the material has enough strength to maintain the setting of the cultivating tool 69.
Tongue member 52 is provided with a hole 53 intermediate its ends and receives both ends of a spring 56 which is wrapped around pivot pin 62. This causes tongue member 52 to be constantly biased toward the front of box member 48 so that the un-notched edges of the tongue member 52 are biased toward the notched edges of the upper and lower plates 57 and 58. When the tongue is pulled against the bias of spring 56 to the rear of slots 51a and 51b notches 55a and 55b register with the facing end of slots 51a and 51b as the leading, un-notched edges are withdrawn from the quadrant notches 65 and 66. With tongue member 52 held in this position, the rear edges 67a and 67b of quadrant plates 57 and 58 clear the forward edge of tongue member 52 and the quadrant plate assembly may be rotated about pivot pin 62. The operator may then select the angle at which he wants the cultivating tool 69 to run with respect to the line of draft of the implement. For example, with the parts set to utilize notch 68, a setting of 10° right is obtained. Engaging the tongue in this notch locks the ground-engaging tool 69 angled at 10° right to the line of draft of the implement. As may be seen from FIG. 5, when tongue member 52 is registered in one of the upper notches 65, the lower forward edge of tongue member 52 is urged against the rear edge 67b of lower quadrant plate 58. Likewise when tongue member 52 is registered in one of the lower notches 66, the upper forward edge of tongue member 52 is urged against a portion of edge 67a of upper quadrant plate 57.
From the foregoing it will be seen that the operator of a cultivating implement embodying the present invention may quickly set the tool working angle relative to the line of draft without the use of wrenches or other hand tools.
As illustrated in FIG. 2, the tool bar assembly 10 includes indicia 22 which are distributed along tool bar 11. The indicia 22 comprise various distinct symbols such as a series of arrows, diamonds, crosses, double headed arrows and triangles accurately spaced along the length of the rear surface of the larger tool bar 11. Each symbol is used to mark the location of a cultivating tool on the tool bar assembly for a given row spacing. For example, the diamond symbols 25a are spaced along the tool bar 11 at intervals which correspond to forty inch crop row spacing. A cultivating tool positioned at each diamond symbol would be located at the proper positions for cultivating in the drill of forty inch crops. In similar manner, the series of crosses 25b, arrows 25c and other symbols 25d indicate the positions for the tools when cultivating in the drills of row crops at thirty-eight inch, thirty-six inch, etc., row spacing. The cultivating tools located between the symbols being used are evenly spaced with respect to each other along the tool bar between those tools located at the tool bar symbols. For example, eight cultivating tools may be located between the cultivating tools aligned with the thirty-six inch spaced arrow symbols.
When the implement has been set for thirty-six inch row spacing and the operator does not wish to cultivate in the drills of the rows of crops which are also spaced at thirty-six inches, the operator lifts and locks the cultivating tools positioned at the arrow symbols. The raised tools ride with the implement, out of contact with the ground and at a height approximately level with the tool bar assembly so as to clear the growing crop. The remaining cultivating tools will rotatably engage the soil with a floating action since they swing independently about their pivots 28. The operator may angle the ground engaging tools to throw dirt toward or away from its adjacent crop row, and each ground engaging tool may be angled independently from the others. For example, the ground engaging tools next adjacent the drill line of the crop row may be angled at five degrees to throw dirt and weeds away from the drill line while the next outward ground engaging tools can be angled more than or in the opposite direction from the inner ground engaging tools to be more aggressive or to throw the dirt in the opposite direction.
The foregoing description of the preferred embodiment of the present invention has been by way of example, and it will be obvious to those skilled in the art that other embodiments of this invention are possible within the scope of the claims appended hereto.
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Closely spaced cultivating tools are mounted along a tool bar and each tool may be locked in a raised position relative to the ground or may be lowered into floating engagement with the ground during use of the implement. A small tool bar is mounted parallel to a larger tool bar and the cultivating tools are slidably clamped on the small tool bar. Improved mounting structure allows each cultivating tool to be mounted on the small tool bar without having to slide each cultivating tool onto or off of the tool bar from the ends of the tool bar and without having to disassemble the mounting structure. The tool bar assembly includes row indicia for indicating where the tools are to be located along the tool bar and which tools should engage the ground and which tools should be raised away from the ground for various cultivating operations on row crops. A tool angling mechanism allows selective adjustment of the angle to the line of draft of each tool without the use of wrenches or other hand tools.
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FIELD OF THE INVENTION
The present invention relates to the field of radiation delivery apparatus. More particularly, this invention provides an apparatus for delivery of controlled doses of radiation to diseased blood vessels. This device is useful for reducing the rate of restenosis of diseased blood vessels without any significant side effects.
BACKGROUND OF THE INVENTION
Cardiovascular disease is the leading cause of deaths in the industrialized world. Most cardiovascular related deaths are caused by blockage of blood flow in stenotic (narrowed) vessels. The primary cause of narrowing of vessels is the build up of plaque. A common treatment for narrowed blood vessels is deployment of devices like balloon catheters or metallic stents that push the plaque against the wall of the vessel. A commonly used technique for treating coronary artery obstruction is percutaneous transluminal coronary angioplasty (hereinafter referred to as "PTCA") and involves insertion of balloon catheters through the femoral artery to the targeted coronary artery. Injection of radio-opaque contrast into the proximal coronary artery allows fluoroscopic localization of the blocked coronary segments. Balloon catheters are advanced to the site of stenosis over thin guide wires to position the catheter at the point of blockage. The distal end of the catheter contains a balloon which is inflated to press the plaque against the wall of the artery.
A common problem following PTCA is reclosure of the blood vessel. This phenomenon, known as restenosis, is thought to result from intimal hyperplasia of the vessel, in part due to proliferation of smooth muscle cells. Generally, 33%. of balloon angioplasty and metallic stent treatments result in restenosis, which is usually observed within one year of the procedure.
Recently, researchers have begun the use of radiation to inhibit smooth muscle cell proliferation. It has been shown that intracoronary delivery of ionizing radiation causes focal medial fibrosis, which when delivered at the site of the angioplasty, impedes the restenosis process. By carefully selecting the type of radiation, adjacent structures and vessels are undamaged by the radiation.
Currently available devices include radioactive wires or stents, and balloon-less catheters containing radiation pellets. Wire-less, balloon-less radiation pellets have several disadvantages. Centering of the device within the lumen of the vessel is difficult to achieve resulting in delivery of uneven doses of radiation to the entire segment of the vessel wall. These pellets often lay on one side of the vessel and burn that side resulting in necrosis without providing adequate radiation to the other side of the vessel. In addition, there is a danger of loss of pellets from the delivery system. Furthermore, the wire and balloon-less catheter systems also irradiate the entire vessel, even the areas which do not require treatment. Uncontrolled doses of radiation in normal non-stenotic vessels can actually cause proliferation of smooth muscles and other side effects. Radioactive stents and wires that are intended to be left in the vessel for an extended period of time may cause more intimal hyperplasia than ordinary non-irradiated stents. While the radioactive stents and wires may be centered, they are likely to be centered within the off center lumen created by the diseased state rather than the true lumen of the vessel. Again, this may result in uneven delivery of radiation dose to the blood vessel wall.
Thus, there is an ongoing need for devices that can be positioned correctly within the lumen of the blood vessels to reduce the rate of restenosis without major side effects.
SUMMARY OF THE INVENTION
The present invention provides a radiation delivery catheter with inflatable chambers which are equipped with a layer of radiation for delivery of an effective dose of radiation as close as possible to the origin of the disease within a blood vessel. The device comprises a multi-lumen catheter with multiple lumen extensions and pressure release valves. At the tip of the catheter are overlapping balloons or inflatable chambers. The centermost balloon is divided into two sections. An outer balloon is filled with radioactive material. The device is also equipped with another balloon wrapped around the outer balloon that forms a controlled cloaking layer that allows the device to be cloaked while being deployed. An operator can release the radiation when desired at the target location and also re-cloak the radiation for removal of the device. Means are also provided for the flow of blood through a channel in the catheter so as to bypass the radiation delivery mechanism. This device may be used in combination with an balloon angioplasty and/or stent placement balloon. Also, a miniature radiation dose sensor may be placed on the catheter to monitor the dose of radiation delivered to the surrounding vessel wall.
To use the device the multi-lumen catheter system is inserted into a patient in a conventional manner. The distal end of the catheter containing the balloons is guided to the desired spot in the vasculature. Upon positioning of the catheter in the desired location, a radioactive material is delivered via a lumen extension to a balloon. A radioprotective material is delivered at the same time to a balloon exterior to the radiation balloon. A shunt in the catheter allows for bypass of the blood while radiation is being delivered to the wall of the blood vessel.
Accordingly, it is an object of the present invention to provide a device for reducing the incidence of restenosis.
Another object of the invention is to provide a device for reducing the incidence of restenosis by delivery of precise dose of radiation to the blocked artery at the blockage area.
A still further object of the present invention is to provide a device for the delivery of radiation to a target in the vascular system without unnecessary exposure to other areas of the body.
A yet another object of the present invention is to provide a device for the delivery of radiation to a blocked blood vessel wall with a shunt for the bypass of fluids.
These and other objects of the invention, the novel features of the invention and the manner of using the invention will be best understood from the accompanying drawings in conjunction with the specifications.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the radiation delivery catheter of the present invention.
FIG. 2 is a partial end view of the radiation delivery catheter of the present invention.
FIG. 3 is a sectional view taken along line 3--3 of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-3 generally and initially referring to FIG. 1, a catheter 10 has a junction 13 where multiple lumens 16, 19, 22, 25, and 28 (shown in FIG. 3) converge. The catheter 10 has a distal end 31 that is sized to be capable of being introduced into the vascular system of the human body percutaneously through the Seldinger technique and the like, as will be apparent to those of ordinary skill in the art. The catheter 10 is elongate and narrow and preferably formed out of plastic. The lumens 16, 19, 22, 25 are disposed inside the catheter 10 on the distal side of the junction 13. Lumen extensions 56, 57, 58, 59, and 61 are disposed on the outside of the catheter on the other side of the junction 13.
On the side of the junction 13 opposite the distal end 31, the lumen extensions 56, 57, 58, 59, and 61 are attached to stopcocks 34 that provide for opening and closing the flow into the lumens. The stopcocks 34 are also provided with pressure relief valves 37 the function of which will be described below.
At the distal end 31 of the catheter 10, a balloon 43, a first inflatable chamber 46, and a second inflatable chamber 49 provide for delivering radiation to a specific area inside a blood vessel. The balloon 43 is preferably constructed of a compliant, soft durometer plastic such as, but not limited to, 80A Pellethane polyurethane. The balloon 43 is preferably divided into two compartments 52 and 55. The compartments 52 and 55 are capable of being inflated with an inert solution such as saline or the like.
The first inflatable chamber 46 is wrapped around the balloon 43. The chamber 46 is hollow and preferably completely surrounds the balloon 43. In this manner, once the catheter 10 is positioned correctly within the lumen of the blood vessel, the inflation of the balloon 43 causes the chamber 46 to be uniformly pressed against the interial walls of the blood vessel. The chamber 46 is preferably constructed of an elastic material that is resistant to rupture such as, but not limited to, a high durometer polyurethane and the like. Once the catheter 10 is positioned inside the lumen of the blood vessel as described above, a radioactive material (not shown) is introduced into lumen 19 through lumen extension 58. With the chamber 46 pressed against the vessel wall by the balloon 43, the chamber 46 conforms to the shape of the vessel wall to provide an even dispersion about 360 degrees to the vessel adventia without necrosis. Injection holes (not shown) for inflating the chamber 46 are disposed above and below the edges of the balloon compartments 52 and 55.
The second inflatable chamber 49 is wrapped around and preferably completely surrounds the first chamber 46. The second inflatable chamber 49 is constructed of a high strength plastic material that is resistant to rupture. The second inflatable chamber 49 is capable of being inflated with a cloaking cover agent that inhibits the spread of radiation from the first chamber 46. An agent such as a graphite solution, low viscosity contrast media, liquid Lucite or any other non-toxic agent that blocks the spread of radiation and particularly Beta emitting radiation is introduced into lumen 16 through lumen extension 61. This chamber 49 provides a shield or cloak for preventing the spread of radiation when the catheter 10 is being removed and also provides a shield in the event that the first chamber 46 ruptures.
The pressure relief valves 37 that are connected to the stopcocks 34 also provide a measure of security against a rupture of the chambers 46 and 49 due to too much pressure build up. The lumen extensions 56, 57, 58, and 61 are preferably filled by controlled, fixed volume syringes 64. If the plunger on the syringe 64 causes too much pressure build up inside the lumens, the pressure relief valve 37 will open to prevent the balloon 43 or the chambers 46 and 49 from rupturing.
The catheter 10 is equipped with a set of openings 67 on the side of the catheter 10 opposite the distal end 31. The openings 67 provide for perfusion of the blood vessel beyond the treatment site in the event that the treatment time exceeds a few minutes.
The catheter 10 accommodates a standard guide wire 70 for placement with the standard percutaneous techniques. Also, the catheter 10 can accommodate an intravascular ultrasound probe to allow for visualization of the vessel for more control of the centering of the device. For monitoring purposes, the catheter 10 can be equipped with a miniature radiation dose sensor at the distal end 31. In order to combine treatments, the catheter 10 could be equipped with an angioplasty balloon or a stent placement balloon for opening the vessel wall prior to the radiation treatment.
Turning to FIG. 2, a perfusion channel 73 is disposed along the center of the catheter 10. A dividing member 76 divides the balloon 43 into compartments 52 and 55.
In operation, the multi-lumen catheter 10 is inserted into the vascular system of a patient in a conventional manner known to those skilled in the art. The distal end 31 of the catheter 10 containing the balloon 43 and the inflatable chambers 46 and 49 are guided to the desired position in the vasculature. Upon positioning of the catheter 10 in the desired location by inflation of the compartments 52 and 55 of the balloon 43, the radioactive material is delivered via the lumen extension 58 to the first chamber 46. The perfusion openings 67 provide for bypass of the blood while radiation is being delivered uniformly to the inner wall of the blood vessel by the radioactive material in the first chamber 46. The uniform application of the radiation equally around the entire periphery of the vessel wall reduces the possibility of necrosis occurring from an unbalanced dosage of radiation and provides the best method of delivering radiation to the outer wall or adventia of the blood vessel.
Once the radiation treatment has been concluded, the balloon 43 and the first chamber 46 are deflated and the second chamber 49 is inflated. Inflation of the second chamber 49 provides a cloak or shield to prevent the spread of radiation to areas of the body other than the treatment site. Filling the second chamber 49, which completely surrounds the first chamber 46, with radiation blocking materials provides the shielding effect. Once the second chamber 49 is filled, the catheter 10 and the guide wire 70 can be removed through the percutaneous opening and the entry site can be attended to.
Accordingly, the present invention provides several advantages. The device can deliver a precise dosage of radiation and deliver it uniformly around the inside wall of a blood vessel. Also, by introducing the radiation through a lumen after the catheter 10 has been positioned, the potential for spreading radiation to unintended areas of the body while the catheter 10 is en route to the targeted area is eliminated. Also, the shielding chamber 49 prevents the spread of radiation once the treatment has been concluded and the catheter 10 is being removed. The uniform dispersion of radiation made possible by centering the device inside the true vessel lumen (not the lumen created by the disease) and by pressing the first chamber 46 against the inside of the vessel wall around the full 360 degrees, reduces the occurrence of necrosis and facilitates treatment of the outer walls of the blood vessel.
While the invention has been described in connection with certain preferred embodiments, it is not intended to limit the scope of the invention to the particular forms set forth, but, on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
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A radiation delivery catheter with inflatable chambers which provide a layer of radiation of minimum effective dose possible to be delivered as close as possible to the origin of disease within a blood vessel. The device can be centered within the true lumen of a vessel to provide even dispersion of the radiation agent to the outer wall of the vessel. The catheter comprises two central self centering balloons, one thin radiation agent inflatable chamber, and one radiation spread cloaking inflatable chamber with high strength properties resistant to rupture.
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TECHNICAL FIELD
[0001] The present invention relates to microwave cooking devices that are capable of cooking by steam.
BACKGROUND ART
[0002] Microwave cooking devices heat food from within by oscillating the molecules of the food with microwaves (high frequency electromagnetic waves). These cooking devices are generally called “microwave ovens” and are today indispensable in households. Some microwave cooking devices are furnished with a mechanism to supply steam into the heating chamber so as to be capable of steam-cooking using steam and combined use of microwaves and steam. An example is seen in Patent Document 1 listed below.
LIST OF CITATIONS
Patent Literature
[0000]
Patent Document 1: JP-A-2008-32294
SUMMARY OF INVENTION
Technical Problem
[0004] When steam is used in a microwave cooking device, the steam condenses inside the heating chamber to produce condensate, of which the disposal poses a problem. One solution is to add a heater to heat the heating chamber to vaporize the condensate back into the gas phase. This approach, however, is not believed to be quite preferable because it increases the number of components and hence increases the manufacturing cost, and in addition increases the power consumption. Proper drainage of the condensate is the best approach to a feasible solution.
[0005] The aim of using steam in cooking is to replace the air inside the heating chamber with steam to lower the oxygen concentration there, in order to lessen oxidation-induced degradation in taste. When a condensate drain port is formed in the heating chamber, it can be used as an exhaust port for air; as the replacement of air with steam progresses, however, it becomes necessary to prevent leakage of steam and entry of outside air through the condensate drain port.
[0006] The present invention has been made against the above background, and a main object of the invention is to provide, for microwave cooking devices capable of cooking by steam, a mechanism that allows reliable drainage of condensate out of the heating chamber but that nevertheless is free from leakage of steam and entry of outside air during cooking.
Solution to Problem
[0007] To achieve the above object, according to the invention, a microwave cooking device which is adapted to be capable of supplying steam into a heating chamber inside the device is characterized in that: a condensate drain port is formed in the bottom wall of the heating chamber, and a water-seal portion which keeps condensate is formed in a drain passage which starts at the condensate drain port.
[0008] According to the invention, in the microwave cooking device constructed as described above, a funnel-shaped slope is formed in the bottom wall of the heating chamber, and the condensate drain port is arranged in the lowest part of the slope.
[0009] According to the invention, in the microwave cooking device constructed as described above, a turntable on which an object to be heated is placed is arranged inside the heating chamber, and a rotary shaft which transmits rotation to the turntable penetrates the condensate drain port.
[0010] According to the invention, in the microwave cooking device constructed as described above, a cup-shaped support base is fixed on the outer face of the bottom wall of the heating chamber, the support base supports a motor which gives rotation to the rotary shaft, and the support base collects condensate that flows out through the condensate drain port.
[0011] According to the invention, in the microwave cooking device constructed as described above, a drain pipe which constitutes part of the drain passage is connected to a drain port which is formed in the support base, and a bend which is formed as a part of the drain pipe constitutes the water-seal portion.
[0012] According to the invention, in the microwave cooking device constructed as described above, a drain pan is arranged where the drain passage ends.
Advantageous Effects of the Invention
[0013] According to the present invention, the condensate produced inside the heating chamber during steam cooking is reliably drained through the condensate drain port formed in the bottom wall of the heating chamber. The drain passage which starts at the condensate drain port has a part of it formed into the water-seal portion in which the condensate keeps. Thus, when the air inside the heating chamber is replaced with steam and the oxygen concentration there lowers, and as a result the steam starts to condense, the flow of steam in the gas phase is blocked by the water-seal portion. Also if outside air tends to enter, it is blocked by the water-seal portion. Thus, during steam cooking, steam is enclosed inside the heating chamber so as to keep a low-oxygen condition and to continue to be used to heat food. In this way, it is possible to prevent oxidation-induced degradation in taste. Moreover, the energy used to generate steam is not wasted, and thus it is possible to perform cooking with improved energy efficiency. Drainage of condensate without passage of steam is achieved by means of a simple mechanism, that is, the water-seal portion, and thus no complicated mechanism needs to be adopted as would lead to increased cost.
BRIEF DESCRIPTION OF DRAWINGS
[0014] FIG. 1 is a perspective view of a microwave cooking device embodying the invention;
[0015] FIG. 2 is a vertical sectional view showing an outline of the construction inside the microwave cooking device;
[0016] FIG. 3 is a side exterior view of a heating chamber inside the microwave cooking device;
[0017] FIG. 4 is a partial vertical sectional view showing the structure of a bottom part of the heating chamber;
[0018] FIG. 5 is a top view of the bottom part of the heating chamber; and
[0019] FIG. 6 is a block configuration diagram of the microwave cooking device.
DESCRIPTION OF EMBODIMENTS
[0020] The construction of a microwave cooking device 1 embodying the invention will be described below with reference to the accompanying drawings. In FIG. 1 , the top and bottom of the page coincide with the top and bottom of the microwave cooking device 1 ; moreover, it is assumed that the left and right sides of the page correspond to the left and right sides, respectively, of the microwave cooking device 1 .
[0021] The microwave cooking device 1 has a cabinet 10 which is a structural member formed of sheet metal in the shape of a rectangular parallelepiped. Inside the cabinet 10 , a heating chamber 20 is provided which is a structural member formed of sheet metal in the shape of a rectangular parallelepiped smaller than the cabinet 10 . The heating chamber 20 has an opening at the front of the cabinet 10 . At the front of the cabinet 10 , a metal door 11 is provided by which the opening of the heating chamber 20 is opened and closed. The door 11 is, at its left end, coupled to the cabinet 10 via a hinge 12 so as to be swingable about the hinge 12 in the horizontal plane.
[0022] The door 11 has a window 13 formed in it which permits a view inside the heating chamber 20 . The window 13 is fitted with a door screen 14 composed of a sheet of punched sheet metal held between two glass plates. This provides an inside view while preventing leakage of electromagnetic waves. The door 11 is provided with, in addition to the door screen 14 , further means for preventing leakage of electromagnetic waves, is fitted with a gasket for preventing leakage of steam, and is furnished with a locking device for keeping a closed state. These all belong to well-known technologies, and therefore will not be discussed in detail.
[0023] In a part of the cabinet 10 to the right of the door 11 , an operation panel 15 is provided. On the operation panel 15 are arranged, as members constituting an operation interface, a set of membrane switches 15 a and a dial 15 b . Over the membrane switches 15 a , a display device 15 c is arranged which includes a liquid crystal panel.
[0024] The cabinet 10 is supported on a table or a stand via a base 16 . The base 16 has front feet 16 F (see FIG. 4 ) at two, left and right, places at the front and rear feet 16 R at two, left and right, places at the rear. The rear feet 16 R have a fixed height; by contrast, the front feet 16 F allow adjustment of their height by means of a screw-based mechanism. Adjusting the height of the front feet 16 F allows the cabinet 10 to be kept level.
[0025] The construction inside the microwave cooking device 1 will now be described. On the outer face of the right side wall of the heating chamber 20 , there are mounted a microwave generating device (magnetron) 21 and a steam generating device 22 . The microwave generating device 21 supplies microwaves into the heating chamber 20 , and the steam generating device 22 supplies steam into the heating chamber 20 . The microwave generating device 21 and the steam generating device 22 are located in a space inside the cabinet 10 behind the operation panel 15 . In the same space, a circuit board (not shown) is also arranged which constitutes a control device, which will be described later.
[0026] On the outer face of the right side wall of the heating chamber 20 , an illumination device 23 is also arranged which illuminates inside the heating chamber 20 . The illumination device 23 includes a light emitting diode (LED) as a light source. In the right side wall of the heating chamber 20 , a large number of light passing perforations 25 are formed in a rectangular array to let through the light from the LED 24 . The light passing perforations 25 are sized and arrayed like the perforations in the punched sheet metal of the door screen 14 , so that no radio waves leak through them.
[0027] The array of light passing perforations 25 is covered, from outside the heating chamber 20 , with a cover 26 in the shape of a rectangular parallelepiped. The cover 26 encloses the LED 24 , and serves as a mounting base for the LED 24 . The cover 26 is formed of punched sheet metal to let through air to cool the LED 24 .
[0028] In the right side face of the cabinet 10 , an exhaust port 17 is formed which is an array of small perforations, and inside the exhaust port 17 , a cooling fan 18 is arranged. When the cooling fan 18 is operated, the air inside the cabinet 10 is exhausted through the exhaust port 17 . As a result, through a suction port (not shown) provided somewhere else in the cabinet 10 , air outside the microwave cooking device 1 is sucked in. The air sucked in flows toward the cooling fan 18 . The flow of the air cools heat-generating components such as the microwave generating device 21 , the LED 24 , and the circuit board.
[0029] In the bottom wall of the heating chamber 20 , a condensate drain port 27 is formed for draining condensate resulting from steam forming dew. In the bottom wall of the heating chamber 20 , a funnel-shaped slope 28 is formed which descends toward its center. In the lowest part of the slope 28 , the condensate drain port 27 is arranged.
[0030] In the heating chamber 20 , a turntable 30 is arranged on which a food item as an object to be heated is placed. The turntable 30 is a glass member circular in shape as seen in a plan view, and has a slightly depressed top face like a dish. The turntable 30 is supported on the bottom wall of the heating chamber 20 via a roller stay 31 . As shown in FIG. 5 , the roller stay 31 is composed of a hub 31 a at the center, three arms 31 b radially protruding from it at angular intervals of 120 degrees, and rollers 31 c rotatably held at the tip end of them respectively. The rollers 31 c make contact with, at one side, a ring-shaped track surface 29 surrounding the slope 28 and, at the other side, the bottom face of the turntable 30 to bear the weight of the turntable 30 and the food item. To prevent the turntable 30 from deviating from the roller stay 31 , on the bottom face of the turntable 30 , a ring-shaped rib 30 a is formed so as to surround the three rollers 31 c.
[0031] The roller stay 31 receives rotation via a rotary shaft 31 d . The rotary shaft 31 d is molded integrally with the hub 31 a so as to extend down from it. The rotary shaft 31 d vertically penetrates the condensate drain port 27 . Between the outer face of the rotary shaft 31 d and the inner face of the condensate drain port 27 , a gap is provided which allows passage of drips of water. The rotary shaft 31 d protrudes down from the bottom wall of the heating chamber 20 , and is unrotatably coupled to an output shaft 32 a of a motor 32 .
[0032] The motor 32 is of a vertical-shaft type, and is supported on the heating chamber 20 via a cup-shaped support base 33 fixed on the outer face of the bottom wall of the heating chamber 20 . The motor 32 incorporates a reduction mechanism, and rotates the output shaft 32 a at reduced speed. Where the output shaft 32 a penetrates the support base 33 , a sealing member 34 is arranged which prevents leakage of water out of the support base 33 toward the motor. The support base 33 is at its top end welded to the bottom wall of the heating chamber 20 with intimate contact between them, so that no water or steam leaks there.
[0033] The support base 33 serves to collect water that flows out through the condensate drain port 27 . As shown in FIG. 4 , the bottom face of the support base 33 is lowest in its part facing the door 11 , and there a drain port 35 is formed.
[0034] To the drain port 35 , the inlet of a drain pipe 36 is connected. The support base 33 and the drain pipe 36 together constitute a drain passage 37 which starts at the condensate drain port 27 and ends at the outlet of the drain pipe 36 . Where the drain passage 37 ends, a drain pan 38 is arranged. The drain pan 38 is removably supported on the cabinet 10 , and can be detached and attached through under the door 11 .
[0035] The drain pipe 36 gradually descends from inlet to outlet, and a part of it near the inlet is formed into a U-shaped bend 36 a . The bend 36 a constitutes a water-seal portion 39 that keeps condensate. The drain pipe 36 may be a pipe of a hard synthetic resin, or a tube or hose of a soft material.
[0036] The controlling components of the microwave cooking device 1 are shown in FIG. 6 . The overall control is assumed by a control device 40 . To the control device 40 are connected, among the components already mentioned, the operation panel 15 , the cooling fan 18 , the LED 24 , and the motor 32 . In addition, the following components are also connected to the control device 40 : a microwave drive power supply 21 a which enables the microwave generating device 21 to perform microwave oscillation; a steam generation heater 22 a incorporated in the steam generating device 22 ; a water feed pump 22 b appended to the steam generating device 22 ; a water level sensor 22 c incorporated in the steam generating device 22 ; a tank water level sensor 22 d incorporated in a water tank (not shown) appended to the steam generating device 22 ; a humidity sensor 20 a and a temperature sensor 20 b provided in the heating chamber 20 ; and a door state sensor 11 a provided for the door 11 to check whether it is open or closed.
[0037] The microwave cooking device 1 operates as follows. To perform heating by microwaves, the user puts a food item as an object to be heated on the turntable 30 , closes the door 11 , and presses, among the membrane switches 15 a on the operation panel 15 , one for “microwave cooking.” If secure closure of the door 11 is detected by the door state sensor 11 a , the microwave drive power supply 21 a is energized, and the microwave generating device 21 starts microwave oscillation. Thus, the food item in the heating chamber 20 is heated by microwaves.
[0038] When the microwave generating device 21 is energized, the cooling fan 18 , the LED 24 , and the motor 32 are also energized. The cooling fan 18 produces a stream of air, and with it cools the heat-generating components in the cabinet 10 . The LED 24 illuminates inside the heating chamber 20 . The motor 32 rotates the output shaft 32 a , which rotates the roller stay 31 .
[0039] As the roller stay 31 rotates, the rollers 31 c with the turntable 30 supported on them roll on the track surface 29 . The rolling rollers 31 c further thrust the turntable 30 placed on them in the rotating direction. Thus, the turntable 30 rotates at twice the angular velocity of the rollers 31 c.
[0040] On passage of a predetermined length of time, or in response to an operation by the user, or on detection of the food temperature having reached a predetermined level by a sensor specially provided for that purpose, the control device 40 stops energizing the microwave drive power supply 21 a , the cooling fan 18 , the LED 24 , and the motor 32 to end cooking by microwave heating. The user opens the door 11 , and takes the food item out. It is also possible to adopt a configuration in which for a predetermined length of time after the end of cooking by microwave heating, the cooling fan 18 continues to operate to keep cooling the heated components.
[0041] To perform cooking by combined use of microwaves and steam, the user puts a food item as an object to be heated on the turntable 30 , closes the door 11 , and presses, among the membrane switches 15 a on the operation panel 15 , one for “microwave-and-steam cooking.” If secure closure of the door 11 is detected by the door state sensor 11 a , the water feed pump 22 b is energized, and water is fed from a water tank to the steam generating device 22 . When the water level inside the steam generating device 22 is found to have reached a predetermined level by the water level sensor 22 c , the water feed pump 22 b stops operating. When, through evaporation, the water level inside the steam generating device 22 becomes so low as to require a new supply of water, the water feed pump 22 b starts to operate again.
[0042] When the steam generating device 22 is supplied with so much water that the water level inside it reaches a predetermined level, the steam generation heater 22 a is energized, and the water inside the steam generating device 22 is heated. When the water boils and steam starts to be supplied to the heating chamber 20 , the control device 40 starts microwave heating. The control device 40 recognizes the start of the supply of steam to the heating chamber 20 on passage of a predetermined length of time after the start of the energizing of the steam generation heater 22 a , or on detection of the humidity inside the heating chamber 20 having raised to a predetermined level by the humidity sensor 20 a , or on detection of the temperature inside the heating chamber 20 having raised to a predetermined level by the temperature sensor 20 b . When microwave heating starts, the microwave drive power supply 21 a , the cooling fan 18 , the LED 24 , and the motor 32 are energized. The LED 24 may be lit at an earlier stage.
[0043] As steam fills the heating chamber 20 , the air inside the heating chamber 20 is removed out of the heating chamber 20 . The condensate drain port 27 serves as one exhaust port for air. As air is replaced with steam, the oxygen concentration inside the heating chamber 20 lowers. Cooked in such a low-oxygen atmosphere, food suffers less from oxidation-induced degradation in taste, and thus the user can have satisfactory cooking results.
[0044] On passage of a predetermined length of time, or in response to an operation by the user, or on detection of the food temperature having reached a predetermined level by a sensor specially provided for that purpose, the control device 40 stops energizing the microwave drive power supply 21 a , the cooling fan 18 , the LED 24 , the motor 32 , and the steam generation heater 22 a to end cooking by combined use of microwaves and stream. The user opens the door 11 , and takes the food item out.
[0045] The steam from the steam generating device 22 alone, without microwaves, may be used to perform steam-cooking. In that case, there is little need to rotate the turntable 30 , and accordingly the control device 40 keeps the motor 32 at a standstill. The cooling fan 18 , on the other hand, needs to cool the LED 24 and also to prevent the interior of the cabinet 10 from becoming too hot from the heat generated by the steam generating device 22 ; thus, the control device 40 operates the cooling fan 18 as usual.
[0046] Irrespective of whether cooking is performed by combined use of microwaves and steam or steam-cooking is performed by steam alone, when cooking proceeds by use of steam with the air inside the heating chamber 20 replaced with steam and thus under low-oxygen-concentration condition, steam in contact with the inner wall faces of the heating chamber 20 , the turntable 30 , and the roller stay 31 condenses to form condensate. The condensate drips onto the bottom wall of the heating chamber 20 . The condensate that has dripped onto the bottom wall moves along the slope 28 to a central part of the heating chamber 20 , and flows out through the condensate drain port 27 . The condensate will then flow down the drain passage 37 .
[0047] The condensate that has flowed down through the condensate drain port 27 is collected in the support base 33 , and is drained through the drain port 35 . The condensate that has flowed out through the drain port 35 proceeds to flow through the drain pipe 36 , where the bend 36 a keeps condensate and thereby seals the drain pipe 36 . Thus, the water-seal portion 39 is formed here. The flow of steam in the gas phase is blocked by the water-seal portion 39 ; also if outside air tends to enter, it is blocked by the water-seal portion 39 .
[0048] Thus, during steam cooking, steam is enclosed inside the heating chamber 20 so as to keep a low-oxygen condition and to continue to be used to heat food. In this way, it is possible to prevent oxidation-induced degradation in taste. Moreover, the energy used to generate steam is not wasted, and thus it is possible to perform cooking with improved energy efficiency. Drainage of condensate without passage of steam is achieved by means of a simple mechanism, that is, the water-seal portion 39 , and thus no complicated mechanism needs to be adopted as would lead to increased cost.
[0049] When condensate overflows out of the bend 36 a , it flows down the drain pipe 36 and, where it ends, flows out of the drain passage 37 into the drain pan 38 . Taking notice of the condensate collecting in the drain pan 38 , the user, as necessary, pulls out the drain pan 38 and clears it of its contents while the microwave cooking device 1 is out of operation. The user then puts the drain pan 38 back in position in preparation for steam cooking next time.
[0050] In the construction according to the embodiment, in the bottom wall of the heating chamber 20 , the funnel-shaped slope 28 is formed and, in the lowest part of the funnel-shaped slope 28 , the condensate drain port 27 is arranged. Thus, the condensate left after steam-cooking using steam can be collected from over a wide area and be disposed of reliably. This facilitates the cleaning after steam-cooking. The rotary shaft 31 d which transmits rotation to the turntable 30 on which an object to be heated is placed penetrates the drain port 27 , and thus there is no need to separately provide a through hole in the bottom wall of the heating chamber 20 to put the rotary shaft 31 d through. This helps simplify the construction and reduce the manufacturing cost. Condensate left collected under the turntable 30 leads to hygienic problems; the construction according to the embodiment, however, is free from such concerns.
[0051] On the outer face of the bottom wall of the heating chamber 20 , the cup-shaped support base 33 is fixed, and this support base 33 supports the motor 32 which gives rotation to the rotary shaft 31 d , and in addition collects the condensate flowing out through the condensate drain port 27 . Thus, it is possible to reliably prevent energized parts of electric components from becoming wet with condensate, and thus to achieve enhanced safety. Moreover, the support base 33 serving both to support the motor 32 and to collect condensate helps reduce the number of components needed and hence reduce the manufacturing cost.
[0052] To the drain port 35 formed in the support base 33 , the drain pipe 36 which constitutes part of the drain passage 37 is connected, and the bend 36 a formed as a part of the drain pipe 36 constitutes the water-seal portion 39 . Thus, it is possible to form the water-seal portion 39 easily. Moreover, where the drain passage 37 ends, the drain pan 38 is arranged. Thus, it is possible to dispose of condensate easily so as not to incur an unhygienic condition.
[0053] The water-seal portion 39 may be formed by any other means than the bend 36 a formed in the drain pipe 36 ; any structure may instead be used so long as it acts as a water-seal portion that keeps water somewhere within it in such a way that the water stops the drain pipe 36 .
[0054] The embodiment by way of which the invention has been specifically described above is in no way meant to limit the scope of the invention; in implementing the invention, many modifications and variations are possible within the spirit of the invention.
INDUSTRIAL APPLICABILITY
[0055] The present invention finds wide application in microwave cooking devices that are capable of cooking by steam.
LIST OF REFERENCE SIGNS
[0000]
1 microwave cooking device
10 cabinet
11 door
15 operation panel
20 heating chamber
21 microwave generating device
22 steam generating device
27 condensate drain port
28 slope
30 turntable
31 roller stay
31 d rotary shaft
32 motor
33 support base
35 drain port
36 drain pipe
36 a bend
37 drain passage
38 drain pan
39 water-seal portion
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High frequency microwaves and stem are supplied to a heating chamber ( 20 ) disposed inside the disclosed high frequency cooking device ( 1 ). On the floor of the heating chamber is formed a funnel-shaped slope ( 28 ), at the bottom of which is formed a condensate drain ( 27 ). A rotation shaft ( 31 d ) for transmitting rotation to a turn table ( 30 ) passes through the condensate drain. A cup-shaped support base ( 33 ) supporting a motor ( 32 ) for rotating the rotation shaft catches the condensate flowing out of the condensate drain. A drain pipe ( 36 ) forming part of the drain path ( 37 ) is connected to a drain ( 35 ) of the support base. A U-shaped bend ( 36 a ) formed in the drain pipe constitutes a water-sealing unit ( 39 ) where condensate accumulates.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor device and a manufacturing method therefor, and more specifically to a structure of a semiconductor device for improving the operation performance of the semiconductor device, and a manufacturing method for obtaining the structure.
2. Description of the Background Art
FIG. 26 shows a circuit diagram of a conventional SOI (Semiconductor On Insulator) type DRAM Dynamic Random Access Memory) cell 100 B. A conventional memory cell transistor consists of an n-channel MOS (Metal Oxide Semiconductor) transistor 100 . A memory cell capacitor 101 is connected to one end of n-channel MOS transistor 100 . A bit line BL is connected to the other end of n-channel MOS transistor 100 . The operation of SOI type DRAM cell 100 B is such that cell 100 B controls a word line WL which is the gate node of n-channel MOS transistor 100 , accumulates charges in memory cell capacitor 101 by bit line BL and stores the charges as cell data.
FIG. 27 shows the cross-sectional structure of a DRAM cell 100 C which employs an SOI type memory cell transistor. A silicon oxide film (SiO 2 ) is formed on a silicon substrate 1 , and a memory transistor is provided on silicon oxide film 2 . A pair of n-type impurity regions 4 and 5 , between which a p-type body section 3 is put, are provided on the main surface of silicon oxide film 2 . A gate electrode 6 of a word line WL node is provided on body section 3 through a gate oxide film 7 . A bit line 15 is connected to n-type impurity region 4 through a contact plug 13 which is provided in an interlayer insulating film 14 . A memory cell capacitor 12 is connected to n-type impurity region 5 through a contact plug 8 which is provided in interlayer insulating film 14 . Memory cell capacitor 12 includes a storage node (lower electrode) 9 , a dielectric film 10 , and a cell plate (upper electrode) 11 .
The parasitic capacitance of the SOI type memory cell transistor is lower than that of an ordinary bulk type memory transistor, the power consumption thereof is lower and the rate thereof is higher since pn junctions are only on the interfaces between p-type body section 3 and n-type impurity regions 4 and 5 . Further, because of the barrier effect of silicon oxide film 2 , the SOI memory cell transistor is superior to the ordinary bulk type memory transistor in soft error resistance which is an important factor for a memory chip.
However, as shown in FIG. 27 , the SOI type memory cell transistor has a so-called floating structure in which body section 3 is not connected to the other nodes, and charges are accumulated in body section 3 by junction leak current on bit line (BL) 15 side and storage node (SN) 9 side. As a result, as shown in FIG. 28 , the potential of body section 3 of the SOI type memory cell transistor rises, an increase in channel leak is induced, and the refresh characteristic of the DRAM cell is eventually, disadvantageously deteriorated.
Conventionally, body section 3 has been stabilized by extracting charges by the amplitude of the bit line to regularly decrease (stabilize) the potential of body section 3 (body refresh), or by providing a gate node region (BG) 21 on the rear side of body section 3 (a deeper region than body section 3 of silicon oxide film 2 ) to decrease the potential of body section 3 as seen in a memory cell transistor employed in a DRAM cell 100 D shown in the cross-sectional view of FIG. 29 and the circuit model diagram of FIG. 30 .
Nevertheless, the structure of body section 3 remains a floating structure, and the potential of body section 3 increases by junction leak as shown in FIG. 28 . Thus, these methods have not been able to essentially solve the disadvantages.
SUMMARY OF THE INVENTION
It is an object of the present invention to propose a novel structure capable of keeping the potential of a body section low, and to provide a semiconductor device and a manufacturing method for semiconductor device, capable of improving the operation performance of the semiconductor device by contriving circuit operation
A semiconductor device according to the present invention is a semiconductor device which includes a transistor provided on a silicon substrate through an insulating layer and has a gate electrode provided on the insulating layer through a gate insulating film and a pair of impurity regions provided in the insulating layer, includes: a body section including a region interposed between the pair of impurity regions; an embedded body line connected to the body section; and a body section controller, which is connected to the embedded body line, for controlling a potential applied to the body section in relation to a potential applied to the gate electrode.
With this configuration, it is possible to control the potential of the body section by the body section controller, and to solve the floating of the potential of the body section which has been the disadvantage of the conventional SOI type semiconductor device.
A manufacturing method for a semiconductor device according to the present invention includes the steps of: forming an insulating film on a first silicon substrate, and forming a silicon layer on the insulating film; forming an isolation insulating layer in a predetermined region of the silicon layer, and specifying a region which becomes an embedded body line; injecting impurities into the region which becomes the embedded body line, and completing the embedded body line; bonding a second silicon substrate onto a surface of the insulating film; reducing a film thickness of the second silicon substrate, and forming a new silicon surface; and forming a transistor on the new silicon surface, the transistor having a pair of impurity regions located on a higher layer than the embedded body line, and a gate electrode extending in the same direction as that of the embedded body line.
According to the manufacturing method for a semiconductor device, it is possible to apply the ordinary semiconductor device manufacturing process to the method only by adding the first embedded body line formation process.
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit model diagram of a semiconductor device according to a first embodiment;
FIG. 2 is a timing chart showing the potentials of a word line and body line of the semiconductor device according to the first embodiment;
FIG. 3 is a graph showing the relationship between a Vbs (body line applied voltage) and a Vth (threshold voltage) of the semiconductor device according to the first embodiment;
FIG. 4 is a conceptual view showing a body line driver circuit according to the first embodiment;
FIG. 5 is a circuit diagram of a level shifter ( 1 ) according to the first embodiment;
FIG. 6 is a circuit diagram of a level shifter ( 2 ) according to the first embodiment;
FIG. 7 is a conceptual view showing a modification of the body line driver circuit according to the first embodiment;
FIG. 8 is a plan view showing the array configuration of a DRAM according to a second embodiment;
FIG. 9 is a partially enlarged plan view showing the half-pitch cell layout structure according to a third embodiment;
FIG. 10 is a cross-sectional view taken along line X—X of FIG. 9 ;
FIG. 11 is a cross-sectional view taken along line XI—XI of FIG. 9 ;
FIG. 12 is a cross-sectional view taken along line XII—XII of FIG. 9 ;
FIGS. 13 to 22 are cross-sectional views showing first to tenth manufacturing steps of a semiconductor device according to a fourth embodiment, respectively;
FIG. 23 is a timing chart showing the potentials of a word line and body line of a semiconductor device according to a fifth embodiment;
FIG. 24 is a circuit model diagram of the semiconductor device according to the fifth embodiment;
FIG. 25 is a graph showing the relationship between Vbs (body line applied voltage) and Vth (threshold voltage) of the semiconductor device according to the fifth embodiment;
FIG. 26 is a circuit model diagram of a conventional semiconductor device;
FIG. 27 is a cross-sectional view showing the structure of the conventional semiconductor device;
FIG. 28 is a schematic view showing a disadvantage of the conventional semiconductor device;
FIG. 29 is a cross-sectional view showing another structure of the conventional semiconductor device; and
FIG. 30 is a circuit model diagram showing another conventional semiconductor device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, embodiments of a semiconductor device and a manufacturing method for semiconductor device according to the present invention will be described with reference to the drawings.
First Embodiment
Referring to FIGS. 1 to 3 , the structure of a semiconductor device according to a first embodiment will be described. It is noted that the same constituent elements of a memory cell transistor employed in a DRAM cell as those of the conventional DRAM cell are denoted by the same reference symbols, respectively and will not be repeatedly described herein.
First, referring to FIG. 1 , the constituent elements of the memory cell transistor of the semiconductor device according to the first embodiment differ from those of the conventional memory cell transistor in that a wiring called a body line (BDL) is provided, a body section of memory cell transistor 100 A is connected to body line BDL, and the potential of the body section is controlled by a body section controller 36 (see FIG. 8 ) connected to body line BDL.
As shown in FIG. 1 , body line BDL is provided at the same pitch in the same direction as a word line (WL), and the body section of memory cell transistor 100 A selected by word line WL is connected to body line BDL.
As shown in FIG. 2 , the potential of the body section is controlled by rocking the potential of body line BDL between first and second potentials. Specifically, if a potential applied to word line WL is in an inactive (a standby) state, a potential applied to body line BDL is set at a low potential (first potential) of negative potential (e.g., −1.0 V), thereby floating the potential of the body section by the floating body effect and solving the disadvantage of deteriorating the data holding characteristic of the memory cell.
If the potential applied to word line WL is active, the potential applied to body line BDL is set at a higher potential (second potential, e.g., 0 V) than the negative potential to which the potential of the body line (BDL) is fixed in the standby state. As shown in FIG. 3 , this operation can decrease the threshold voltage (Vth) of memory cell transistor 100 A, and improve the driving ability thereof. Thus, it can be expected to read and write data at high rate.
Further, by decreasing the threshold voltage of memory cell transistor 100 A, the High level voltage (Vpp) of word line WL can be decreased, so that the reliability of the memory cell transistor can be improved. In addition, by controlling body line BDL to connect only the same cell as that selected by word line WL, other unselected memory cell transistors 100 A are not activated. Therefore, it is possible to float the body potentials of other inactive memory cell transistors 100 A and to prevent the deterioration of the data holding characteristics of DRAM. In other words, it is possible to maintain the data holding characteristic of bulk DRAM while maintaining the high rate characteristic of the SOI transistor.
Concrete Example of Body Line Driver Circuit
The concrete example of a body line driver circuit will be described with reference to FIGS. 4 to 7 .
The potential of body line BDL is 0V when word line WL is active and −1.0 V when word line WL is inactive. Therefore, the potential amplitude of the body line driver circuit needs to have H level: 0 V and L level: −1.0 V.
A signal for activating word line WL is normally obtained by changing a signal having an amplitude of 0(V) to Vdd(V) to a signal having an amplitude of 0(V) to Vbb(V). Thus, using the original signal having an amplitude of 0(V) to Vdd(V), a body signal is generated by a circuit configuration shown in, for example, FIG. 4 .
In FIG. 4 , a level shifter [1] 301 is a circuit which shifts a signal having an amplitude of 0(V) to Vdd(V) to a signal having an amplitude of Vbb(V) (−1.0V) to Vdd(V) (see FIG. 5 ). A level shifter [2] 302 is a circuit which shifts a signal having an amplitude of Vbb(V) to Vdd(V) into a signal having an amplitude of Vbb(V) to 0(V) (see FIG. 6 ). Therefore, the signal having an amplitude of 0(V) to Vbb(V) can be obtained from the original signal having an amplitude of 0(V) to Vdd(V).
In the body line driver circuit shown in FIG. 4 , since level shifters [1] 301 and [2] 302 are mainly intended to shift level, transistor size is often small. In this case, parasitic load on body line BDL may possibly become heavy. Considering this, it is possible to provide inverters 303 and 304 which drive such heavy parasitic load in rear of level shifter [2] 302 as shown in FIG. 7 .
Second Embodiment
As a second embodiment, the configuration of the array of DRAM (Dynamic Random Access Memory) based on the operation principle according to the first embodiment will be described with reference to FIG. 8 . In FIG. 8 , memory cell transistors 100 A are provided in a matrix in portions denoted by circles, respectively. Memory cell transistors 100 A are present at the intersections between bit line pairs ( 31 a to 34 a ) and word lines (WL 1 to WL 5 ), respectively, which intersections are connected to memory cell sense amplifiers SA 31 to 34 . FIG. 8 shows one example of the configuration of the array in which folded bit lines at half cell pitches are provided.
Word line drivers WD 35 are connected to word lines WL 1 to WL 5 to drive respective word lines WL 1 to WL 5 . Body drivers BD 36 are connected to body lines BDL 1 to BDL 5 arranged in parallel to word lines WL 1 to WL 5 to drive respective body lines BDL 1 to BDL 5 . Similarly to word lines WL 1 to WL 5 , adjacent body lines BD 1 to BD 5 are isolated from each other by insulating films, respectively. Body lines BL 1 to BDL 5 are connected only to the body sections of memory cell transistors 100 A selected by word lines WL 1 to WL 5 , respectively. By employing this array configuration, it is possible to realize the array of DRAM having body lines BDL as described in the first embodiment.
Third Embodiment
As a third embodiment, the structure of the half-pitch cell layout employed in the DRAM array having body lines BDL according to the second embodiment will be described with reference to FIGS. 9 to 12 .
First, referring to FIG. 9 , the DRAM array includes active regions 40 having convex plane shapes and word lines WL arranged at predetermined intervals along a longitudinal direction (a direction in which the convex regions 40 a of active regions 40 extend). A white circle mark 41 shown in convex region 40 a of active region 40 denotes a contact region with bit line BL, and a black circle mark 42 in active region 40 denotes a contact region with the storage node of a cell capacitor. Although not shown in FIG. 9 , bit lines BL are arranged in a direction orthogonal to word lines WL (a lateral direction). Further, in a plan view, body lines BDL are provided as embedded wirings arranged almost at the same positions as those of word lines WL which are arranged in the longitudinal direction, in the same direction as that of word lines WL.
Referring to FIGS. 10 to 12 , the cross-sectional structure of the DRAM array will be described. Each word line WL is arranged on silicon oxide film (SiO 2 ) 2 formed on silicon substrate 1 through a gate oxide film 7 . Word lines WL are arranged equidistantly on silicon oxide film 2 . On the main surface of silicon oxide film 2 , memory cell transistors each having word line WL as a gate electrode and an n-impurity region 43 as a source/drain region are constituted in portions in which n-type impurity regions 43 are provided to put word lines WL therebetween, respectively.
A contact electrode 42 p connected to the storage node of a cell capacitor is connected to one n-type impurity region 43 and a contact electrode (not shown) connected to bit line BL is connected to the other n-type impurity region 43 , with word line WL, which constitutes the gate electrode, put between two n-type impurity regions 43 .
A p-type impurity region put between n-type impurity regions 43 constitutes a body section 33 . The impurity diffusion depth of body section 33 is set to be larger than that of n-type impurity region 43 .
As shown in FIG. 12 , in silicon oxide film 2 , an embedded body line BDL 37 is formed in a region deeper than body section 33 in the same direction as the extension direction of word line WL.
By forming body line BDL 37 as an embedded wiring, it is possible to employ body line BDL equal in shape to ordinary word line WL without the need to arrange body line BDL 37 adjacent the active region of the memory cell transistor. As a result, it is possible to realize the half-pitch cell array configuration employed for ordinary DRAM cells without any problems.
Fourth Embodiment
As a fourth embodiment, the manufacturing steps of manufacturing a memory cell transistor including embedded body line BDL as described as in the third embodiment will be described with reference to FIGS. 13 to 22 .
Referring to FIG. 13 , silicon oxide film (SiO 2 ) 2 is formed on first silicon substrate 1 , and a silicon layer (Si) 40 is formed on silicon oxide film (SiO 2 ) 2 , thereby forming a bare SOI wafer. Referring to FIG. 14 , predetermined regions of silicon layer 40 are then oxidized to form silicon oxide film (SiO 2 ) 2 as an isolation insulating layer, thereby specifying regions which become embedded body lines BDL 37 having a thickness of about 100 nm. Referring to FIG. 15 , p-type impurities (B, BF 2 or the like) are injected only into the regions which become embedded body lines BDL 37 to complete embedded body lines BDL 37 . If the p-type impurities are Boron (B) impurities, impurity injection conditions are injection energy of 5 kev to 30 kev and injection quantity of 1×10 15 cm −2 to 1×10 16 cm −2 .
Referring to FIG. 16 , a second silicon substrate 1 A is then prepared. Hydrogen is introduced from the surface of second silicon substrate 1 A to generate a wall broken region 101 having a depth of 100 nm. The hydrogen injection conditions are injection energy of about 1 kev to 10 kev and injection quantity of about 3.5×10 16 cm −2 to 1×10 17 cm −2 . Thereafter, referring to FIG. 17 , second silicon substrate 1 A is bonded onto the surface of silicon oxide film (SiO 2 ) 2 with second silicon substrate 1 A turned upside down.
Since a silicon layer for forming an ordinary SOI transistor is thin (1000 angstrom to 2000 angstrom), silicon substrate 1 A located above the wall broken region (new silicon surface) 101 provided in the intermediate region of second silicon substrate 1 A is cut off (see FIG. 18 ). The thickness of second silicon substrate 1 A having the new silicon surface is about 50 nm to 100 nm.
Next, new silicon substrate 1 A is subjected to ordinary SOI type memory cell transistor formation steps. Referring to FIG. 19 , silicon oxide film (SiO 2 ) 2 is first formed in a predetermined region and an active region of the memory cell transistor is specified by trench isolation. Thereafter, p-type impurities (B, BF 2 or the like) are injected into active region 1 B. If the p-type impurities are Boron (B) impurities, the p-type impurity injection conditions are injection energy of about 5 kev to 30 kev and injection quantity of about 1×10 12 cm −2 to 3×10 13 cm −2 . As a result of the injection of the p-type impurities, active region 1 B which becomes body section 33 is electrically connected to embedded body line BDL 37 .
Referring to FIG. 21 , a gate electrode 36 which becomes word lines WL is formed on active region 1 B through gate oxide film 7 . Referring to FIG. 22 , n-type impurities (P, As or the like) are injected into active region 1 B to form n-type impurity region 43 and specify p-type body section 33 by using gate electrode 36 as a mask. If the n-type impurities are As impurities, the n-type impurity injection conditions are injection energy of about 20 kev to 50 kev and injection quantity of about 5×10 13 cm −2 to 1×10 16 cm −2 .
Through the above-stated steps, an SOI type memory cell transistor including embedded body line BDL 37 is completed. In the following formation of a memory cell capacitor, an ordinary DRAM process flow can be employed.
Therefore, in this embodiment, it is possible to apply ordinary SOI type memory cell transistor formation process and DRAM memory cell formation process to the manufacturing process of manufacturing an SOI type memory cell transistor including embedded body line BDL as they are by adding the first body line BDL formation process.
In the above-stated manufacturing process, the wall broken region by injecting hydrogen is employed to form bare silicon substrate 1 A having a new silicon surface. Alternatively, it is possible to employ a process of polishing a silicon wafer by CMP (Chemical Mechanical Polishing) and forming bare silicon substrate 1 A having a new silicon surface. Further, in the above-stated manufacturing process, monocrystalline silicon of the SOI wafer is used to form embedded body line BDL 37 . The same function and advantage can be attained by using polysilicon (polycrystalline silicon).
Fifth Embodiment
In a first embodiment, body line BDL is dynamically rocked between the high negative voltage (−1.0 V) and 0 V synchronously with the activation of word line WL as shown in FIG. 2 . In the fifth embodiment, the voltage of body line BDL is fixed to a high negative voltage (e.g., −1.0 V) (first potential) as shown in FIG. 23 .
Body line BDL is as thin as word line WL and high in resistance. Therefore, the body section behaves like a region isolated by high resistance (see FIG. 24 ). Namely, as indicated by an operation waveform view shown in FIG. 25 , the potential of the body section rises in response to the coupling of word lines WL. However, since the voltage of body line BDL is fixed to −1.0 V despite high resistance, the increased potential gradually falls to −1.0 V.
In other words, in a static state such as a standby state, the potential of the body section is fixed to such a high potential as −1.0 V and the floating of the potential of the body section does not occur. On the other hand, if word line WL is activated, the potential of only the body section of the selected cell momentarily floats, which contributes to high rate access operation.
In recent years, demand for DRAM which pays much attention to acceleration of random cycle such as an SRAM (Static Random Access Memory) cache has risen. Therefore, if it suffices that a word line activation period is short, it is possible to employ the above-stated configuration and operation.
That is, the semiconductor device according to the fifth embodiment similarly to that according to the first embodiment can attain both the advantage of the high rate operation of the SOI transistor and the advantage of the data holding characteristic of bulk DRAM. In addition, there is no need to provide a body line driver circuit, which contributes to the reduction of layout area.
According to the semiconductor device based on the present invention, the potential of the body section can be controlled by the body section control means, making it possible to solve the floating of the potential of the body section which has been the disadvantage of the conventional semiconductor SOI structure.
It is preferable that the semiconductor devices is a dynamic random access memory in which a plurality of memory cells each including the transistor are arranged in a matrix, the gate electrode consists of a word line, and that the embedded body line is arranged in parallel to the word line.
With this configuration, it is possible to solve the disadvantage of the floating of the potential of the body section as stated above. It is, therefore, possible to improve the reliability of the operation characteristic of the dynamic random access memory.
It is preferable that the embedded body line is connected to the body section of the transistor of each of the plurality of memory cells selected by the common word line. As a result, the body potentials of the other inactive memory cell transistors are floated to prevent the deterioration of the data holding characteristic. That is, it is possible to attain the data holding characteristic of the bulk type dynamic random access memory while maintaining the high rate characteristic of the SOI type transistor.
It is preferable that the adjacent embedded body lines are isolated from each other by an insulating film.
Further, it is preferable that the embedded body line consists of a wiring layer embedded into a deeper position than the pair of impurity regions in a depth direction of the insulating layer. With this configuration, there is no need to arrange the body line adjacent the active region of the memory cell transistor, making it possible to employ the embedded body line equal in shape to an ordinary word line. As a result, it is possible to realize the array configuration employed for ordinary DRAM cells without any problems.
It is preferable that the embedded body line is made of monocrystalline silicon or polycrystalline silicon.
It is also preferable that in the semiconductor device, the body section control means controls the body section to have a first potential when a potential applied to the word line is inactive and to have a second potential higher than the first potential when the potential applied to the word line is active.
By doing so, when the potential applied to the word line is inactive, the potential applied to the embedded body line is set at a low potential such as the first voltage (e.g., −1.0 V), thereby floating the potential of the body section by the floating body effect and solving the disadvantage of deteriorating the data holding characteristic. Further, when the potential applied to the word line is active, the potential applied to the embedded body line is set at the second potential (e.g., 0 V) higher than the first voltage to which the potential of the embedded body line is fixed in a standby state. This operation can decrease the threshold voltage (Vth) of the transistor, and improve the driving ability thereof. Thus, it can be expected to read and write data at high rate.
Furthermore, it is preferable that the first potential is not more than 0 V, and that the second potential is not less than 0 V.
It is also preferable that a potential of the body section is fixed to a first potential by the body section control means. By doing so, in a static state such as a standby state, for example, the potential of the body section is fixed to such a high potential as the first potential (e.g., −1.0 V) and the floating of the potential of the body section does not occur. When the word line is activated, the potential of only the body section of the selected cell momentarily floats, making it possible to contribute to high rate access operation.
According to the semiconductor device manufacturing method based on the present invention, it is possible to apply the ordinary semiconductor device manufacturing process to the method only by adding the first embedded body line formation process.
It is preferable that the step of reducing the thickness of the second silicon substrate includes a step of introducing hydrogen into a predetermined thickness of the second silicon substrate to break a wall of the second silicon substrate, and removing a substrate on an upper layer side.
It is also preferable that the step of reducing the thickness of the second silicon substrate includes a step of polishing a surface of the second silicon substrate by chemical mechanical polishing.
Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the terms of the appended claims.
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This semiconductor device is provided with a wiring called a body line (BDL), a body section of a memory cell transistor is connected to this body line (BDL), and a potential of the body section is controlled by a body section controller connected to the body line. As a result, it is possible to propose a novel structure capable of keeping the potential of the body section low and to provide a semiconductor device and a manufacturing method therefor, capable of improving operation performance by contriving circuit operation.
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FIELD OF THE INVENTION
This invention relates to the method of making a needlework graph and more specifically to the method of graphing by the average person, who is not skilled in the art of graphing, of a specific colored design desired to be reproduced by needlework on canvas or fabric.
BACKGROUND OF THE INVENTION
It is known to provide needlework graphs to be used for the needlework reproduction on canvas or fabric of the design shown on the graph.
The closest known prior art graphs comprise sheets of smooth-surfaced transparent plastic printed with intersecting lines and arranged to define spaces that are either square, rectangular, or another shape, depending on the type of needlework to be used in reproducing the selected design. The spaces in the graph correspond to the stitches in the canvas or fabric on which the design will be reproduced. The design is formed on the graph by coloring the spaces in the graph with appropriate colors to form the intended design, and the design is reproduced on canvas, for example, by locating stitches in the canvas that correspond to the overlying spaces in the graph and crossing those stitches with yarn of the same color as the corresponding spaces in the graph.
The said graph of the prior art is completed by a user placing a selected printed sheet of the smooth-surfaced transparent plastic over a specific colored design and coloring the spaces overlying each color in the selected design with correspondingly colored felt-tipped markers of the type commonly known as MAGIC MARKER felt tip pens.
Difficulty has been experienced in matching the colors on the selected design with colors of so-called MAGIC MARKER felt tip pens because of the wide discrepancy between the infinite variety of colors on designs to be selected and the limited number of colors available when selecting MAGIC MARKER felt tip pens. Other objections to the use of MAGIC MARKER felt tip pens to complete the said prior art graphs are that the liquid-based MAGIC MARKER felt tip pens sometimes smear in use; and the MAGIC MARKER felt tip pens dry out and become unusable after a period of time.
The users of the prior art printed sheets of smooth-surfaced transparent plastic are limited to the use of MAGIC MARKER felt tip pens for coloring the spaces on said smooth-surfaced sheets because neither colored pencils or anything else will stick to the smooth-surfaced plastic sheets.
SUMMARY OF THE INVENTION
It is a primary object of this invention to provide a method of making a graph for needlework that enables an average person interested in reproducing a specific colored design by needlework, for which there is no existing graph, to quickly and easily graph the colored design for reproduction by such needlework as cross stitch, needlepoint, quilting, smocking, duplicate stitch, or knitting.
According to this invention, a plurality of intersecting lines are printed, without a design, on a transparent plastic sheet, having a matte finish on one surface, with different sizes of squares, rectangles, etc. that give a spread of sizes to form transparent foundations for the finished graphs. The type of plastic on which the patterns of intersecting lines are printed is preferably sheets of plastic known in the engineering trade as TELEDYNE POST Style #18×4 drafting film.
In use, the person desiring to make a needlework graph of a colored design first selects a transparent foundation appropriately printed as described above for the definition of detail to be used in reproducing the design. The appropriate transparent foundation is placed over the colored design to be reproduced, and colored pencils are then used to copy the underlying design onto the overlying spaces on the superposed transparent foundation. That completes the graph and the graph is then used in the conventional manner to reproduce the design by needlework on canvas or fabric.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a sheet of prior art TELEDYNE POST Style #18×4 drafting film;
FIG. 2 is a greatly enlarged sectional view taken substantially along the line 2--2 in FIG. 1, showing the matte finish on one surface of the prior art drafting film;
FIGS. 3, 4, and 5 are top plan views of the prior art drafting film shown in FIGS. 1 and 2, after being printed to form a transparent foundation for a needlepoint graph, a duplicate stitch graph, and a cross stitch graph, respectively;
FIG. 6 is a plan view of a colored design to be reproduced by needlework, the hatching illustrating different colors in the specific design;
FIG. 7 is an exploded perspective view of the transparent foundation shown in FIG. 5 superposed over the colored design shown in FIG. 6, and illustrating the completion of the graph by the tracing with colored pencils of colors on the transparent foundation corresponding to the subjacent colors in the design of FIG. 6; and
FIG. 8 is a plan view of a reproduction by cross stitch of the design of FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
Referring more specifically to the drawings, the numeral 10 broadly designates a sheet of prior art tracing film known in the engineering trade as TELEDYNE POST Style #18×4 drafting film. It is a coated, matte polyester product.
The film base is a crystalized, aligned polyester (polyethylene terphthalate) film. The crystallization and alignment enhances the dimensional stability over ordinary film products, such as packaging films.
The coating on the film is comprised of silica (silicon dioxide) dispersed in an acrylic (polymethyl methacrylate) resin. The silica provides a matte surface for drafting, plotting, coating, coloring, etc. The acrylic resin binder is hard, and one of the more light stable, discoloration resistant materials available. The matte surface on the film 10 is indicated at 11 in FIG. 2.
According to the invention, the prior art tracing film 10 is printed with a plurality of intersecting lines 12 to form a transparent foundation 13 for making a needlework graph (FIGS. 3, 4, and 5). In FIG. 3, the intersecting lines 12 form diagonally extending rows of ellipses 14 for making a needlepoint graph; in FIG. 4, the intersecting lines 12 form rectangles 15 for making a duplicate stitch graph; and in FIG. 5, the intersecting lines 12 form squares 16 for making a cross stitch graph.
The sheets of film 10 are preferably cut to a desired size, such as 8.5×11 inches. The transparent foundations 13 are printed in different sizes for the convenience of the user in making graphs for needlework having the desired definition of detail.
FIG. 6 shows an example of a specific colored design to be reproduced by needlework. It is a floral design, broadly indicated at 20, on wallpaper 21. The floral design 20 is hatched to indicate the colors in the design. The stem 22 and the leaf 23 are green; the leaf 24 is brown; the leaf 25 and the bud 26 are red; and the foliage 27 is blue.
FIG. 7 shows the transparent foundation 13 of FIG. 5 positioned in superposed relation to the design 20 to graph the design by using water color pens, chemical colored pens, or colored pencils 30 to copy the colors in the design onto the matte surface 11 of the foundation 13. The use of colored pencils to copy the colors in the design on the matte surface 11 of the foundation 13 is preferable because colored pencils are readily available in at least one hundred and twenty (120) different colors and shades of color, making it relatively easy to match the colors in the design. Another advantage of using colored pencils is that it is easier to erase and wash off the marks made by colored pencils than the marks made by other types of markers.
A brown colored pencil 30 is shown being used to color those spaces on the transparent foundation that overlie the brown leaf 24. A green colored pencil has already been used to color the spaces in the transparent foundation that cover the stem 22 and leaf 23. The graph of the colored design 20 will be completed by using a red colored pencil to color the spaces overlying the leaf 25 and bud 26, and a blue colored pencil to color those squares in the transparent foundation 13 that overlie the foliage 27.
The graphed design 31 will be used in the conventional manner to reproduce the design 20 by cross stitch 32 on canvas 33, as shown on the leaves 23 and 24 in FIG. 8.
There is thus provided a novel method for an average person who is not skilled in graphing to graph a colored design for reproduction by needlework.
Although specific terms have been employed in describing the invention, they have been used in a generic and descriptive sense only and not for the purpose of limitation.
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This invention provides a graphing system that enables an average person interested in reproducing a colored design by needlework, for which there is no existing graph, to quickly and easily graph the colored design for reproduction by such needlework as cross stitch, needlepoint, quilting, smocking, duplicate stitch, or knitting.
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This application is a division of application Ser. No. 430,775, filed Sept. 30, 1982 now U.S. Pat. No. 4,461,643 which is a continuation-in-part of application Ser. No. 402,831 filed July 29, 1982, now abandoned application Ser. No. 259,857 filed May 4, 1981, now abandoned and application Ser. No. 98,996 filed Nov. 30, 1979, now abandoned.
SUBJECT MATTER OF THE INVENTION
The present invention relates to an improved brake lining utilizing a mineral such as vermiculite as a basic component, and further relates to the use of such material in the manufacture of composite friction materials in which the manufacturing process involves the production of a preform.
DESCRIPTION OF THE PRIOR ART
The prior art discloses brake lining for use in automotive, truck, bus, or similar vehicles as well as off-the-road equipment such as farm machinery and construction equipment. Varying compositions for the brake lining are disclosed in the prior art, but predominantly the prior art brake lining consists of two basic systems. In one system, organic or inorganic fibers are dispersed in a resin composition. The fibers are ordinarily asbestos, metal, other minerals or glass and are used for strength, thermal and frictional properties. The other system comprises a sintered metal in combination with metal oxides. In this latter system there are no organic binders. Of these systems, the first, which uses asbestos as the fiber, is the most popular because asbestos is relatively inexpensive, is easily performed and provides a brake lining having excellent wear, durability, friction and strength properties. However, asbestos has been found to expose workers making or installing the brake linings as well as the public to a potentially serious health hazard. It has been determined in recent years that the inhalation of small asbestos fibers can result in a disease known as asbestosis in which these fibers accumulate on the lungs, scar lung tissue, and may cause many respiratory problems. It has become increasing clear that inhalation of asbestos fibers over an extended period of time can lead to a cancer of the lining of the lungs known as mesothelioma as well as lung cancer. In view of these recent findings under investigations conducted by the federal government as well as private concerns, it has become urgent to find substitutes for asbestos in those applications involving the manufacture and use of materials containing asbestos.
In the operation of conventional asbestos-based brake lining, as the brake lining wears away some of the asbestos discharges into the atmosphere in its fibrous form posing a potential hazard. In view of the potential hazard of asbestos materials, it has become increasingly desirable for manufacturers of friction materials such as asbestos-based brake lining to find suitable substitutes for asbestos. While mineral and metal fiber material have been substituted for the fibrous asbestos material, brake linings employing such materials to date have had inferior physical strength and brittleness. These materials are also very heavy and costly to manufacture and as a result such substitute formulations have had only limited applicability. Other materials have been tried in brake linings and related products but are unacceptable because of difficulties in performing and because of prohibitive costs of materials and processing. Therefore, the search for substitutes for asbestos in recent years has concentrated on fibrous materials such as glass fibers, steel wool fibers, iron filings, mineral wool fibers, and comparable fibrous materials. An example of these alternatives is illustrated in U.S. Pat. No. 2,012,259. This patent teaches the substitution of talc called asbestine. This material is, however, a short fiber material and therefore may have some of the same health hazards associated with asbestos. Some effort has been made to incorporate a non-fiber material such as perlite (see U.S. Pat. No. 3,307,969) in a friction material. However, such compositions in U.S. Pat. No. 3,307,969 contain asbestos as a major constituent, and the resultant product is not capable of being preformed, since perlite has no green strength when compressed. While some of these substitutes provide the strength and others provide the frictional properties and still others provide wear resistance, none of these has as yet been found to provide all of these properties coupled with economical material and manufacturing costs. In addition, many of these fibers may themselves pose potential health hazards. Therefore, a brake lining formulation which contains no asbestos, yet produces a brake lining material comparable to conventional asbestos-based brake lining in wear, durability, friction and strength, would be an important improvement over the prior art.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an asbestos-free brake lining which has wear, durability, friction and strength characteristics comparable to or exceeding those of conventional asbestos type brake linings.
It is also an object of the present invention to provide a non-asbestos composition of material which can be shaped into brake pads, discs, and the like using a conventional process of first compressing the composition at ambient temperatures into a preform and subsequently subjecting the preform to compression at elevated temperatures.
It has been determined that a brake lining comprised of vermiculite and a thermosetting resin having heat resistant properties, preferably phenol formaldehyde, produces a satisfactory asbestos-free brake lining. Alternative thermosetting resins may include phenol furfural, melamine formaldehyde, epoxy resins, cross-linked alkyd resins, diallyl phthalate resins, urea-formaldehyde, heat bodied linseed oil and cashew nut liquid resins. It has been found that a satisfactory brake lining is produced if the weight ratio of resin to vermiculite is in a range having a upper limit not exceeding about 1.2/1 to 1.5/1 and a lower limit not less than about 1.15/1. A suitable range is between about 1.2/1 and 0.15/1, preferably 1.2/1 to 0.4/1. The total weight percent of resin plus vermiculite in the brake lining is preferably between about 35% and 100%. The remainder of the mixture is comprised of filler components.
A satisfactory mixture of filler components for automobile disc pads brake lining or truck blocks or segments to be used in conjunction with the vermiculite-resin combination has been found to consist of cashew-based friction particles, brass chips, soft bituminous coal, chromite ore, calcium carbonate and graphite, or their equivalents.
In the case of roll-brake lining which is used for passenger car drum brakes, a heat bodied linseed oil is preferred; however, the above-cited group of thermosetting resins preferably in liquid form is also suitable. A satisfactory mixture of filler components for roll-brake lining has been found to consist of bituminous coal, calcium carbonate, barium sulphate, brass chips, talc, sulphur and hydrated lime.
The method of manufacture of the brake lining in the form either of disc pads for typical application in passenger cars or block or segment lining for typical application in trucks usually consists of a preforming step followed by a molding step. Generally, the preforming step is carried out by subjecting the mixture of dry constituents to pressures of between 300 and 5500 p.s.i.g. at room temperature for a period of at least two seconds, and preferably between two seconds and two minutes, depending on the size and thickness of the part. The resulting preform is then subjected to a molding step wherein the preform is compressed at pressures of approximately 1500 to 2500 p.s.i.g. at a temperature of about 280° F. to 360° F. for 4 to 14 minutes depending upon the size and thickness of the part.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred brake lining of the invention is composed of vermiculite, preferably expanded vermiculite, resin, and filler components. The vermiculite and resin in the preferred embodiment may have a total composition in the mixture in the range between 35% and 100% by weight. The filler components (i.e. components other than resins and vermiculite) may comprise 0% to 65% by weight of the brake lining composition. It has been determined by experiment that a brake lining having a combined weight of vermiculite and resin in the range between 35 and 100 weight percent and having a weight ratio of resin to vermiculite in a range between 1.2/1 and 0.4/1 produces a particularly strong and durable brake lining which is easily preformed and molded.
The relative percentages of vermiculite and resin determine the wear and processability characteristics.
When the relative amount of vermiculite is high the wear is high; conversely, when the amount of resin is comparatively high the composition becomes difficult to process and the resulting product has a tendency to fade. Since there appears to be no abrupt change in the properties with change in composition, the recited range is intended to define a spectrum of commercially preferred materials.
The resinous material used in the brake lining of the present invention may be generally any thermosetting resin having heat-resistant properties sufficient to withstand temperatures up to 1000° F. It has been determined that phenol formaldehyde, phenol furfural, melamine formaldehyde, epoxy resins, cross-linked alkyd resins, diallyl phthalate resins, and urea-formaldehyde thermosetting resins form particularly suitable binders with vermiculite. Additionally, cashew nut liquid resins, drying oils such as china wood oil and heat bodied linseed oil, latices, and elastomeric resins are suitable. A phenol formaldehyde resin suitable for use in the present formulation is available from Schenectedy Chemicals Co., Inc., of Schenectedy, N.Y. and is manufactured under the catalog code SP6416.
Vermiculite is a hydrated magnesium-aluminum-iron silicate having in its natural form a platelet-type crystalline structure and in its expanded form an accordian-like structure with a typical diameter of about 1 mm and a typical length of about 3 mm.
An expanded grade of vermiculite mineral crushed to particle size no larger than 3.35 mm and no smaller than 0.15 mm is preferred for use in the present invention. A vermiculite of the designation Montana expanded grade vermiculite is particularly suitable. A typical weight analysis of Montana vermiculite ore is given as follows: SiO 2 38.64%, MgO 22.63%, Al 2 O 3 14/94%. Fe 2 O 3 9.29%, K 2 O 7.84%, CaO 1.23%, Cr 2 O 3 0.29%, Mn 3 O 4 0.11%, Cl 0.28%. A vermiculite mineral of this type is readily obtained from W. R. Grace & Co. under the trade name designation "Industrial Vermiculite".
A microscopic examination of industrial vermiculite indicates that it has a three-dimensional accordian structure with typical particle maximum diameter of 1 mm and length of 3 mm.
It has been determined that asbestos, which is commonly employed in conventional brake linings typically comprising about 40 wt% to 60 wt%, can be eliminated when the above-stated brake lining composition of the invention containing vermiculite is used. The only asbestos present in the formulation of the invention is a trace amount of less than 0.5 wt% in the vermiculite itself.
At this level the trace asbestos provides no reinforcing or other properties to the brake lining. The vermiculite when used as an asbestos substitute in addition to providing much of the friction and wear properties of asbestos additionally functions in part as a reinforcing agent, thermal stabilizer and filler. The reinforcing property of the vermiculite is unexpected in view of its nonfibrous character. The present formulation employing vermiculite has the significant advantage that a noncarcinogenic material has been substituted for the asbestos, a known carcinogen, without sacrifice in the wear or strength properties of the brake lining.
The filler components comprising the brake lining formulation of the invention may range from 0 to 65% by weight of the total mixture.
Although substitutes for these filler components are possible, a particularly suitable formulation for disc brake lining or block or segment lining is one component group wherein the filler components (i.e., components other than resin or vermiculite) consist of the components designated in Table 1 in the approximate portions indicated as wt. percent of the total filler component group.
TABLE 1______________________________________Typical Filler Components,Wt % of Filler Component Group______________________________________Friction Particles 17.Brass Chips 3.Sea Coal 9.Chromite 4.Marblewhite 27.Graphite 40. 100.______________________________________
The friction particles are preferably a cashew-based material such as cashew shell oil-based friction particles. Suitable cashew-based friction particles are available from Colloid Chemicals, Inc., having its main office in Cedar Knolls, N.J. and are sold under grade No. 6250-30. It is theorized that these particles serve to control the friction and wear of the brake lining.
The brass chips may be any clean brass chips. Typically, these chips may have an average particle size of about 0.4 mm in thickness and 3 mm in length. Other brass chips either larger or smaller may also be used. The brass chips provide additional abrasive properties, it is theorized, and also serve to clean the brake rotor or drum. Alternatively, instead of brass, chips such as zinc of about the same size may be used.
The sea coal used is a preferred grade of ground bituminous (soft) coal and may be obtained from Whitehead Brothers Co., having its main office in Florham Park, N.J. It is theorized that the sea coal provides the necessary friction in the 200°-400° F. temperature range. Alternatively, instead of sea coal other types of coal such as anthracite may be used.
The chromite is a chrome ore containing typically about 40 wt% Cr 2 O 3 and 25 wt% Fe 2 O 3 , 15 wt% Al 2 O 3 , 14 wt% MgO and 6 wt% SiO 2 . A chromite ore suitable as a filler may be obtained from Foote Mineral Company having a main office at Route 100, Exton, Pa. The chromite should be ground to an average particle size of about 325 mesh. Alternatively, many other minerals such as red iron oxide or fused aluminum oxide could be substituted for chromite.
The marblewhite has the composition calcium carbonate and may be purchased from Pfizer Co. having a principal place of business in Clifton, N.J. Alternatively, other filler materials instead of marblewhite such as barium sulfate (barytes) may be used.
The graphite used is preferably of grade 608A (industrial designation) and may be purchased in powdered form from Superior Graphite Co. having its main office in Chicago, Ill. The graphite is used in the brake lining as a lubricant and in connection with the vermiculite formulation of the invention to aid in ejecting the preformed disc pads from the molds. Alternatively, many other grades of graphite in flake or powder form may be used.
A typical composition for the disc, block or segment brake lining of the invention is set forth in Table 2.
TABLE 2______________________________________ WT %______________________________________Resin 20.8Expanded Vermiculite 45.2Friction Particles 5.9Brass Chips 1.1Sea Coal 3.2Chromite 1.3Marblewhite 9.0Graphite 13.5 100.0______________________________________
It will be noted that in the composition set forth in Table 2 the resin plus expanded vermiculite comprise 66% of the mixture and the filler components comprise 34% of the mixture. With the individual filler component distribution as in Table 1 and the filler components at 34 wt% of the total mixture, brake linings of the invention were manufactured at various ratios of resin to vermiculite. Six brake lining compositions were prepared, each with a total filler content of 34 wt% of the mixture and distributed as in Table 2 and with resin-to-vermiculite weight ratios at 1.5, 1.2, 0.46, 0.4, 0.27 and 0.15, respectively. The six brake lining compositions were then subjected to moldability, friction, strength and wear tests as reported in Table 3. The test results for preforming and moldability characteristics were compared to results obtained with a conventional asbestos type brake lining having a composition 53 wt% asbestos, 15 wt% phenolic resin, 10 wt% cashew particles, 6 wt% rubber particles, 4 wt% zinc chips, 1 wt% carbon black, 7 wt% brass chips and 4 wt% calcium aluminate.
The ingredients were first blended in a Littleford Mixer. The mixed ingredients were then put into a preform mold cavity having roughly the desired product shape. The mixture was then compressed at room temperture and at a pressure of about 2600 p.s.i. for a period of about 15 seconds. The preformability characteristics of the brake lining composition resulting from the preforming step and the ease with which the preformed part could be ejected from the preforming mold cavity (ejectability) were compared with results obtained with a conventional type brake lining having the above-cited composition.
The preform was then removed from the preforming mold cavity and was subjected to a molding step. In the molding step the preform was placed into a second mold cavity of similar shape wherein it was compressed at pressures of approximately 1,900 p.s.i. at a temperature of about 320° F. for a period of about 4 minutes. The molded pads were then ground and drilled to their specifications. During the molding step three characteristics of the product were evaluated and recorded in Table 3 and compared with results obtained from the above-cited conventional asbestos-type brake lining. The three characteristics evaluated were: (a) the flowability of the material within the mold; (b) its tendency to blister and form air pockets; and (c) its tendency to stick in the mold. They show that for all ratios of resin to vermiculite between 1.5 and 0.15, the formulations are able to be preformed as well or better than the conventional asbestos formulation, but that its moldability as evidenced by flow, blisters and sticking is best at resin to vermiculite ratios of between 0.46 and 0.27.
The flexural and shear strengths as well as the friction and wear properties of the molded brake lining product of the invention were then measured and are also reported in Table 3.
A flexural strength of about 400 p.s.i. is currently considered well within the requirements of the automotive industry. Brake lining having a flexural strength as low as 200 p.s.i., or in some applications lower, are also considered satisfactory. All compositions except the one having a resin to vermiculite ratio of 0.15 had acceptable flexural strengths.
The shear strength of the molded brake lining product is a measure of the ability of the brake pad to withstand the braking forces which tend to shear the brake pad from the steel to which it is attached. The automotive industry currently requires a minimum shear strength of about 160 to 300 p.s.i. All ratios evaluated met this requirement.
The friction and wear tests as set forth by the Society of Automotive Engineers (SAE) Test Designation No. J661a have been applied to the brake lining of the invention and the results are reported in Table 3.
The hot friction coefficient is comparable to that coefficient of friction which results after the automobile rotor and brake lining have been heated due to prolonged or repeated stopping. A range of 0.350 to about 0.450 for both the hot and cold coefficient of friction have been found to be suitable for most automotive and truck applications, but higher or lower coefficients of friction may be desirable depending on the particular application. Hot and cold friction coefficients of 0.550 and higher have been found to be required in some cases. SAE Test J661a also determines brake lining wear by measuring the decrease in sample thickness which occurs during the test. A decrease of up to 0.010 inch is considered reasonable. All ratios of resin to vermiculite except 0.15 had acceptable wear. During the test, the lining will tend to swell or grow in thickness. An increase in thickness no greater than 0.002 is considered acceptable.
Upon inspection of the test data of the brake lining of the invention reported in Table 3 for varying resin-to-vermiculite weight ratios for mixtures containing about 34 wt% of total filler components, it may be observed that ratios of resin-to-vermiculite in a range having an upper limit not exceeding about 1.2/1 to 1.5/1 and a lower limit not less than about 0.15/1, thus having a weight ratio between about 1.2/1 to 0.15/1, preferably 1.2/1 to 0.4/1, produce a brake lining product complying with the aforementioned criteria and modern test standards.
TABLE 3__________________________________________________________________________Filler Content: 34 wt %of Total MixtureWt. Ratio of Resin toVermiculite 1.5 1.2 0.46 0.4 0.27 0.15__________________________________________________________________________1. Preforminga. Preformability ** ** ** ** ** **b. Ejectability 0 0 ** * ** *2. Moldabilitya. Flow 0 * ** ** ** **b. Blisters 0 * ** ** * *c. Sticking 0 * ** ** ** 03. Flexural Str. (psi) 400+ 400+ 400+ 362 400+ 1034. Shear Strength (psi) 490 490 490 450 510 3145. SAE J661aa. Cold Friction Coef. X 0.388 0.392 0.387 0.398 0.398b. Hot Friction Coef. X 0.383 0.386 0.375 0.367 0.405c. Wear (inches) X 0.004 0.0072 0.007 0.009 0.014d. Swell (inches) X 0.003 0.0015 0.001 0.000 -0.001__________________________________________________________________________ Note 1: 0 is somewhat less than satisfactory or unsatisfactory *is satisfactory but less satisfactory than the asbestos brake lining **performance equal to or better than the asbestos based brake lining X = could not run
TABLE 4__________________________________________________________________________Wt Ratio of Resin toVermiculite 1.5 0.46 0.15 1.5 0.46 0.15__________________________________________________________________________FILLER CONTENTWt % of total Mixture 45% 45% 45% 25% 25% 25%1. Preforminga. Preformability ** ** * ** ** *b. Ejectability * ** ** 0 * **2. Moldabilitya. Flow 0 ** ** 0 ** **b. Blisters 0 * ** 0 * *c. Sticking 0 ** ** * ** **3. Flexural Str. (psi) 400+ 400+ 15 390 400+ 4004. Shear Str. (psi) 560 560 185 608 716 4125. SAE J661aa. Cold Friction Coef. 0.413 0.405 0.415 0.320 0.385 0.390b. Hot Friction Coef. 0.454 0.392 0.407 0.314 0.393 0.405c. Wear (inches) 0.004 0.006 0.0128 0.0026 0.0059 0.018d. Swell (inches) 0.0035 0.002 -0.001 0.004 0.0025 -0.003__________________________________________________________________________ Note 1: 0 is somewhat less than satisfactory or unsatisfactory *is satisfactory but less satisfactory than than the asbestos brake linin ** performance equal to or better than the asbestos brake lining
TABLE 5__________________________________________________________________________Resin/Vermiculite Ratio 0.46 0.46 0.46 0.46 0.46 0.46__________________________________________________________________________Filler Content % by Wt. 0 15 20 50 60 701. Preforminga. Preformability ** ** ** ** ** *b. Ejectability 0 * * * * *2. Moldabilitya. Flow ** ** ** ** ** **b. Blisters * ** ** ** ** **c. Sticking 0 * * ** ** **3. Flexural Str. (psi) 400+ 400+ 400+ 387 319 204. Shear Strength (psi) 594 603 726 343 288 05. SAE J661aa. Cold Friction Coef .362 .375 .394 .388 .382 .322b. Hot Friction Coef .297 .365 .384 .371 .369 .338c. Wear .0147 .0099 .0088 .0074 .0067 .0073d. Swell +.001 .0025 .002 .001 -.0005 -.0015__________________________________________________________________________ Note 1: 0 is somewhat less than satisfactory or unsatisfactory *is satisfactory but less satisfactory than the asbestos based brake lining **performance equal to or better than the asbestos based brake lining
The same tests reported in Table 3 were then repeated over the same range in ratios of resin-to-vermiculite (i.e., between 1.5/1 and 0.15/1) but with the total filler components varied in a range between about 25 and 45 wt% of the total mixture. (The distribution of filler components or their alternative substitutes in this series of tests was approximately as that given in Table 1). Approximately the same test results reported in Table 3 were obtained at corresponding resin-to-vermiculite weight ratios with the filler components varied in a range between about 25 and 45 wt% of the total mixture. A specific illustrative set of test results for the latter series of tests are reported in Table 4 for specific cases--namely, a mixture comprised of a resin-to-vermiculite weight ratio between 0.15/1 and 1.5/1 and filler components between about 25 wt% and 45 wt% of the total mixture.
Experiments were then conducted for total filler components ranging from 0 wt% to 70 wt% of the total mixture. The distribution of the filler components was approximately the same as given in Table 1. A specific illustrative set of test results over a range of filler components between 0 wt% and 70 wt% of the total mixture at a specific illustrative resin-to-vermiculite ratio of 0.46 is given in Table 5.
Based on all the tests it has been determined that a satisfactory product will result at a weight ratio of resin to vermiculite in a range having an upper limit not exceeding about 1.2/1 to 1.5/1 and a lower limit not less than about 0.15/1, with filler components in a range between 0 wt% and 65 wt% of the total mixture. With the filler components in a range between about 0 wt% and 65 wt% of the total mixture, a particularly satisfactory product results at a resin-to-vermiculite weight ratio in a range between 1.2/1 to 0.4/1 and more preferably at about 0.46/1.
Examples illustrative of the methods of manufacture of the brake lining of the invention for various applications are set forth as follows:
EXAMPLE 1
A method of manufacture and a disc pad brake lining for typical application in automobiles is given as follows:
Dry ingredients having the following composition were first thoroughly blended in a Littleford mixer:
______________________________________ WT %______________________________________Expanded Vermiculite 45.2Phenolic Resin 20.8Friction Particles 5.9Brass Chips 1.1Sea Coal 3.2Chromite 1.3Marblewhite 9.0Graphite 13.5 100.0______________________________________
About 150 gms of the mixture was then added to the preform mold having a shape approximately that of the desired product. The material was compressed under 2,600 p.s.i. at room temperature for about 15 seconds. The pressure was released and the compacted preform was then placed in a hot press mold. The preform was molded at about 350° F. for 4 minutes at a pressure of about 1,350 p.s.i. The cured pad was removed from the mold and post cured in an oven at 300° to 350° F. for 7 hours. The pad was machined to desired dimensions.
EXAMPLE 2
A method of manufacture and a block brake lining for application typically in heavy duty trucks is given as follows.
About 12 pounds of dry ingredients having the following composition were mixed in a Littleford mixing vessel:
______________________________________ WT %______________________________________Expanded Vermiculite 52.0Phenolic Resin 14.0Friction Particles 5.9Brass Chips 1.1Sea Coal 3.2Chromite 1.3Marblewhite 9.0Graphite 13.5 100.0______________________________________
The mixture was then compressed at about 350 p.s.i. pressure at room temperature for about 40 seconds to form the preform. The preform was then hot-pressed to the desired shape by molding in a hydraulic press at 300° to 360° F. for 14 minutes at a pressure of about 1,750 p.s.i. The cured slab was the removed from the mold and placed in a post-curing oven for 7 hours at 300° to 350° F. The slab was then cut, finish ground and drilled to desired specification.
EXAMPLE 3
A method of manufacture and a roll lining brake material for use in passenger cars is given as follows:
Approximately 20 pounds of ingredients having the following composition were blended in a Sigma mixer to form a wet mix batch:
______________________________________ WT %______________________________________Expanded Vermiculite 49.0Sea Coal 14.7Marblewhite 3.7Barytes 6.1Talc 3.7Sulfur 1.5Hydrated Lime 1.0Brass Chips 0.1Heat Bodied Linseed Oil 20.2 100.0______________________________________
The wet mixture batch was then fed to a 2 roll molding machine, extruded at room temperature into a roll of compressed strip brake lining material approximately 2 inches wide by 1/4 inch thick. The roll of brake lining material was then baked a 325° F. for 13 hours to produce a brake lining product material. The brake lining material was then cut into segments and finish ground.
EXAMPLE 4
11 pounds of the following ingredients in the following weight percentages were mixed in a Sigma mixer: Unexpanded Vermiculite Ore, 45.3 wt%; cashew-based friction particles grade No. 6250-30, 5.9 wt%; Brass Chips, 1.4 wt%; Sea Coal, 3.2 wt%; Chromite Ore, 0.7 wt%; Graphite, 13.6 wt%; Marblewhite 9.0 wt%; Phenol formaldehyde resin, 20.8 wt%. The mixture was processed at ambient temperatures and 1000 p.s.i. pressure to form a preform. The preform was then hot pressed at 300°-300° F. for four minutes at 1850 p.s.i. to form a friction material. The resultant friction material was postbaked for seven hours at 325° F. and ground and drilled to specification. The mixture was slightly more difficult to preform and to mold than the conventional asbestos-based disc pad and was more prone to chipping; however, a suitable friction material for use as a brake lining was made. The friction, wear, and strength properties were found to be substantially the same as that reported in Table 2 for the corresponding resin-to-vermiculite weight ratio; however, the flexural strength was found to be somewhat lower, approximately about 60 to 200 p.s.i.
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A friction material for use as a brake lining in automobiles, trucks, buses or similar vehicles. The brake lining contains no more than traces of asbestos and utilizes the mineral vermiculite as a basic constituent. The formulation of the brake lining comprises a non-fibrous natural or synthetic mineral or mineral-like material which on being compressed at ambient temperatures and at pressures of 1700 to 2600 p.s.i. has significant green strength in the order of 2 to 25 p.s.i. and also has appropriate thermal resistance, frictional properties, and shear and flexural strengths, together with a thermosetting resin as the basic components together with other organic and inorganic materials as friction modifiers and fillers. The mineral preferably comprises vermiculite, and together with the resin comprises preferably about 35% to 100% by weight of the brake lining formulation. The ratio by weight of resin to vermiculite is preferably in a range having a upper limit not exceeding about 1.2/1 to 1.5/1 and a lower limit not less than about 0.15/1.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of application Ser. No. 11/637,659 filed Dec. 12, 2007, which issued on Nov. 6, 2007 as U.S. Pat. No. 7,292,939, which is a continuation of application Ser. No. 10/445,861 filed May 27, 2003, which issued on Mar. 6, 2007 as U.S. Pat. No. 7,188,027, which is a continuation of application Ser. No. 10/032,853 filed Oct. 25, 2001, which issued on Aug. 3, 2004 as U.S. Pat. No. 6,772,064.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present methods and systems generally relate to processing and transmitting information to facilitate providing service in a telecommunications network. The methods and systems discussed herein more particularly relate to use of global satellite positioning to facilitate processing and transmission of information associated with telecommunications service locations and routing travel between more than one such service location.
[0004] 2. Description of the Related Art
[0005] Efficient and effective customer service is an essential requirement for commercial enterprises to compete successfully in today's business world. In the telecommunications industry, for example, providing customer service is an important part of sustaining market share in view of the many competitors in the industry. Customers whose telephone service, for example, is interrupted or disconnected for even a relatively short period of time may desire to seek an alternative source for service, especially if the interruption or disconnection is not addressed by a quick and effective customer service response.
[0006] One important aspect of providing customer service is maintaining accurate and complete knowledge of the customer's location. Computer systems and databases that provide customer addresses often only provide vague references, however, to the exact location of the customer. Such customer addresses typically do not include information of sufficient specificity to permit efficient identification of a service location associated with the customer. In the context of a technician transporting a vehicle to a customer's service location, for example, this lack of sufficient service location information can generate excessive driving time and slow response time. Where the response time is unacceptably high, the lack of sufficient service location information can result in delayed or missed customer commitments. It can be appreciated that such delayed or missed customer commitments can cause a commercial enterprise to lose valuable customers.
[0007] What are needed, therefore, are methods and systems for acquiring information associated with a customer's service location. Such methods and systems are needed to obtain, for example, a latitude and longitude associated with the customer's service location. In one aspect, if latitude and longitude information could be collected by a service technician when the customer's service location is visited, those coordinates could then be used to find the customer at a later date. Moreover, if latitude and longitude coordinates could be made available in a database associated with that specific customer, the coordinates could be used to assist in determining the service location of that customer. Such service location information could permit a service technician to drive directly to the customer service location with little or no time lost searching for the service location.
[0008] What are also needed are methods and systems for providing a service technician with directions, such as driving directions between two or more service locations. Such directions could be employed to route travel from a first customer service location to a second customer service location. It can be seen that such directions would further reduce the possibility of error in locating a customer service location and thereby enhance customer service response time.
SUMMARY
[0009] Methods and systems are provided for obtaining information related to a customer service location. One embodiment of the method includes requesting at least one set of coordinates associated with the customer service location; accessing a technician server to direct a global satellite positioning system to obtain the set of coordinates for the customer service location; obtaining the coordinates and updating one or more databases with the coordinates. The coordinates may include at least one of a latitude and a longitude associated with the customer service location. One embodiment of a system for obtaining information related to a customer service location includes an input device configured for use by a service technician at the customer service location. A technician server is included in the system for receiving data transmissions from the input device. The technician server is in communication with a global positioning satellite system for determining a set of coordinates associated with the input device. Computer-readable media embodiments are also presented in connection with these methods and systems.
[0010] In addition, methods and systems are discussed herein for generating directions for a service technician traveling from a first customer service location to at least a second customer service location. One embodiment of the method includes obtaining through a technician server at least one set of “from” coordinates associated with the first customer service location and at least one set of “to” coordinates associated with the second customer location; transmitting the ‘from” and “to” coordinates to a mapping system; and, generating directions in the mapping system based on the “to” and the “from” coordinates. One system embodiment includes an input device configured for use by a service technician at a first customer service location. A technician server is provided for receiving data transmissions from the input device. A global positioning satellite system, which is configured for determining at least one set of ‘from” coordinates associated with the input device is provided for use on an as needed basis. At least one database is included in the system for storing a “to” set of coordinates associated with the second customer service location and the “from” set of coordinates. The system further includes a mapping system operatively associated with the input device for generating travel directions based on the “from” and “to” coordinates. At least one of the sets of coordinates includes latitude and a longitude data. Computer-readable media embodiments of these methods and systems are also provided.
BRIEF DESCRIPTION OF THE FIGURES
[0011] FIG. 1 is a schematic diagram depicting one embodiment of a system for obtaining, processing, and transmitting information related to providing customer service at a customer service location;
[0012] FIG. 2 is a schematic diagram depicting a portion of the system of FIG. 1 in more detail;
[0013] FIG. 3 is a process flow diagram showing one embodiment of a method for obtaining, transmitting and processing information related to providing service at a customer service location;
[0014] FIG. 4 is a schematic diagram depicting one embodiment of a system for obtaining, processing, and transmitting information related to providing customer service at a customer service location; and,
[0015] FIG. 5 is a progress flow diagram depicting one embodiment of a method for obtaining, processing, and transmitting information related to providing customer service at a customer service location.
DETAILED DESCRIPTION
[0016] Referring now to FIGS. 1 and 2 , a service technician visiting a customer service location is provided with a technician input device 2 for receiving and transmitting information related to a disruption or interruption of service at the service location. The input device 2 can be a wireless PC, for example, a laptop, a personal digital assistant (PDA), a wireless pager or any other device suitable for receiving and transmitting data associated with providing service at the customer service location. A transponder system 4 is operatively associated with the input device 2 for receiving and transmitting signals such as satellite transmission signals, for example.
[0017] The input device 2 is configured and programmed to permit the service technician to access a technician server 6 . As shown in FIG. 1 , access to the technician server 6 can be enabled through a wireless data network 8 through a radio connection 10 . Access to the technician server can also be enabled by a modem connection 12 through a landline server 14 . The landline server 14 can be a server configured in accordance with a server having a CSX 7000 trade designation employed by BellSouth Telecommunications (BST—Atlanta, Ga.).
[0018] A protocol server 16 receives and processes communications from both the wireless data network 8 and the landline server 14 . In operation of the input device 2 , the protocol server 16 processes information transmitted from the input device 2 including, for example, a user ID, a password, a radio serial number, an input device serial number, and other similar data associated with a service technician and service provided at a customer service location. In one aspect, the protocol server 16 can include one or more WINDOWS NT servers (Microsoft Corporation) configured to assign one or more logical ports to transmissions received from the input device 2 .
[0019] In one aspect of the present methods and systems, the technician server 6 can be a server having a TECHACCESS trade designation (Telcordia Technologies). The technician server 6 can be a conventional server configured and programmed to verify and/or process information received from the input device 2 . The technician server 6 functions as a transaction request broker between the protocol server 16 and one or more other systems operatively connected to the technician server 6 . The systems operatively associated with the technician server 6 can include, among other possible systems, a global positioning satellite system 18 (GPS system), a dispatch system 20 , an address guide system 22 , and a customer records system 24 .
[0020] In one embodiment of the present methods and systems, the GPS system 18 can be configured in accordance with the BellSouth Telecommunications Global Positioning Satellite System (GPS) as implemented by SAIC's Wireless Systems Group (WSG). The GPS system 18 is operatively associated with the transponder system 4 and can be employed to track, dispatch, and monitor service technicians and their input devices at numerous customer service locations. In one aspect, the GPS system 18 interacts with a transponder mounted on a mobile vehicle (not shown) employed by the service technician at a customer service location.
[0021] One purpose of the GPS System 18 is to provide supervisors and managers of service technicians with more comprehensive technician activity information. The GPS system 18 can include one or more servers (not shown) and one or more databases (not shown) for transmitting, receiving and storing data associated with satellite communications. In the context of the present methods and systems, the GPS system 18 serves to acquire information associated with a customer service location including, for example, the latitude and longitude coordinates of the customer service location.
[0022] The dispatch system 20 serves to receive, process and transmit information related to service required at one or more customer service locations. In one embodiment, the dispatch system 20 includes a server, a database and one or more graphical interfaces for receiving commands from a user. Such commands can include, for example, entry on a graphical user interface (GUI) of customer information and a problem description associated with a particular interruption or disruption of service. The dispatch system 20 communicates with the technician server 6 to process and transmit information related to actions to be performed at a customer service location. Examples of dispatch systems suitable for use in connection with the present methods and systems include the “LMOS,” “IDS” and “WAFA” systems of BellSouth Telecommunications.
[0023] The address guide system 22 includes a database 26 for storing universal type address information, examples of which are shown in FIG. 2 . The address guide system 22 can be considered the keeper of all addresses in the universe of telecommunications services. The address guide system 22 helps to promote valid addresses as customer service locations. For example, if a customer contacts a telecommunications service provider, the customer can be queried for the customer's address. If the customer provides an address of 123 XYZ Street and there is no 123 XYZ Street in the database 26 of the address guide system 22 , then a correct address for the customer can be confirmed and entered into the database 26 . An example of an address guide system 22 suitable for use in accordance with the present methods and systems is the “RSAG” application of BellSouth Telecommunications.
[0024] The customer record system 24 is operatively connected to the address guide system 22 and includes a database 28 for storing customer related information, examples of which are shown in FIG. 2 . In one embodiment of the present methods and systems, the customer record system 24 serves to store information related to a particular service location and customer. For example, when telephone service is initially requested by a customer, a record in the database 28 can be populated with information that will create a correspondence between the customer's address and the details of the telephone service to be installed. Records in the database 28 of the customer record system 24 typically remain effective as long as service at a particular address remains the same for that customer. The customer record system 24 interfaces with the dispatch system 20 during the operation of the dispatch system 20 to generate work orders associated with service issues at customer service locations. For example, if problems arise with a customer's service, such as the initial installation order for that service, the dispatch system 20 schedules the work order. The dispatch system 20 draws on information contained in the customer record system 24 to create the dispatch order for a service technician to perform any actions required by the work order.
[0025] Referring now to FIGS. 1 through 3 , an operative example of the present methods and systems include a service technician at a customer service location with an input device 2 . In accordance with the connections described above, in step 32 the technician server 6 can request the coordinates, in terms of latitude and longitude, from the service technician at the customer service location. The request of step 32 can be performed, for example, in step 34 by a job closeout script application of the technician server 6 that is adapted to query the service technician regarding the customers location at the conclusion of a service call. The technician server 6 may check to determine whether a latitude and longitude are already present in the customer's information in the database 28 of the customer record system 24 .
[0026] The technician server 6 can then instruct the service technician in step 35 to verify his presence at the customer service location. In step 36 , the GPS system 18 is accessed, such as through a “Fleet Optimizer” application (BellSouth Technologies) associated with the technician server 6 , to obtain latitude and longitude coordinates derived from the location of the service technician's input device 2 . In step 38 , the GPS system 18 transmits a signal to the transponder system 4 operatively associated with the input device 2 and obtains coordinates of the customer service location in step 40 . The GPS system transmits the obtained coordinates to the technician server 6 in step 42 . In step 44 , the dispatch system 20 is updated with the newly obtained latitude and longitude information. In step 46 , the database 28 of the customer records system 24 is updated to reflect this latitude and longitude information. In step 48 , the latitude and longitude information is transmitted to and stored in the database 26 associated with the address guide system 22 .
[0027] It can be seen that just because one has a street address for a customer service location, it does not necessarily follow that locating the customer service location can be readily performed. For example, a street address in Pittsburgh, Pa. might be Three Rivers Stadium Park. If this is the only information available, however, it may be difficult to find the customer service location where work needs to be performed. Use of a GPS system to associate coordinates with a street address permits one to know the position of a customer service location, and hence the location of a service technician performing work at that customer service location.
[0028] In another example of the present methods and systems, a new customer requests service installation at ABC Street. Verification is performed to determine that ABC Street is a valid address. If it is a valid address, and if latitude and longitude information has been populated in the address guide system 22 , then the information can be used effectively by a service technician to address the customer's needs. In addition, if a service issue later arises with the customer service location, the dispatch system 20 can obtain the customer record, including the customer name, contact number, the type of facilities the customer has, and latitude and longitude information associated with the customer service location. This complete record of information provides enhanced response time for addressing the customer's service needs.
[0029] Referring now to FIGS. 4 and 5 , in another aspect of the present methods and systems, a mapping system 52 can be provided for routing travel of a service technician between more than one customer service location. The mapping system 52 is configured and programmed to provide travel or routing directions to a service technician from a first location to at least a second location where customer service is to be performed. The mapping system 52 can include conventional mapping software installed on a computer-readable medium operatively associated with the input device. The mapping system 52 can also be accessed remotely, such as through a wireless connection between the mapping system 52 and the input device 2 .
[0030] In one embodiment, the technician server 6 functions to provide latitude and longitude information to the mapping system 52 . This information includes “from” information (i.e., the origin customer service location of the service technician) and “to” information (i.e., the destination customer service location to where travel is desired for the service technician). Before dispatch to the next customer service location, the service technician requests driving instructions in step 62 . The technician server 6 queries the “Fleet Optimizer” application, or its functional equivalent, in step 64 to obtain the current customer service location in step 66 , which can be used by the mapping system 52 as the ‘from” location. If necessary, and in accordance with previous discussion of the present methods and systems, the GPS system 18 can be accessed to obtain ‘from” latitude and longitude coordinates in step 68 .
[0031] The address guide system 22 can then be accessed by the technician server 6 in step 70 to provide the “to” location to the mapping system 52 , including latitude and longitude information for the destination customer service location. In step 72 , the technician server 6 transmits the “from” and ‘to” coordinates to the technician input device 2 . In step 74 , the mapping system 52 processes the “from” and “to” coordinates. The mapping system 52 can then generate and output driving directions from the “from” location to the “to” location for the service technician in step 76 . It can be appreciated that the output of the mapping system 52 including the driving directions can be in any conventional format suitable for communicating the directions to the service technician. For example, the output including the driving directions can be in electronic format or hard copy format.
[0032] As discussed above, accurate latitude and longitude coordinates may have already been established for the present or origin customer service location. In the process of dispatching a service technician to a next customer service location, however, it may be necessary to engage the GPS system 18 to obtain these latitude and longitude coordinates. The GPS system 18 can therefore be employed to provide knowledge of one or more service technician locations for various customer service locations where service is required. The GPS system 18 also functions to promote providing correct customer service location information, including latitude and longitude coordinates associated with customer addresses and/or associated critical equipment. It can be seen that algorithms can be applied in the dispatch system 20 and/or the technician server 6 to use this knowledge of service technician whereabouts and customer service locations to facilitate moving the next best or available service technician to the next highest priority or most appropriate service location.
[0033] The term “computer-readable medium” is defined herein as understood by those skilled in the art. A computer-readable medium can include, for example, memory devices such as diskettes, compact discs of both read-only and writeable varieties, optical disk drives, and hard disk drives. A computer-readable medium can also include memory storage that can be physical, virtual, permanent, temporary, semi-permanent and/or semi-temporary. A computer-readable medium can further include one or more data signals transmitted on one or more carrier waves.
[0034] It can be appreciated that, in some embodiments of the present methods and systems disclosed herein, a single component can be replaced by multiple components, and multiple components replaced by a single component, to perform a given function. Except where such substitution would not be operative to practice the present methods and systems, such substitution is within the scope of the present invention.
[0035] Examples presented herein are intended to illustrate potential implementations of the present communication method and system embodiments. It can be appreciated that such examples are intended primarily for purposes of illustration. No particular aspect or aspects of the example method and system embodiments, described herein are intended to limit the scope of the present invention.
[0036] Whereas particular embodiments of the invention have been described herein for the purpose of illustrating the invention and not for the purpose of limiting the same, it can be appreciated by those of ordinary skill in the art that numerous variations of the details, materials and arrangement of parts may be made within the principle and scope of the invention without departing from the invention as described in the appended claims.
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Methods and systems are provided for obtaining information related to a customer service location and directions for routing a service technician from one customer service location to another. One embodiment includes requesting at least one set of coordinates associated with the customer service location; accessing a technician server to direct a global satellite positioning system to obtain the set of coordinates for the customer service location; obtaining the coordinates and updating one or more databases with said coordinates. The coordinates may include at least one of a latitude and a longitude associated with the customer service location. Another embodiment includes obtaining through a technician server at least one set of “from” coordinates associated with the first customer service location and at least one set of “to” coordinates associated with the second customer location; transmitting the “from” and “to” coordinates to a mapping system; and, generating directions in the mapping system based on the “to” and “from” coordinates. At least one of the sets of coordinates includes latitude and longitude data. System and computer-readable media embodiments of these methods are also provided.
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RELATED APPLICATION
This is a continuation-in-part of Ser. No. 08/706,302, filed Aug. 30, 1996, now U.S. Pat. No. 5,830,454 and incorporated by-reference herein.
FIELD OF THE INVENTION
This invention relates to the treatment of pathological conditions which are treatable via administration of interleukin-9 ("IL-9") or interleukin-9 analogs, antagonists, and so forth. In particular, fibrotic, and autoimmune diseases are treatable via administration of IL-9 or its analogs, alone or together with other drugs.
BACKGROUND AND PRIOR ART
Interleukin-9 ("IL-9" hereafter), is a glycoprotein which has been isolated from both murine and human cells. See, e.g., U.S. Pat. No. 5,208,218, incorporated by reference. This reference also teaches isolated nucleic acid molecules encoding the protein portion of the molecule, and how to express it.
Various uses of the molecule can be seen in, e.g., U.S. Pat. No. 5,164,317 (proliferation of mast cells); U.S. Pat. Nos. 5,246,701 and 5,132,109 (enhancing production of IgG and inhibiting production of IgE), in addition to its first recognized utility, which is as a T cell growth factor. Exemplary of the vast scientific literature on the molecule are Van Snick, et al, J. Exp. Med. 169(1): 363-368 (1989) (cDNA for the murine molecule, then referred to as P40). Houssiau, et al, J. Immunol 148(10): 3147-3151 (1992) (IL-2 dependence of IL-9 expression in T lymphocytes). Renauld, et al, Oncogene 9 (5): 1327-1332 (1994) (effect on thymic lymphomas); Renauld, et al, Blood 85(5): 1300-1305 (1995) (anti-apoptotic factor for thymic lymphoma). Review articles may be found at, e.g., Renauld, et al, Cancer Invest 11(5): 635-640 (1993); Renauld, et al, Adv. Immunol 54: 79-97 (1993).
There is no literature on the influence of IL-9 on autoimmune disorders.
The art is familiar with a vast number of autoimmune disorders, which are classified in various ways. One way of classification is by way of the aspect of the immune system most intimately involved with the disorder. For example, in humoral response associated autoimmune diseases, B cells are involved. Antibodies are generated against self molecules, such as the acetylcholine receptor (myasthenia gravis), or the TSH receptor (Graves disease). In autoimmune diseases involving a cellular response, T cells, macrophages, and NK cells react with self molecules. Exemplary of these conditions are insulin dependent diabetes and thyroiditis. This family of diseases result, inter alia, from a skewing of Th1/Th2 balance.
One problem in the study of autoimmune diseases is the absence of suitable animal models. Without an appropriate system for studying a particular condition, one cannot draw conclusions as to the potential efficacy of a given drug in a therapeutic context.
An appropriate animal model for cell mediated diseases does exist, however, and it has been used in the disclosure which follows. Using the specific case of induced thyroiditis in a murine model, it has now been shown that IL-9 has therapeutic efficacy in Th1 associated autoimmune disorders. This will be shown in the detailed description of preferred embodiments which follows.
The murine model used in the disclosure which follows is also one which can be used to study diseases such as sialoadenitis, autoimmune hemolytic anemia, and other conditions. Further, a murine model is available which is useful in studying pathologies involving fibrosis, such as interstitial lung disease. Characteristic of these fibrosis related pathologies is inflammation in the afflicted tissue or organ, leading to scarring and distortion of tissue. Exemplary of this group of pathologies are interstitial lung diseases such as silicosis, asbestosis, white lung disease, black lung disease, Shaver's disease, etc. These conditions are known as pneumoconioses, (or anthracotic tuberculosis), and involve inflammation and lung fibrosis, caused, e.g., by inhalation of fine mineral particles. Other fibrotic conditions include all forms of sclerosis, fibrosis related rheumatism, such as chronic rheumatoid arthritis, and collagen related fibrosis, such as conditions involving keloids, scarring, renal diseases involving related conditions, and so forth.
The murine models for these conditions have been employed, as will be seen infra, to show the efficacy of IL-9 in their treatment.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1A shows effect of high doses of iodide following induction of goiter in NOD mice.
FIG. 1B shows the effect of IL-9 on iodide treated NOD mice.
FIG. 1C shows staining for CD4 + T cells in thyroids of goitrous NOD mice after a high iodide diet and without IL-9.
FIG. 1D is comparable to 1C, but shows results with IL-9.
FIGS. 1E and 1F show the result of experiments testing long term IL-9 therapy.
FIG. 1G shows parallel results when IL-4 was used.
FIG. 1H shows induction of thyroiditis in animals previously rescued from thyroiditis by IL-9 administration.
FIGS. 2A and 2B depict results of lymph node biopsies designed to measure B cell activation via immunostaining of B cells.
FIG. 3 shows results of ELISAs to determine anti-thyroglobulin antibodies in subject animals. Reading from left to right in this figure, it shows results taken from NOD mice without thyroiditis, NOD mice which received iodide only, and mice which received iodide and IL-9. The two optical densities come from two dilutions of tested serum.
FIGS. 4A and 4B present immunostaining data for B cells in the thyroid of FVB mice. FIG. 4A shows immunostaining without IL-9 and 4B with it.
FIG. 5 presents results following a study of islets of Langerhans after administration of IL-9.
FIGS. 6A and 6B show the effect of IL-9 on pancreatic insulitis in NOD mice, where 6A shows islets of a 10 week old NOD mouse which received the high iodide diet and no IL-9, and 6B shows islets of a 10 week old, NOD mouse which received the HID diet and IL-9.
FIGS. 7A and 7B show histology of lungs of normal and IL-9 transgenic mice which received silica particles intratracheally.
FIG. 8 shows hydroxyproline levels in the lungs of normal mice and transgenic mice which overproduce IL-9, which have been exposed to particles.
FIG. 9 shows FACS analysis of cells present in bronchoalveolar lavage of normal or IL-9 mice which were or were not treated with silica.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
EXAMPLE 1
Two strains of mice, i.e., the FVB strain, and the NOD strain, were used in the experiments which follow. The NOD strain of mice is recognized as an appropriate model for studies on human diseases. This is because the strain is a non-obese, diabetic mouse (hence "NOD"), which spontaneously develops pancreatic and thyroid lesions resulting from autoimmune disorders, such as diabetes. The mouse strain is also useful as a model for pathogenesis and immunotherapy of autoimmune disease, such as cell mediated autoimmune diseases. See, e.g., Many, et al, J. Endrocrinol 147: 311-320 (1995); Male, et al, Advanced Immunology Third Edition (1996). pg. 12.15; Kikutani, et al, Adv. Immunol 51: 285-322 (1992) all of which are incorporated by reference. Specifically, with reference to autoimmune diabetes, mononuclear cell infiltration of pancreatic islets is detected as soon as 4-6 weeks of age, followed by destruction of insulin producing pancreatic islet β cells.
Th1 cells are associated in this process of inflammation of islets of Langerhans. This, in turn leads to diabetes in 70%-80% of females, and 20% of males, after 30 weeks. This is borne out by studies which show acceleration of onset following administration of IL-12, and protection with IL-4 or IL-10. See, e.g., Trembleau et al., J. Exp. Med. 181: 817-821 (1995); Rapaport et all, J. Exp. Med. 178: 87-89 (1993); Rabinovitch et al., Transplantation 60: 368-374 (1995). Many, et al, supra, suggest that the same mechanism is involved in thyroiditis. Hence, the NOD strain is an appropriate model for the work which follows.
Two month old female NOD mice (haplotype H-2g) were used, as were two month old female FVB mice (haplotype H-2q), as a control. The FVB mice can be treated with iodine to develop transient thyroiditis, while the NOD mice develop a persistent form of the condition. Also, the intensity of CD4 + T cell infiltration in affected organs differs. See infra.
Mice were made goitrous by feeding them a low iodine diet (0.1 ug iodine per day), supplemented with 0.25% propylthiouracil for 10 days, followed by the low iodine diet alone, for another 2 days. They then received high doses of iodine (10 ug/day), via intraperitoneal injection, for 4 days. Five mice from each strain also received 1 ug/day of recombinant, murine interleukin-9, for 6 days. The interleukin-9 was administered in 0.2 ml/volumes of PBS via intraperitoneal injection, starting 2 days before the high iodine diet was administered. In controls, only PBS was administered. Interleukin-4 ("IL-4") was used as a control with the NOD mice.
Following treatment, mice were anaesthetized with an intraperitoneal injection of 7.5 mg of Nembutal, diluted with saline solution 1/3. Blood samples were collected to measure thyroxin levels via a radio-immunoassay, and then the thyroid glands were removed. One lobe of each gland was designated for morphological and stereological analysis, and the other for immunohistochemical analysis.
To carry out the former, lobes were immersed for 2 hours in 2.5% glutaraldehyde in 0.1M cacodylate buffer, post fixed for 1 hour in 1% osmium tetroxide, and embedded in resin. Sections were cut to 0.5 um thickness, and were stained with toluidine blue. Relative volumes of the various glandular components were measured with a projection microscope.
Immunohistochemical analysis was carried out by quick freezing lobes in isopentane cooled in liquid nitrogen. Cryostat sections were taken, and used for immuno peroxidase staining, following Toussaint-Demylle, et al Autoimmunity 7:51-62 (1990), using a monoclonal antibody specific for CD4 + T cells, and one specific for B cells.
Numbers of the cell types (CD4+, B+) were evaluated via magnification (×250), in ten microscopic fields chosen at random from thyroid sections.
The results from these experiments are presented in FIGS. 1-5 and Tables 1 and 2, which are discussed infra.
These show that administration of a high dose of iodide after goitrogenic treatment had a strong necrotic effect on thyroid cells. Cell debris accumulated in the follicular lumina. After 4 days of treatment, cell necrosis was associated to the interstitial infiltration of inflammatory cells.
After the 6 days of IL-9 administration which started two days before the high iodide diet began, the histology of the thyroid of the FVB mice was very similar to what was obtained with a high iodide diet alone. Signs of cell necrosis and of thyroiditis were evident, and analysis suggested that the IL-9 aggravated the interstitial infiltration of inflammatory cells. The relative volume of the interstitium was higher than in those control mice (FVB mice), which were not treated with IL-9. See Table 2.
In FIG. 1A, it can be seen that in the case of the goitrous NOD mice, all the follicular lumina were filled with necrotic debris, and the interstitium was extensively infiltrated by inflammatory cells. In contrast to the FVB mice, administration of IL-9 to the goitrous NOD mice prevented thyroid-induced thyroiditis. FIG. 1B shows that the large follicular lumina contained little necrotic debris, and few inflammatory cells were found in the interstitium. Table 1 shows that its relative volume was significantly decreased after IL-9 treatment. The relative volumes of epithelium and colloid were increased, as compared to mice which had not received the IL-9. A significant drop in thyroid weight was also observed after administration of the IL-9.
With respect to immunohistochemical analysis, the cells which infiltrated the thyroids of goitrous FVB mice treated with the iodide for 4 days were mainly MHC-Class II positive APCs, as well as T cells. CD4 + T helper cells predominated in this group. The administration of IL-9 increased the number of CD4 + cells, but increased the number of B cells even more so. The data for NOD mice are set forth in Table 1, and those for FVB mice in Table 2, which follows, infra.
In contrast, administration of iodide to NOD mice resulted in infiltration of numerous CD4 + T cells, and few B cells. When IL-9 was administered, the number of infiltrating CD4 + cells was drastically reduced. See FIGS. 1C and 1D.
TABLE 1__________________________________________________________________________ InfiltrateThyroid Relative volumes CD4.sup.+ B220.sup.+Treatment weight Epithelium Colloid Interstitium T cells B Cells__________________________________________________________________________NO 3.0 ± 0.3 38.2 ± 2.7 46 ± 2.7 14.0 ± 2.0 2.2 ± 0.5 0.5 ± 0.1GOITER (G) 6.9 ± 0.1* 73.5 ± 0.6* 6.5 ± 0.6* 20.0 ± 0.5* 5.6 ± 0.5* 0.6 ± 0.1G + HID 7.3 ± 0.4* 45.9 ± 2.9* 15.4 ± 5.1* 38.7 ± 5.7* 46.6 ± 5.3* 1.9 ± 0.6*G + HID + .sup. 4.5 ± 0.7°* .sup. 54.1 ± 3.6°* .sup. 32.0 ± 3.1°* 13.8 ± 1.9° .sup. 2.9 ± 0.3° 1.3 ± 0.1*IL-9: 6 daysG + HID + .sup. 4.6 ± 0.4°* n.d n.d n.d .sup. 3.1 ± 0.4°* 1.6 ± 0.1*IL-9: 4 daysG + HID + .sup. 4.9 ± 0.3°* n.d n.d n.d .sup. 4.6 ± 0.5°* 1.5 ± 0.16*IL-9: 1 inj.G + HID + 6.4 ± 0.7* n.d n.d n.d 42.3 ± 4.8* .sup. 7.1 ± 3.8°*IL-4: 6 days__________________________________________________________________________ *Mean (± SD, n = 5) thyroid weight (mg), relative volumes (%) of the various glandular components, and numbers of CD4.sup.+ and B220.sup.+ cells per ten follicular profiles, in thyroids of untreated and goitrous NOD mice and of goitrous NOD mice treated for 4 days with iodide (HID) alone, iodide plus IL9, or iodide plus IL4. °p < 0.05 vs HID treated mice *p < 0.05 vs untreated mice
TABLE 2__________________________________________________________________________ InfiltrateThyroid Relative volumes CD4.sup.+ B220.sup.+Treatment weight Epithelium Colloid Interstitium T cells B Cells__________________________________________________________________________G + HID 5.8 ± 0.4 55.8 ± 5.5 17.2 ± 2.4 27.0 ± 3.7 3.53 ± 0.8 2.05 ± 0.2G + HID + 5.9 ± 0.5 .sup. 46.8 ± 3.9° 18.8 ± 1.1 .sup. 34.4 ± 4.1° .sup. 7.97 ± 1.3° .sup. 10.3 ± 0.8°IL-9: 6 days__________________________________________________________________________ *Mean (± SD, n = 5) thyroid weight (mg), relative volumes (%) of the various glandular components, and numbers of CD4.sup.+ and B220.sup.+ cells per ten follicular profiles, in thyroids of goitrous FVB mice treated for 4 days with iodide (HID) alone or plus IL9. °p < 0.05 vs HID treated mice
These results suggested additional experiments to determine the minimal length of treatment which would produce the desired effect, specifically, parallel experiments were carried out where the original six daily treatments were reduced to four, or one single injection. Similar results were secured, indicating that only a very short treatment is needed. See Table 1, supra.
The long term effect of the IL-9 therapy was studied by analyzing thyroid glands of the NOD mice, sixty four days after treatment on the high iodide diet described supra. The study of the thyroid glands paralleled those presented supra, and representative data are shown in FIGS. 1E and 1F, showing HID mice, and mice treated with IL-9, in addition to the HID diet. Figure 1E shows marked thyroiditis, while the biopsy shown in FIG. 1F demonstrates normal morphology, and evidences the fact that IL-9 did more than delay onset of autoimmune processes, and actually blocked them.
Further support for the conclusion that IL-9 had suppressed the cellular autoimmune response came from the data generated following the administration of IL-4, which is known as a major TH2 promoting factor. As will be seen in Table 1, and in FIG.1G, IL-4, when administered using the same protocol which was used for IL-9, did not inhibit iodide induced inflammation, while there was an increase in the levels of thyroid-infiltrating B cells, i.e., B220+ cells.
Yet further evidence came from a study in which mice, which had been protected via administration of IL-9 during a first HID regime were treated similarly, two months later. FIG. 1H shows that no resistance against iodide induced thyroiditis was detected, thus indicating that IL-9 does not support a protective memory response. Further analysis of the data does suggest that some B cell response is involved. For example, FIGS. 2A and 2B evidence B cell activation. Specifically, these figures show an analysis of draining lymph nodes of NOD mice, after HID treatment alone (examined at the fourth day of treatment), and with HID plus IL-9 (again, after four days). Germinal centers are enlarged in FIGS. 2A and 2B.
EXAMPLE 2
Further evidence of the phenomenon discussed above was found by carrying out a standard immunoassay (an ELISA) for anti-thyroglobulin antibodies. All measurements were taken at day four of either the HID diet alone, or HID and IL-9. As is shown in FIG. 3, the measurements were taken in a model where IL-9 was being administered once a day for six days. Two optical densities are shown for two different dilutions of the same serum, for NOD mice without thyroiditis for NOD mice which received iodide and no IL-9, and NOD mice where both iodide and IL-9 were administered. These run, left to right, in FIG. 3.
EXAMPLE 3
The observations reported supra, suggested extension to non-autoimmune disease prone mice. In these experiments, mice of FVB strain were treated with the high iodide diet, after they were fed a goitrogenic diet, just like the NOD mice.
It was found that, in this strain, IL-9 administration did not modify histological aspects of the thyroid gland, significantly increased the interstitium relative volume, provoked moderate increases in CD4 + cells, and a strong increase in B220+ infiltrating B220+ cells. This can be seen in Table II, supra, and FIGS. 4A and 4B.
In line with this, germinal center formation was increased in the draining lymph nodes of FVB mice, treated with IL-9, and the mice also showed anti-thyroglobulin antibodies, after four days.
These data indicate IL-9 stimulates B cell response in all animals tested.
An analysis of thyroxin content in plasma showed levels to be nearly the same. Non-IL-9 -injected mice had levels of 2.4±.08 ng/ml, while mice who had received injections of IL-9 showed levels of 2.2±0.6 ng/ml.
EXAMPLE 4
An additional study was carried out on a murine model for pancreas insulitis. Specifically, using the model, supra, the pancreas of 10 week old mice were examined following 6 days of administration of IL-9. See Table 3, which follows:
TABLE 3______________________________________ Iodide Only Iodide & IL-9 (5 mice) (5 mice)______________________________________Exp. 1 41.14 ± 8.05 10.9 ± 4.56Exp. 2 38.5 ± 2.4 11.5 ± 1.2______________________________________
One group of NOD mice, i.e., the IL-9 group, received IL-9 (1 ug/injection), every three days, for 66 days, but no iodide treatment. The second group received either HID alone, or HID plus IL-9. These NOD mice were sacrificed at day 6, or day 66 of the experiment. This was two months after the end of treatment. As FIG. 5 shows, there was still a significantly lower percentage of inflamed islets. Finally, NOD mice received three weekly injections of IL-9, at from 10-18 weeks of age. In these mice, IL-9 mediated protection was increased, with only 20.9% of the islets showing inflammation, thus demonstrating a protective effect for the drug. Additional evidence of this is seen in FIGS. 6A and 6B, which compare pancreatic islets of untreated and treated NOD mice.
EXAMPLE 5
The FVB mouse used in the experiments, supra, is an appropriate model for study of interstitial lung diseases, such as silicosis. See, e.g., Kumar, Am. J. Pathol. 135: 605-614 (1989); Suzuki, et al., Thorax 51: 1036-1042 (1996), incorporated by reference.
Silica (DQ12, d50, 2.2 μm) or saline was injected directly into either normal FVB mice or a transgenic strain of FVB mice which overexpressed IL-9. Injection was via intratracheal instillation (100 ul/mouse). The animals had been anesthetized, using 2 mg of phenobarbital prior to treatment, and their necks had been surgically opened. Silica was sterilized, prior to use, by heating to 200° C. for four hours. This also inactivated endotoxin.
The mice received either 1 mg or 5 mg of silica in the 100 uls discussed supra. Mice were sacrificed either 60 days or 120 days after treatment and a bronchoalveolar lavage was performed via cannulating the trachea and infusing the lungs with 1.5 ml of 0.9% NaCl, six times. Collagen deposition was estimated by determining hydroxyproline content of the right lung. This was accomplished by excising the lung and homogenizing and hydrolyzing it in 6N HCl, overnight, at 110° C., followed by HPLC analysis. Left lungs were excised, and fixed in Bouin's solution for histopathology. Paraffin embedded sections were stained with hematoxylin and eosin, Masson's trichrome or toluidine blue for light microscopy. Histological examination showed multiple cellular nodules appeared rapidly after administration, which then converted to collagen containing nodules, with mesenchymal cells. See FIGS. 7A and 7B, which also shows that, in contrast, the TGIL-9 ("TGIL-9", which is an acronym for "transgenic IL-9 ") mice developed cellular nodules exclusively in the vicinity of blood vessels.
FIG. 8, which shows hydroxyproline levels, measured two months, and four months after administration confirm this. As will be seen from the figures, in those mice which over produce IL-9 the amount of hydroxyproline is significantly less at 120 days. Table 4 summarizes these results:
TABLE 4______________________________________ Normal Mice TGIL-9______________________________________collagen accumulation +++ -localization alveolar walls near vesselscell types mixed B lymphocytes______________________________________
The broncho-alveolar lavage was assayed, and no significant differences were seen in the number of cells, when comparing silica treated normal and TGIL-9 mice; however, the TGIL-9 mice showed a significant increase in the percentage of lymphocytes, especially IgM + B cells. See the analysis in FIG. 9. The lavage of normal mice, however, contained a majority of macrophages and neutrophils. There was no observed increase in immunoglobulin levels of the TGIL-9 mice. While the presence of B cells might be unrelated to anti-fibrotic effects of IL-9, it is consistent with the recognized fact that lymphocytes in broncho alveolar lavage of human patients is indicative of good prognosis. See Christman et al., Am. Rev. Respir. Dis. 132: 393-399 (1985).
The foregoing data show that, in appropriate animal models, IL-9 was effective in treating and preventing autoimmune pathologies associated with the thyroid gland, e.g., thyroiditis and with diabetes. Its antifibrotic effect is also shown, again in an appropriate animal model. As was pointed out, supra, the models used (the NOD and FVB mice), are useful in the study of other autoimmune pathologies, such as thyroiditis and autoimmune diabetes and fibrotic diseases such as silicosis. Hence, one aspect of the invention is a method for treating such disorders, via the administration of an effective amount of IL-9. The dosing regimen may vary, depending on the subject and the severity of the condition. In general, however, a dose of from about 500 ng to about 50 ug/kg of body weight of the subject, administered daily, is preferred; preferably, a dose of from about 1 ug to about 10 ug/kg of body weight is administered daily. The IL-9 may be naturally occurring, or recombinant in source, and may or may not be glycosylated. The cytokine can be administered via any standard therapeutic modality, such as via intravenous, intraperitoneal, sublingual, intradermal, subcutaneous, oral, intratracheal, intranasal or other forms of administration. The IL-9 may be administered alone, or in combination with pharmaceutically acceptable carriers, adjuvants, diluents, in aerosol form etc. Further, the IL-9 may be combined with one or more therapeutically effective material for treatment of the condition for which it is being used. Many drugs are used to treat diabetes, thyroiditis, and other cell mediated autoimmune disorders, such as IL-4. See, e.g., Rapoport, et al, J. Exp. Med. 178: 87-99 (1993). The IL-9 may be combined with these in pharmaceutical compositions and/or kits, wherein the therapeutically active IL-9 and the second drug may be combined (such as a composition), or in kit form, wherein separate portions of the drugs are made available for mixing at the convenience of the physician, patient, etc. Also a part of the invention is a method for blocking the inhibitory effect of IL-9 or its analogs on cellular immune responses, by administering an effective amount of an IL-9 antagonist, such as an antibody, soluble IL-9 receptor, a peptide based on IL-9 which inhibits interaction with receptors for IL-9, and so forth.
Other aspects of this invention will be clear to the skilled artisan and need not be discussed further.
The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, it being recognized that various modifications are possible within the scope of the invention.
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A method for the treatment and prevention of immune disorders and fibrosis associated disorders is disclosed. The method involves administering interleukin-9 in an effective amount to the subject. Among the conditions treatable are thyroiditis, autoimmune diabetes and silicosis.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. patent application Ser. No. 10/856,643 filed May 28, 2004, entitled “Common Class Loaders.”
BACKGROUND
1. Field of the Invention
The embodiments of the invention relate to component loading. Specifically, embodiments of the invention relate to optimizations of a component loading system to group components with component loading modules to prevent deadlocking during resolutions of dependencies between components by component loading modules.
2. Background
A cluster system is utilized to provide a set of services and resources to a set of client computers. The cluster system includes a collection of server nodes and other components that are arranged to cooperatively perform computer-implemented tasks, such as providing client computers with access to the set of services and resources. A cluster system may be used in an enterprise software environment to handle a number of tasks in parallel. A cluster system is scalable and has the flexibility to enable additional cluster elements to be incorporated within or added to the existing cluster elements.
The cluster system is a client-server system that employs a multi-tiered architecture. In the multi-tiered system, presentation logic, business logic and a set of services and resources are logically separated from a user interface of an application. A client may execute a user interface. Other layers are moved off of the client to one or more dedicated servers on a network.
A multi-tiered architecture may be implemented using a variety of different application technologies at each of the layers of the multi-tier architecture, including those based on the Java 2 Enterprise Edition Specification created by Sun Microsystems, Santa Clara, Calif. (“J2EE”), the Microsoft .NET Framework created by Microsoft Corporation of Redmond, Wash. (“.Net”) and/or the Advanced Business Application Programming (“ABAP”) standard developed by SAP AG. For example, in a J2EE environment, the business layer, which handles the core business logic of the application, is comprised of Enterprise Java Bean (“EJB”) components with support for EJB containers. Within a J2EE environment, the presentation layer is responsible for generating servlets and Java Server Pages (“JSP”) interpretable by different types of browsers at the user interface layer.
Many of these platforms provide inefficient loading schemes with rigid relationships between loading modules and application files. This rigid relationship prohibits cyclic dependencies between application files. This prohibition limits the ability of programmers to use direct references from one application file to other application files to use data and programs from those other files in the system. This rigid structure limits flexibility in programming and may force the use of redundant code. This rigid structure extends load times because loads of referenced files may require that a single or small set of loading modules be used that share a single thread to prevent deadlocks in file loading.
SUMMARY
Embodiments include a system for analyzing a set of references between components. The analysis may determine if any reference cycles are present in a set of components. Loader modules may be utilized to load components in the system. A loader manager module may detect reference cycles. In additional embodiments, if a reference cycle is detected, each member components in the reference cycle may be assigned to a single loader module.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that different references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and such references mean at least one.
FIG. 1 is a block diagram of one embodiment of a component loading system.
FIG. 2A is a diagram of one example of a set of component references.
FIG. 2B is a diagram of the example set of component references of FIG. 2A where a new component has been added.
FIG. 3 is a flowchart of one embodiment of a process for generating a set of load modules.
FIG. 4 is a flowchart of a process for resolving a reference in a component.
FIG. 5 is a diagram of a computer system running the component loading system.
FIG. 6 is a diagram of one embodiment of a cluster system running the component loading system.
DETAILED DESCRIPTION
FIG. 1 is one embodiment of a component loading system. As used herein a “component” may be a file, class, object, data structure or similar data that may be loaded an operating system, virtual machine, application or similar program. In one embodiment, the component loading system operates on a local machine to load components required by applications, services, virtual machines and similar programs. In one embodiment, the local machine is an application server 101 . Application server 101 may provide access to services and resources for a set of clients. Clients may be remote computers, local applications, and similar programs local to application server 101 or remote from application server 101 . In one embodiment, the services and resources provided by application server 101 may be applications and services related to enterprise software and resources.
In one embodiment, the local machine may have a file system 105 . File system 105 may be used to organize and store components related to the applications and services provided by application server 101 . In one embodiment, components stored by file system 105 may include archive files 119 , 129 . Archive files 119 , 129 may be components that contain multiple files in a compressed or encrypted format. In one embodiment, archive files 119 , 129 may be java archive files. A java archive file may be used to store a set of class files to be used to instantiate objects in a java virtual machine 103 . Class files may be components that contain class definitions written in the java programming language. Classes may represent programs, data and data structures in an objected oriented format. In another embodiment, other types of archive files may be supported by the component loading system including zip files, software deployment archives, and similar archive files. In one embodiment, archive files 119 , 129 may store other types of files including binary files, data, text files and similar file types. In one embodiment, file system 105 may store any type of file including archive files, binary files, text files, database files and similar file formats.
In one embodiment, the local machine may execute applications and services using a virtual machine 103 environment. Virtual machine 103 may be a java virtual machine such as a java virtual machine based on the Java 2 Enterprise Edition Specification (“J2EE”) created by Sun Microsystems, Santa Clara, Calif., or similar virtual machine. Virtual machine 103 may support any number of applications and services including a component loading system. Applications, services and similar programs and modules may be executed by the local machine in the form of objects 117 , 127 , 137 , 147 , 157 and 167 or sets of objects.
In one embodiment, applications and services in the form of objects may be loaded by loader modules 115 , 125 or a set of loader modules. A loader module may be a class loader 115 , 125 or similar loading utility. In one embodiment, during operation a virtual machine 103 may invoke class loaders 115 , 125 or a set of class loaders to open files and archives to retrieve the code of the applications and services to be executed by virtual machine 103 . Opening components may involve decompressing a file or archive and performing security checks such as certificate checks or similar security checks. As a result, opening components may require significant processing or system time. Applications and services may be loaded from compiled binary files, code files and similar components to be executed or interpreted. A loader module or program may be used to retrieve data and instructions from the components. This loader program may open the component to read the data and instructions and resolve dependencies or references to other components.
For example, class loader 115 may load a class file 121 from java archive file 119 during system startup at the request of java virtual machine 103 . The class loader may initiate a load of a referenced file. For example, file A 121 may reference file B 131 . In one embodiment, components may be grouped with designated loader modules based on the membership of the component in a reference cycle. A “reference” may be an incorporation of data or code from another component by using a pointer, file name, or similar indicator of the other component to instruct a loader to retrieve the needed data or code from that component. The indicated component may include references that must then be resolved. A reference cycle may be a set of references amongst components that create a cycle where following a string of references amongst components leads back to the original components. For example, if a first component references a second component and the second component also references the first component, a reference cycle exists. Similarly, if a first component references a second, the second references a third, and the third references the first, the three components form a reference cycle. Components in reference cycles may be grouped and assigned to a single loader module or common loader module. Components that are not part of the reference cycle may be assigned to any loader module. For example, class loader 115 may be responsible for loading file A 121 , file B 131 , and file C 141 where file A 121 , file B 131 and file C 141 form a reference cycle.
In one embodiment, the component loading system may include a loader manager to generate a set of loader modules and to assign component loading responsibilities to the loader modules. In one embodiment, a loader manager may be a class loader manager 123 that examines file dependencies and generates, invokes, instantiates or similarly initiates a set of class loaders and assigns a set of files to each one to load. A loader manager 123 may generate and maintain a mapping of component dependencies and references. In one embodiment, the loader manager may examine each component that an access request is made for that has not been assigned to a loader module. The loader manager may map the references of the component and search for reference cycles. The loader manager may then assign the component to a class loader module dependent on its membership in a reference cycle.
FIG. 2A is a diagram of an example reference mapping supported by the component loading system. The reference mapping or graph may represent an example set of files A-F. Directional arrows between nodes in the graph indicate a dependency or reference. For example, file A 201 may have a reference 221 to file B 203 . The example mapping may include two cycles. The first cycle may contain file A 201 , file B 203 and file C 205 . The second cycle may contain file D 207 , file E 209 and file F 211 . During an initial system start up or loading of files in a system, a loader manager may examine each of the files to be loaded in the system to determine their dependencies and references. The loader manager may generate a mapping to identify the reference cycles. For example, the loader manager may generate a first loader module to handle the reference cycle containing file A 201 , file B 203 and file C 205 . The loader manager may generate a second load module to handle the reference cycle containing file D 207 , file E 209 and file F 211 .
FIG. 2B is a diagram of an example of adding file references to a reference mapping. In this example a first loader 235 has been generated by a loader manager to handle the reference cycle including file A 201 , file B 203 and file C 205 . A second loader 245 has been generated by the loader manager to handle the reference cycle including file D 207 , file E 29 and file F 211 . In this example, an application, virtual machine or similar program has requested to load file H 215 and file G 213 . The loader manager examines and maps the dependencies or references from file H 215 and file G 213 . File H 215 is referred to by file C 205 and refers to file E 209 . This results in a new reference cycle including file H 215 , file C 205 , file B 203 , file D 207 and file E 209 . The loader manager will prohibit the loading of file H 215 because it may result in a deadlock between loader modules when the references are resolved. The addition of file G 213 does not result in a new reference cycle. In one embodiment, the loading of file G 213 may be assigned to a new loader module or to loader module 245 or 235 .
FIG. 3 is a flowchart of one embodiment of a process for generating and monitoring a component loading system. In one embodiment, the component loading system may be initiated during system startup (block 301 ). A virtual machine, operating system or similar platform may initiate, instantiate, invoke or similarly start a loader manager to generate a set of loader modules to load applications, services and similar programs (block 303 ).
In one embodiment, the loader manager catalogs or similarly collects a list or set of components to be loaded by an operating system, virtual machine, application or similar program. The loader manager may then map the references in the components to be loaded and related components. The loader manager may parse or similarly examine each component to determine their dependencies or references to other components. The loader manager may then utilize any well known cycle detection algorithms to determine the presence and constituents of any reference cycles amongst the components to be loaded and their referenced components (block 305 ). In one embodiment, the cycle detection algorithm may be a depth first search algorithm.
In one embodiment, the loader manager may then generate a set of loader modules, or a set of loader modules may be generated by another application, the virtual machine or other program based on the reference cycles found by the loader manager (block 307 ). Each loader module that is generated may be assigned a set of components that it is responsible for loading when data may be requested from those components. In one embodiment, components that are part of a reference cycle may be assigned to a single loader module. Each reference cycle may have its own loader module. Other components that are not a part of a reference cycle may be assigned to any loader module including loader modules that are responsible for components in a reference cycle or additional loader modules.
In one embodiment, the loader manager continues to monitor for additional requests to load components after the initial startup and loader module generation sequence (block 309 ). Additional component loads may be requested dynamically during the main operating time of a virtual machine, application, or similar program. If adding a new component does not result in a new reference cycle then the component may be added to the responsibilities of an existing loader module or a new loader module may be invoked, instantiated, or similarly initiated by the loader manager or similar application. The detection, examination and management of new components to be loaded may continue until system shutdown.
In one embodiment, if a component or set of components to be loaded after initial start up generates a new reference cycle then the loader manager may block or prohibit the loading of the component or components (block 311 ). The loader manager may notify the requesting application of the failure of the load. The loader manager may continue to examine component load requests and check for new cycles. New cycles are not allowed by the loader manager to avoid deadlocks that may be caused by multiple loader modules where a first loader module holds a first component and attempts to load a second component that is referenced by the first while a second loader holds the second component and tries to load the first component which is referenced by the second component. Stated differently, two loader modules may hold separate components while requesting the component held by the other loader module resulting in deadlock. Grouping the components of the reference cycle together avoids deadlocks because a single loader module is handling the load of all references in the cycle which prevents multiple loader modules having locks on components other loader modules require. In one embodiment, the component loading system may be a system based on java virtual machine. The component loading systems may also meet the java specification requirements that a class loader use a single thread. Each class loader may have a thread and thereby comply with java specification requirements.
FIG. 4 is a flowchart of one embodiment of a process for loading components. In one embodiment, a loader module receives a request from a virtual machine, application, or other program to access data from a component (block 401 ). The request may contain an identifier for the component or data to be retrieved. The identifier may be a component name, path name or similar identifier of data or components. In one embodiment, the loader module may need to parse the input to determine the component name or path name.
In one embodiment, the loader module may invoke, call or similarly pass the request to a ‘parent loader’ module (block 403 ). The parent loader module may have responsibility for loading a specific set of components, these components may be core system components or a similar subset of components. The parent loader module may determine if it is responsible for loading a component by searching a set of pathnames, components or other indicators that the parent loader module has responsibility for loading. For example, in a java virtual machine environment a system loader may have responsibility for loading class files from the core java packages such as the java.* and javax.* packages. The system loader in the java virtual machine environment may be a parent loader to all other class loader modules. If a parent loader module is determined to be responsible for loading a requested component the parent loader may be called to load the component (block 405 ). The parent loader module may return requested data to the originally called loader module which may in turn return the data to the requesting program. In another embodiment, the requested data may be directly or indirectly returned by the parent loader module using any return means or intermediate data structure or device.
In one embodiment, if the parent loader module is determined not to have responsibility for loading a component then the loader module may invoke, call or similarly pass the request to a set of peer loader modules (block 407 ). A peer loader module may be any non parent loader module. Each peer loader module may have a set of pathnames, component names or similar indicators that it is responsible for loading. Each peer loader module may check its set of indicators against the received request and return a positive or negative acknowledgement to the original loader module. If a peer loader module is found to have responsibility for loading the requested component or data, that peer loader may load the requested component and return the data to the original loader module which may then return the data to the requesting program (block 409 ). In another embodiment, the peer loader modules may use any return means or intermediate data structure or device.
In one embodiment, if the parent and peer loader modules are not determined to have responsibility for loading a component then the loader module may check its own paths or sets of indicators to determine if it has responsibility for loading the requested component (block 411 ). If the loader module does have responsibility for loading the component it may load the requested data and return it to the requesting program (block 413 ). The loader module may utilize any return process or intermediate data structure or device to return the data to the requesting program. If the loader module does not have responsibility for loading the requested component or data then the loader module may generate a notification or other return data that indicates that the load was unsuccessful, the component could not be found or similar notification or return data for the requesting program (block 415 ).
In another embodiment, the process of determining loader module responsibility may be ordered in any manner that is logically complete in searching the possible loading modules to determine the responsible loader module. FIG. 4 is an example embodiment of a top down approach. Other approaches such as a bottom up, distributed or similar approach may be used.
FIG. 5 is a block diagram of an example computer system for executing the component loading system. In one embodiment, the computer system may include a processor 501 or set of processors to execute the component loading system, virtual machine, applications, services and similar programs. The processor may be a general purpose processor, application specific integrated circuit (ASIC) or similar processor. Processor 501 may be in communication via a bus 511 or similar communication medium with a memory device 505 . Memory device 505 may be a system memory device or set of devices such as double data rate (DDR) memory modules, synchronized dynamic random access memory (SDRAM) memory modules, flash memory modules, or similar memory devices. Memory device 505 may be utilized by processor 501 as a working memory to execute the virtual machine, applications, the file handling system and similar programs.
In one embodiment, the computer system may include a storage device 503 . Storage device 503 may be a magnetic disk, optical storage medium, flash memory, or similar storage device. Storage device 503 may be utilized to store components. Storage device 503 may organize components in a file system. Stored components may include program files, file handling system files, class files, temporary components, index files and similar files and data structures. The computer system may also include a set of peripheral devices 507 . Peripheral devices 507 may include input devices, sound system devices, graphics devices, display devices, auxiliary storage devices, or similar devices or systems utilized with a computer system.
In one embodiment, the computer system may include a communication device 509 . Communication device 509 may be a networking device to allow the computer system and applications, services and similar programs to communicate with other computers, applications, services and similar programs. In one embodiment, communication device 509 may be utilized to communicate with a remote database and retrieve or receive components from the database.
FIG. 6 is one embodiment of a cluster system that includes a component loading system. In one embodiment, the system architecture may include a central services instance 600 and a plurality of application server instances 610 , 620 . In one embodiment, the application servers are organized into groups referred to as “instances.” Each instance includes a group of redundant application servers and a dispatcher for distributing service requests to each of the application servers. A group of instances may be organized as a “cluster.” The application server instances, 610 and 620 , may each include a group of application servers 614 , 616 , 618 and 624 , 626 , 628 , respectively, and a dispatcher, 612 , 622 , respectively. The central services instance 600 may include a locking service, a messaging service, and similar services. The combination of the application server instances 610 , 620 and the central services instance 600 may be the primary constituents of the cluster system. Although the following description will focus primarily on instance 610 for the purpose of explanation, the same principles and concepts may apply to other instances such as instance 620 .
In one embodiment, the application servers 614 , 616 , 618 within instance 610 may provide business and/or presentation logic for the network applications supported by the cluster system. Each of application servers 614 , 616 and 618 within a particular instance 610 may be configured with a redundant set of application logic and associated data. In one embodiment, dispatcher 612 distributes service requests from clients to one or more of application servers 614 , 616 and 618 based on the load on each of the servers.
In one embodiment, application servers 614 , 616 and 618 may be Java 2 Enterprise Edition (“J2EE”) application servers which support Enterprise Java Bean (“EJB”) components and EJB containers (at the business layer) and Servlets and Java Server Pages (“JSP”) (at the presentation layer). In another embodiment, the cluster system, applications servers and component loading system may be implemented in the context of various other software platforms including, by way of example, Microsoft .NET platforms and/or the Advanced Business Application Programming (“ABAP”) platforms developed by SAP AG.
In one embodiment, each application server may include a common loader module 644 , 654 or set of common loader modules. Common loader modules 644 , 654 may be utilized by applications, virtual machines and similar programs to access components needed by the applications, virtual machines and similar programs. Common loader modules 644 , 654 may manage the retrieval of data from components stored in the file systems 646 , 656 of each application server. Common loader modules 644 , 654 may have responsibilities for loading a designated set of components and data. Each component that is part of the same reference cycle is assigned to the same common loader 644 , 654 . Components that are not part of a reference cycles may be assigned to any common loader. The reference cycle may be detected by a loader manager 648 , 688 . Common loaders 644 , 654 may be generated by loader managers 648 , 658 and assigned a set of components to load based on the detected reference cycles. The relationship between components and the common loaders is dynamically determined at start up. This system allows greater flexibility in inter-component dependencies while avoiding deadlock scenarios.
In the foregoing specification, the invention has been described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes can be made thereto without departing from the broader spirit and scope of the invention as set forth in the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.
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Embodiments include a system for loading components with complex intra-dependencies. Components in the system may be assigned at start up to a common loader module. The system detects reference cycles amongst the set of components in the system. All components in a reference cycle may be assigned for loading to the same common loader. This system avoids deadlock scenarios by identifying reference cycles at start up and assigning each cycle to a single common loader. The embodiments of the system also analyze components to be loaded that are identified after start up to determine if they cause a new reference cycle. Components that cause a new reference cycle may not be allowed to be loaded to prevent deadlock loading scenarios.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a filter apparatus which is mounted on an internal-combustion engine, particularly on a diesel engine, that captures and removes particulates such as soot exhausted from the engine so as to purify the exhaust gas, thereby preventing environmental pollution.
2. Description of Prior Art
The exhaust of particulates from diesel engines has recently been controlled because it contains carcinogens and because it causes a deterioration in visibility. As a measure against such exhaust particulates, a method has been investigated in which a heat-resistant filter is provided in an intermediate position of an exhaust pipe to remove particulates by filtering them out. This method is characterized by a filter element which can be regenerated and repeatedly used by being incinerated after particulates have been accumulated therein. There have been many proposals in which a burner for regenerating the filter is provided upstream of the filter element to ensure that the temperature of the exhaust gas is increased to the ignition temperature of the particulates by using the combustion heat of the burner. Such a method must increase the temperature of a large amount of gas exhausted from the engine, and thus it requires an enormous quantity of heat.
There has also been a proposal for solving the above-described problem in which the route of exhaust gas is branched at a filter element, and a bypass that is separated from the filter element is provided therein so that the exhaust gases from the engine are passed through the bypass by a valve when the burner is operating. This method obviates the need for heating a large amount of exhaust gas (Japanese Patent Laid-Open No. 118514/1981). This apparatus is provided with a bypass in the filter element of the exhaust gas route and exhausts the gas through the bypass during regeneration, thereby reducing by half, the effect of controlling the exhaust of particulates.
In addition, an apparatus has been proposed in which an exhaust gas inlet of a filter element is divided into two portions and is provided with a switching plate in such a way that the filter element is divided into a regeneration side and an exhaust gas side by the switching plate during regeneration (Japanese Patent Laid-Open No. 101210/1983). In this apparatus, since the regeneration portion and the portion through which the exhaust gas flow coexist in the one filter during regeneration, large thermal stresses occur, which readily lead to the fracture of the filter element.
Prior art with respect to a combustion apparatus for vehicles is also described in Japanese Patent Laid-Open No. 11415/1986.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a compact exhaust gas purifier which is extremely economical, which exhausts no particulates during regeneration, and can control to a small amount of the combustion of a burner without exhausting particulates during regeneration.
To achieve this end, an exhaust gas purifier of the present invention comprises two filter elements connected in parallel, a burner having a small combustion chamber which has excellent heat resistance, and a four-way valve for switching the route of exhaust gas. A filter element which has a small heat capacity and a corrugated honeycomb form and is made of fiber ceramics obtained by sintering heat-resistant inorganic fiber and clay is used as each of the filter elements in the purifier.
When the filter elements must be regenerated, one of the filter elements is removed from the inflow of the exhaust gas by the four-way valve and is heated by the burner, while the exhaust gas containing particulates continue to pass through the other filter element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of an embodiment of an exhaust gas purifier for diesel particulates;
FIG. 2 is a sectional view of a four-way valve of the present invention; and
FIG. 3 is a sectional view of a second embodiment of the combustion chamber portion of the present invention.
FIG. 4 is a view illustrating a combustion chamber in a third embodiment, in cross-section.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In an exhaust gas purifier of the present invention, two gas outlets of a four-way valve are connected to two filter elements which are received in a case, and one of two gas inlets thereof is connected to an exhaust pipe from an engine and the other is connected to a combustion chamber. This four-way valve switches over a gas flow through one of the filter elements from the exhaust gas from the engine to preheated gas from a burner to provide regeneration.
The operation of this exhaust gas purifier is described below.
During the normal operation of the engine, an elliptical vane of the four-way valve is at a neutral position with respect to the two gas outlets, so that the exhaust gas flowing into the four-way valve flows to the filter elements from the respective gas outlets, with the particulates being filtered off and the purified exhaust gas being exhausted to the air.
When particulates have accumulated in the filter elements so that they must be regenerated, the elliptical vane in the four-way valve is moved so that one of the gas outlets communicates with the gas inlet connected to the exhaust pipe from the engine, and the other communicates with the gas inlet connected to the combustion chamber. The former gas outlet leads the exhaust gas to the corresponding filter element to continue capturing particulates, and the latter gas outlet leads preheated gas from the burner, which has started combustion, to the other filter element to regenerate it. After one of the filter elements has been completely regenerated, the elliptical vane is rotated so as to cause the exhaust gas to flow through the filter element which has been regenerated and the preheated gas to flow through the other filter element to regenerate it. Therefore, no particulates are exhausted to the air during the regeneration. Further the preheated gas from the burner is supplied to the filter elements after being agitated by the four-way valve so that its temperature becomes uniform and it thus heats the filter elements uniformly, and no large thermal stresses occur so that the filter elements do not rupture.
The exhaust gas purifier of the present invention allows an engine to be operated with a very low back pressure during normal operation in which the two filter elements are being used, and thus it can maintain the engine power with only a small penalty, and be an effective purifier which does not exhaust unpurified exhaust gas to the air during regeneration. In addition, since the exhaust gas from the engine and the combustion gas from the burner are isolated from each other by the four-way valve, the exhaust gas is not unnecessarily heated. Furthermore, since filter elements made of fiber ceramics with a small heat capacity are used, the size of the burner can be greatly reduced, resulting in the possibility of a great reduction in fuel consumption. Since the temperature gradient produced when the filter elements are heated is also very small, and thus does not create any problems concerning fracture and melting, regeneration can be economically and safely performed.
First Embodiment
A first embodiment of the present invention is described below.
FIG. 1 shows a first embodiment of the present invention in which a burner 1, a nozzle 2, a burner body 3 and a stabilizer 4 are shown. The nozzle 2 has an atomization air supply 5 and a fuel supply 6 which are connected to an air compressor and an oil pump (both not shown), respectively. The burner body 3 has a combustion air supply 7 which has an annular shape that is concentric with the nozzle 2. The stabilizer 4, which has a funnel shape, extends from the combustion air supply 7 to a position in front of the nozzle 2. The stabilizer 4 is provided with a swirler 8. A spark plug 9 connected to an induction coil (not shown) passes through the burner body 3 and the stabilizer 4 to a position near the nozzle 2. An annular intake air supply 10 is provided around the peripheral surface of the stabilizer 4 in the vicinity of the top of the burner body 3.
A combustion chamber 13 comprising an outer sleeve 11 and an inner sleeve 12 is connected to the front of the burner 1. A thermal insulator 14 made of ceramic fibers is charged between the outer sleeve 11 and the inner sleeve 12. The side of the combustion chamber 13 opposite the burner 1 is connected to a preheated air inlet 15 of a four-way valve 16.
FIG. 2 is a sectional view of the four-way valve 16.
One side of a cylinder 17 is includes an opening forming a preheated air inlet to the combustion chamber 13, and the other end is closed by a back cover 19 provided around a bearing 18. Gas outlets 20a, 20b open at positions located a distance of one-third of the length of the cylinder from the preheated air inlet 15 so as to be opposite to each other in the direction perpendicular to the axis of the cylinder 17. A shaft 21 is inserted into the cylinder 17, passing through the bearing 18, so as to be coaxial with the cylinder 17. An elliptical vane 22 is fixed to one end of the shaft 21, and a cylindrical vane 23 is fixed to the other end of the shaft 21, near the back cover 19 in the cylinder 17. The elliptical and cylindrical vanes 22, 23 are provided with slots 24, 25, respectively, around their peripheries, and elliptical and circular rings 26, 27 for sealing are inserted into the slots 24, 25, respectively. The part of the shaft 21 passing through the bearing 18 is connected to a motor 28. A gas inlet 29 opens at the cylinder 17 in a position between the elliptical vane 22 and the cylindrical vane 23, and is connected to an exhaust pipe 30 from the engine.
In FIG. 1, connection pipes 31a, 31b are connected to the gas outlets 20a, 20b, respectively, and funnel-shaped inlet covers 32a, 32b and cylindrical cases 33a, 33b are connected to the connection pipes 31a, 31b, respectively, in such a manner that they are parallel to the axis of the cylinder 17. The cases 33a, 33b receive filter elements 34a, 34b, respectively, the peripheries of which are covered with mounting mats 35a, 35b, that are mainly composed of ceramic fibers capable of thermal expansion. The filter elements 34a, 34b each have a corrugated honeycomb skeletal structure made of a fiber ceramic formed by sintering alumino-silicate fiber and clay and they have a large number of cells 36a, 36b that are alternately closed at either end by plugs 37a, 37b, respectively. The cases 33a, 33b are connected to an exhaust pipe 39 through an exhaust outlet cover 38.
The operation the first embodiment is as follows.
During normal operation of the engine, the shorter axis of the ellipse of the elliptical vane 22 in the four-way valve 16 is parallel to the line connecting the opposite gas outlets 20a, 20b, i.e., in a state wherein the four-way valve 16 is in a neutral position so as to cause all the openings of the cylinder 17 to communicate with each other. In this case, the exhaust gases from the engine are branched to the connection pipes 31a, 31b from the gas outlets 20a, 20b, respectively, of the four-way valve 16, and thus enter and are dispersed over the entire surfaces of the filter elements 34a, 34b by the inlet covers 32a, 32b. At the same time, the particulates contained in the exhaust gases are filtered off by and accumulate in the walls of the cells that are made of porous fiber ceramics. The filtered exhaust gases are then passed as clean gases through the outlet cover 38, to the exhaust pipe 39, and are finally exhausted to the air. During this operation, air continuously flows from the combustion air supply 7 and/or the intake air supply 10 of the burner 1 so that no exhaust gases enter the burner 1. During this time, atomization air and fuel are cut off at an intermediate position of the path by a solenoid valve (not shown). The exhaust gases introduced in the four-way valve 16 are prevented from leaking past the back cover 19 by the circular rings 27 provided on the cylindrical vane 23.
The procedure used when the filter elements 34a, 34b must be regenerated because particulates have become accumulated therein is described below.
The motor 28 is first energized to rotate the shaft 21. When the elliptical vane 22 has rotated 90° from its neutral position, the motor is stopped. In this state, the combustion chamber 13 and the exhaust pipe 30 from the engine communicate with the connection pipes 31a and 31b, respectively. Then a high voltage of about 10,000 V is applied to the spark plug 9 to produce an electric discharge with spark at the top thereof. Several seconds later, the solenoid valves which had cut off the atomization air and the fuel are simultaneously opened to supply the air and the fuel under pressure by means of the air compressor and the oil pump, respectively, to the atomizing nozzle 2. The fuel is atomized by the atomization air in the atomizing nozzle 2 and is then blown into the combustion chamber 13. The fuel is then uniformly mixed with combustion air which has been forced into a vortex flow by being passed though the swirler of the stabilizer 4. At this point, the atomized fuel is ignited by the discharge of the spark plug 9 to form a flame. The flame is stabilized in front of the burner 1 by the vortex flow of the stabilizer 4 so that a good combustion state is maintained in the combustion chamber 13. The intake air is blown out from the intake air supply 10 which is provided in the peripheral surface of the stabilizer 4. The air then passes along the inner periphery surface of the combustion chamber 13 while surrounding the flame, and reaches the inlet 15 of the four-way valve 16. The burned gas and the intake air are well mixed during the time they pass through the combustion chamber 13 and the four-way valve 16. As they are passed through, they to form a high-temperature gas which contains a large amount of oxygen and is at a controlled temperature. This gas mixture is then passed to the inlet cover 32a through the connection pipe 31a. The high-temperature gas is uniformly dispersed over the entire surface of the filter element 34a in the inlet cover 32a and flows through the filter element 34a. During this time, the filter element 34a and the particulates accumulated therein are heated to about 600° C. which starts incinerating the particulates. The burned gas generated by the combustion is passed through the outlet cover 38 and is exhausted to the air through the exhaust pipe 39. The temperature of the preheated gas can be controlled by controlling the amount of combustion in the burner 1 or the amount of intake air, or by controlling both amounts, whereby the oxygen content is controlled. The exhaust gas from the engine is passed through the gas inlet 29, between the elliptical vane 22 and the cylindrical vane 23, and flows into the inlet cover 32b through the other connection pipe 31b while cooling the elliptical vane 22 and the shaft 21 which are at a high temperature because of the preheated gas. The exhaust gas continues to be filtered by the filter element 34b, with particulates being accumulated in the cells 36b. After this process has been completed over a period of several minutes, the motor is inversely energized so as to reverse the shaft 21 by 180°. In this state, the combustion chamber 13 and the gas inlet 29 are communicated with the connection pipes 31b, 31a, respectively, in a manner opposite to the above-described operation. Therefore, the preheated gas from the burner 1 and the exhaust gas from the engine are switched so that the engine exhaust gas is passed through the filter element 34a which has been regenerated by the burning of the particulates therein by the flow of the preheated gas, and the preheated gas is passed through the filter element 34b in which particulates have been accumulated by the flow of the engine exhaust gas. Consequently, the particulates accumulated in the filter element 34b are rapidly heated to 600° C., which is their ignition temperature, and thus the particulates start to become incinerated. At the same time, particulates are again accumulated in the regenerated filter element 34a. After this operation has been completed over a period of several minutes, the motor is again energized to rotate the shaft 21 by 90° and return the elliptical vane 22 to its initial neutral position.
Therefore, the two filter elements are generally operated at the same time, producing extremely low back pressure, and this purifier can thus be operated without imposing any load on the engine. On the other hand, since one of the filter elements is operated for regeneration purposes and the other is operated as a filter during the regeneration, the exhaust gases from the engine are always passed through the filter element 34a or 34b which captures particulates. In addition, since, during regeneration, the preheated gas of the burner 1 carrying out complete combustion passes through the four-way valve 16 and the connection pipe 31a or 31b, and the gas is dispersed over the entire surface of the filter element 34a or 34b in the inlet cover 32a or 32b, the temperature distribution in the filter element 34a or 34b is uniform. Further, since the exhaust gas from the engine is also shut out by the elliptical rings 26 provided in the elliptical vane 22 in the four-way valve 16, the exhaust gas will not be mixed with the preheated gas of the burner 1. Although the four-way valve 16 is heated during the operation of the engine, particularly during the regeneration, the elliptical rings 26 and the circular rings 27 respectively provided in the elliptical vane 22 and the cylindrical vane 23, prevent any leakage of the gas, and prevent stoppage of the rotation of these vanes due to any increase in friction resulting from the difference in thermal expansion between the vanes and the cylinder 17.
Second Embodiment
A second embodiment of the present invention is described below.
FIG. 3 is a longitudinal sectional view of another embodiment of the present invention where similar members as those in the first embodiment are denoted by the same reference numerals. In the drawing, reference numerals 32c, 32d denote inlet covers which are provided in front of and on the axes of cases 33a, 33b, respectively, and which are respectively connected to connection pipes 31c, 31d, on the lines tangent to the outer surface of the inlet covers. Consequently, the gas that passes through the connection pipe 31c or 31d and flows into the inlet covers 32c or 32d so that it circulates inside the covers. From the covers 32c or 32d it then passes into the filter element 34a or 34b. Therefore, the exhaust gas from the engine enters the inlet covers 32c or 32d at an angle to the axis of the filter element 34a or 34b during normal operation of the engine, and thus the gas does not directly collide with the front of the filter element 34a or 34b. This helps to prevent the cell walls in the front of the filter element 34a or 34b from becoming deteriorated by hard solids such as scales of iron rust contained in the exhaust gas from the engine. In addition, since, during regeneration, the high-temperature gas is dispersed over the periphery of the filter element 34a or 34b by the vortex flow and this supplies sufficient heat thereto, the temperature in the vicinity of the periphery of the filter element 34a or 34b is not lowered by heat conduction to the mounting mats 35a or 35b.
Third Embodiment
A third embodiment is described below with reference to FIG. 4 where similar members as those in the first embodiment are denoted by the same reference numerals. In this embodiment, a combustion chamber 13b has a dual structure comprising an outer sleeve 11b, an inner sleeve 12b, and a space formed between the outer sleeve 11b and the inner sleeve 12b which serves as an intake air passage 40. An intake air connection portion 41 is provided on the side of the intake air passage 40 near the preheated gas inlet 15 of the four-way valve 16, and the other side communicates with the intake air inlet 10. During regeneration, the combustion is started in the burner 1 so as to form a flame which starts to heat the inner sleeve 12b. At the same time, the intake air flows through the intake air passage 40 while cooling the inner sleeve 12b. This air then passes into the combustion chamber 13b from the intake air inlet 10, is mixed with the flame, and is sent as a preheated gas at a given temperature to the filter element to be regenerated. In this embodiment, the temperature of the preheated gas is kept at 600° C.
When the combustion chamber 13b of this embodiment is used, the fuel consumption of the burner in a stationary state is smaller than that immediately after the ignition, resulting in a smaller amount of fuel being consumed than in the first embodiment. In addition, the temperature of the outer sleeve 11b is increased 50° C. or less by the combustion of the burner. This is because no heat of combustion of the burner is unnecessarily used for heating the thermal insulators. Therefore, the heat of the burner is most efficiently used for heating the filter elements, and thus produces a remarkable thermal insulation effect.
The present invention provides an effective purifier which uses two filter elements during normal operation of an engine and thus allows the engine to be operated with very low back pressure, ensures a high engine efficiency, and prevents emission of any gas not purified during regeneration of the filter elements. In addition, since the exhaust gas from the engine is isolated from the preheated gas from a burner by a four-way valve during regeneration, the exhaust gas does not need to be heated. Furthermore, since each of the filter elements is made of fiber ceramics having a small heat capacity, the size of the burner and the fuel consumption can be greatly reduced.
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An exhaust gas filtering element is provided for filtering diesel particulates. The system comprises two filter elements disposed parallel to each other, a burner mechanism, and a four-way valve mechanism for switching over an exhaust gas flow and a preheated gas flow obtained by combustion in the burner mechanism. The exhaust gas flow is generally passed uniformly through the two filter elements which filter off particulates. However, when regeneration is required, an ellipitical vane, provided in a cylinder of the four-way valve mechanism, is rotated so as to cut off the exhaust gas flow passing through one of the filter elements and cause the preheated gas to flow through this filter, whereby particulates are oxidized and incinerated. At this time, the exhaust gas flow is passed through the other filter element, without any particulates being emitted into the atmosphere. Then, the exhaust gas flow and the preheated gas flow are switched by rotating the vane so that the other filter element is regenerated.
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BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
The present invention relates to a tool retention mechanism, for example, typically used to retain a cutting tool holder in a tool pocket of a tool changer magazine. A horizontal machine tool apparatus typically contains a plurality of tool pockets attached to a movable tool changer magazine and the mechanism of the present inventions provides an affirmative mechanism for retaining tool holders so that they do not separate from their respective tool pockets unless removal is desired. More particularly, a pair of opposed pivotal fingers each include a latch which can engage with or disengage from the internal groove of a tool holder to perform this function. A biasing force can be provided, for example, by one or more springs, to encourage this affirmative engagement of the latches with the internal groove.
2. Brief Description of the Related Art
The present invention relates to a cutting tool retention mechanism. This mechanism is designed to be received in a tool pocket and to interface with and retain within the tool pocket a tool holder having an internal groove, such as, for example, a “hohlschaftkegel” (or “HSK”) tool holder. An HSK tool holder is a special form of tool holder configured according to a “DIN” (German engineering) standard and designates short, hollow, tapered tool shanks, wherein the tool shank includes a conical surface and a face formed on an integral tool changer gripping flange thereof, and wherein a machine tool spindle is adapted to grip both the conical surface and the face of the tool holder for positive rotation thereof. Unlike well-known ANSI (American National Standards Institute) standard solid tool holders, which are pulled into a spindle seat by way of a retention stud extending from the generally cylindrical shank thereof, an HSK tool shank has an internal relief, or retaining groove, so that, once inside a machine spindle, internal gripping fingers of the spindle assembly direct outward and rearward forces against the tool shank, to retain it securely.
Low-force analogues of spindle gripping arrangements are known for retaining hollow shank tools within tool storage pockets, for example, the employment of spring loaded balls which engage the tool retaining groove. Typically, an external actuating means is employed to release the tool from its tool storage receptacle.
SUMMARY OF THE INVENTION
The present invention relates to a cutting tool retention mechanism, for example, typically used to retain a tool holder in a tool pocket of a tool changer magazine. A tool changer magazine of a horizontal machining center contains a plurality of tool pockets, each of these tool pockets being adapted to store one tool such that, by the tool changer magazine, a plurality of tools are accessible to the machining center for performing a variety of machining operations, for example, utilizing a rotating spindle. In operation, when the machining center needs to utilize any specific tool for a specific machining operation, the tool changer magazine is moved such that the desired tool in its tool pocket is positioned in an index location where the desired tool can be removed from the pocket and mounted to the spindle. Typically, a machining center will retrieve (and replace) between 5 and 25 cutting tools during a complete machining cycle of a typical workpiece. With each tool change, the entire magazine, and as such, each of the tools held in the pockets thereof, moves. Therefore, because of the frequent, and sometimes jerky, movement of the magazine, it is desirable to provide for affirmative retention of the various tool holders in their respective tool pockets until such time as a specific tool is needed is desirable, and the current invention provides for this retention.
All of the embodiments disclosed herein have similar function. In function, a fulcrum supports at least a pair of opposed fingers which function as levers. Springs are used to provide a biasing force such that the bias portions of the opposed fingers are urged toward each other to a physical limit controlled, in one embodiment hereof, by a pair of channels provided in a spring plate. The finger bias portions are on one side of the fulcrum and the finger latch portions are on an opposite side of the fulcrum, such that, in this configuration, opposed latches toward the end of the finger latch portions are spaced a furthest distance from each other. In this configuration, the latches are spaced to engage an internal groove in an HSK tool holder to retain that tool holder in its respective tool pocket.
A tool holder can be forced on and off the latches. For example, when pushing a tool holder into the receiving portion of the tool pocket body, the holder will engage the opposed latches. As these latches are spaced a distance apart greater than the smallest diameter of the holder, a force will be applied to the latches overcoming the biasing force, provided by the springs, which is applied toward the opposite end of the fingers on the other side of the fulcrum. When the holder is pushed into the receiving portion a sufficient distance for engagement of the latches with the HSK tool holder internal groove, the springs will force the latches away from each other to affirmatively hold the tool holder. Alternatively, the finger bias portions can have a force applied thereto to overcome the force of the springs to push the finger bias portions away from each other, as permitted by the geometry of the spring plate channel. The separation of the finger bias portions causes the opposed latches on the finger latch portions on the opposite side to the fulcrum to move toward each other. This action can be initiated for insertion or removal of a tool holder and would cause less parts “wear and tear”, but requires additional components to implement.
The preferred embodiment of the present invention employs a unitary tool retention mechanism constructed of plastic. In another embodiment, a unitary plastic tool retention mechanism employs a wear-resistant surface in the form of, in one embodiment hereon, shields attached to the finger latch portions. The shields can be of metal or other material with high wear resistance to prolong the life of the mechanism. Alternatively, the mechanism, itself, can be constructed of a wear-resistant material, in which case, the shields are unnecessary. In yet another embodiment, a plurality of components are employed to permit the fingers to be made of a wear-resistant metallic material, such as steel, with the inclusion of the lever pivot by insertion of pins through bores in a retention support and each finger.
In still another embodiment hereof, a plurality of pairs of opposed fingers, or an odd number of individual fingers, are spaced equidistantly around the support. In an even further embodiment hereof, the pair of opposed fingers is replaced with a single finger, in which case, the latch distance and the bias distance are defined as the distance of the latch and the bias portion, respectively, to a reference, such as, for example, the central axis of the support.
More particularly, in the preferred embodiment hereof, the present invention comprises a retention mechanism having a pair of opposed fingers, each of the fingers extending from a support, each of the fingers having a latch spaced from the support, the support permitting each of the fingers to be pivoted to vary a latch distance between the latches.
Further, where each of the fingers has a latch portion including the latch and a bias portion, and where, when at least one of the fingers is pivoted to vary the latch distance, a bias distance between the bias portions varies oppositely thereto, as permitted by the support. That is, where at least one of the fingers is pivoted to decrease the latch distance, the bias distance will increase, although not necessarily inversely thereto. Additionally, each bias portion may have a spring to exert a biasing force on the bias portion, thereby urging the bias portion in a direction toward the bias portion of the other finger.
As the retention mechanism is designed to permit the latches to engage an internal groove of a tool holder, the latches preferably have an orientation away from each other, although the latches may have any configuration suitable to engage the internal groove of the tool holder.
These and additional objects, features and advantages of the present invention will become apparent to those reasonably skilled in the art from the description which follows, and may be realized by means of the instrumentalities and combinations particularly pointed out therein.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings in which like numerals refer to like parts, and wherein:
FIG. 1 shows a perspective view of a typical machining center, having a tool storage matrix with a plurality of tool pockets;
FIG. 2 shows an exploded perspective view of a tool pocket according to a preferred embodiment of the present invention;
FIG. 3 shows a front view of the tool pocket of FIG. 2;
FIG. 4 shows a rear view of the tool pocket of FIG. 2;
FIG. 5 shows a cross-section view of the tool pocket of FIG. 2, shown along section line 5 — 5 of FIG. 3;
FIG. 6 shows a perspective view of a tool retention mechanism of the tool pocket of FIG. 2;
FIG. 7 shows a side view of the tool retention mechanism of FIG. 6;
FIG. 8 shows an end view of the tool retention mechanism of FIG. 6;
FIG. 9 shows a cross-section view of the tool retention mechanism of FIG. 6, shown along section line 9 — 9 of FIG. 8;
FIG. 10 shows a cross-section view of the retention mechanism of FIG. 6, shown along section line 10 — 10 of FIG. 8;
FIG. 11 shows a perspective view of a tool cage bushing according to the tool pocket of FIG. 2;
FIG. 12 shows a side view of the tool cage bushing of FIG. 11;
FIG. 13 shows an end view of the tool cage bushing of FIG. 11;
FIG. 14 shows a perspective view of a cage spring plate according to the tool pocket of FIG. 2;
FIG. 15 is a rendering generally demonstrating how a latch of the tool retention mechanism of FIG. 6 engages an internal retaining groove of an HSK tool holder so that the tool pocket retains the tool holder;
FIG. 16 is a rendering generally demonstrating how a latch of the tool retention mechanism of FIG. 6 is pivoted so that an HSK tool holder can be removed from the tool pocket of FIG. 2;
FIG. 17 shows an exploded perspective view of a tool pocket according to an alternative embodiment of the present invention;
FIG. 18 shows a perspective view of a tool retention mechanism of the tool pocket of FIG. 17;
FIG. 19 shows a perspective view of a latch shield for the tool retention mechanism of the tool pocket of FIG. 17;
FIG. 20 shows an exploded perspective view of a tool pocket according to another alternative embodiment of the present invention;
FIG. 21 shows a perspective view of one finger of the tool retention mechanism of the tool pocket of FIG. 17;
FIG. 22 shows a perspective view of a retainer support of the tool pocket of FIG. 17;
FIG. 23 shows a perspective view of a tool retention mechanism according to yet another alternative embodiment of the present invention;
FIG. 24 shows a perspective view of a tool retention mechanism according to yet another alternative embodiment of the present invention; and,
FIG. 25 shows a perspective view of a cage spring plate according to another alternative embodiment of the present invention
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the Figures and, in particular, to FIG. 1 thereof, a machine 10 includes a tool spindle 11 for supporting and driving a variety of tools 12 for performing a variety of machining operations on a workpiece 15 . The tool spindle 15 is adapted to grip for positive rotary motion thereof a tool holder 16 , which itself, securely grips the cutting tool 12 according to known and conventional techniques, such as, by press-fitting a shank portion 12 a of the cutting tool 12 into a shank opening 16 a of the tool holder 16 . Because each cutting tool 12 can perform but one type of specific machining operation (e.g., milling, boring, etc.), and because a typical machining cycle of the workpiece 15 requires a number of different machining operations, the machine 10 is equipped with a tool storage matrix or magazine comprising a movable chain 13 , along which are positioned a plurality of tool storage modules or tool pockets 14 , especially adapted for supporting a hollow shank tool holder, such as an HSK tool holder. The present invention is directed to the tool pocket 14 and, more specifically, its capability to affirmatively retain an HSK tool holder 16 therein.
Reference numerals are used in the figures for identification, as follows: 2 —portion of tool holder; 4 —internal groove in tool holder; 10 —machine; 11 —tool spindle; 12 —cutting tool; 12 a —tool shank; 13 —movable chain or magazine; 14 —tool pocket; 15 —workpiece; 16 —tool holder; 16 a —tool holder shank opening; 20 —HSK tool pocket body; 22 —front of body; 24 —rear of body; 26 —tool holder receiving portion; 28 —latch opening; 30 —retainer/cage receiving opening; 32 —alignment member channel; 34 —bore; 40 —tool retention mechanism (first embodiment); 42 —center support; 44 —alignment member; 45 —latch; 46 —finger; 48 —latch portion; 50 —latch; 52 —bias portion; 54 —spring support tip; 60 —tool cage bushing; 62 —center support engaging end; 64 —plate engaging end; 66 —base; 68 —opposed curved sides; 70 —channel; 72 —elongated opening; 74 —bore; 76 —spring channel; 80 —cage spring plate; 82 —center opening; 84 —side spring receiving channel; 86 —spring support tip; 88 —bore; 90 —threaded screw or bolt; 92 —washer; 94 —nut; 96 —compression spring; 140 —tool retention mechanism (second embodiment); 146 —finger; 148 —latch portion; 150 —latch; 156 —opening; 157 —“V”-shaped shield; 158 —lips; 240 —metal retainer (third embodiment); 241 —near center bore; 243 —washer; 245 —pin; 246 —finger; 248 —latch portion; 250 —latch; 252 —bias portion; 253 —bore; 254 —pin; 260 —tool cage bushing retainer support; 268 —opposed sides; 269 —bore; and, 270 —channel.
With reference to FIGS. 2-16, a tool pocket 20 according to the preferred embodiment hereof is shown. In FIG. 2, the tool pocket body 20 is shown having a front 22 and a rear 24 . With additional reference to FIGS. 3-5, tool pocket body 20 includes a tool holder receiving portion 26 , opposed latch openings 28 , a retainer/cage opening 30 , opposed alignment member channels 32 ; and a pair of throughbores 34 . From the rear 24 , a tool retention mechanism 40 is inserted into opening 30 so that alignment members 44 engage channels 32 and latches 50 are received in latch openings 28 . A tool cage bushing 60 , a cage spring plate 80 , and springs 96 are also inserted from the rear 24 . Then, threaded bolts 90 are inserted through respective bores 34 of body 20 , bores 74 of bushing 60 (FIG. 11 ), and bores 88 of plate 80 (FIG. 14 ), and washers 92 and nuts 94 are inserted onto the ends of bolts 90 , the nuts 94 being tightened to secure the mechanism 40 , bushing 60 , and plate 80 within the tool pocket body 20 .
With particular reference to FIGS. 6-10, the preferred tool retention mechanism 40 is shown. Mechanism 40 is preferably made from a molded plastic, although other materials, such as sufficiently flexible metal or composite materials including shape memory and superelastic metal alloys, could be used. FIG. 2 shows the proper orientation of mechanism 40 for insertion into opening 30 in the rear 24 of pocket body 20 . Mechanism 40 includes a center support 42 , to which a pair of opposed fingers 46 and a pair of opposed alignment members 44 are attached or are integrally-formed therewith. From the view of FIG. 8, it is seen that opposed fingers 46 are at the top and bottom, such as at the twelve o-clock and six o-clock positions, respectively, and opposed alignment members 44 are at the left and right, such as at the three o-clock and nine o'clock positions, respectively. In this orientation, fingers 46 and alignment members 44 are spaced equidistantly around the support 42 and alternate with one another.
FIG. 10 shows that opposed alignment members 44 can each include a latch 45 . As is best seen in FIG. 5, when tool retention mechanism 40 is inserted into body 20 , latches 45 of opposed alignment members 44 each engage in one of the alignment member channels 32 of body 20 to retain mechanism 40 so that latches 50 are properly positioned, relative to the latch openings 28 .
Fingers 46 include a latch portion 48 , shown positioned to the right side of center support 42 in FIG. 7, and a bias portion 52 , shown positioned to the left side of center support 42 in FIG. 7 . Latch 50 is seen toward an end of the latch portion 48 of each finger 46 , distant from center support 42 . Spring support tip 54 is shown positioned toward an end of bias portion 52 of each finger 46 , distant from center support 42 .
Center support 42 functions as a fulcrum for the fingers 46 , which work like a pair of opposed levers. As will be explained in greater detail below, with particular reference to FIG. 7, it will be apparent to one of ordinary skill in the art upon reading the within description, that if opposed bias portions 52 are forced toward one another, for example by exerting inwardly-directed biasing forces at spring support tips 54 , the center support 42 will function as a fulcrum for the pivoting of both fingers 46 such that, the opposed latches 50 , in response, will be forced away from each other. In contrast, if opposed bias portions 52 are forced away from one another, with center support 42 providing the fulcrum for the pivoting of both fingers 46 , the opposed latches 50 , in response, will be forced toward one another.
With particular reference to FIGS. 11-13, the preferred tool cage bushing 60 is shown. Bushing 60 is preferably made from aluminum, although other materials could be used, for example, any sufficiently rigid plastic, hard rubber or composite material. FIG. 2 shows the proper orientation of bushing 60 for insertion into opening 30 in the rear 24 of pocket body 20 . Bushing 60 includes a center support engaging end 62 , which abuts the center support 42 of the mechanism 40 , and a plate engaging end 64 . A pair of opposed curved sides 68 with channel 70 therebetween extend from base 66 , a distal end defining support engaging end 62 . Base 66 contains an elongated opening 72 therethrough which is sized such that the end portions of the bias portion 52 of fingers 46 can pass therethrough and be operable to and from each other without interference from opening 72 . From the plate engaging end 64 of base 66 , a spring receiving channel 76 extends across the base 66 and is in alignment with opening 72 . Base 66 also contains a pair of throughbores 74 , spaced from the spring receiving channel 76 , which are sized to receive bolts 90 therethrough.
With particular reference to FIGS. 14 and 2, the preferred cage spring plate 80 is shown. Plate 80 includes a center opening 82 and a pair of outwardly extending side spring receiving channels 84 , the inner edge of each of which serving as an inner limit or stop for movement of respective bias portions 52 . The outer edges of both channels 84 each include an inwardly extending spring support tip 86 . Plate 80 also contains a pair of throughbores 88 which are sized to receive bolts 90 therethrough. Plate 80 will abut the plate engaging end 64 of bushing 60 .
As seen best in FIGS. 2, 4 , and 5 , with the mechanism 40 , bushing 60 , and plate 80 inserted into opening 30 in the rear 24 of pocket body 20 , throughbores 34 (in pocket body 20 ), 74 (in tool cage bushing 60 ), and 88 (in plate 80 ) are in axial alignment with one another and receive bolts 90 from the front 22 of the pocket body 20 , with bolts 90 extending beyond plate 80 toward the rear 24 of the pocket body 20 , and receive washers 92 and nuts 94 from the rear 24 of the pocket body to engage rearwardmost ends of the bolts 90 , thereby securing mechanism 40 , bushing 60 , and plate 80 within the pocket body 20 . The bias portions 52 of each finger 46 extend through elongated opening 72 through one of channels 84 in the plate 80 . With plate 80 abutting end 64 , channels 84 and channel 76 are in alignment with the spring support tip 54 of each finger 46 and also in facing alignment with an opposed spring support tip 86 in the plate 80 . Two compression springs 96 are employed to bias the bias portions 52 of the fingers 46 toward one another, as permitted by the plate channels 84 . The open ends of each spiral spring 96 are received by a pair of cooperating tips 54 , 86 , the springs 96 being partway received in respective cooperating channels 84 , 76 .
Therefore, springs 96 urge opposed bias portions 52 of fingers 46 toward one another to the inner limit permitted by the inner edges of channels 84 or by the stiffness of the fingers 46 or of the finger 46 -support 42 connection. Channels 84 permit movement of portions 52 away from each other if the force of the springs 96 is opposed. A representation of this is shown in FIGS. 15 and 16. In FIG. 15, bias portion 52 is spaced a distance “d 1 ” from a reference surface, such as, a portion of pocket body 20 , for example, an inner surface of the opening 30 . When the bias portion 52 is in the position shown in FIG. 15, latch 50 of latch portion 48 is received by the internal groove 4 of a portion of an HSK tool holder 2 . Internal groove 4 preferably is a continuous circular groove and, while not shown in this rendering, both of the latches 50 will be received in the groove 4 . The latches 50 are shaped such that, when received by the groove 4 , the tool holder 20 is retained in the tool holder receiving portion 26 of tool pocket body 20 .
As shown in FIG. 16, spring 96 may be compressed more than spring 96 of FIG. 15, such as, by applying a release force “F” directed against the biasing force of the spring 96 . As such, when the release force “F” exceeds the biasing force, the bias portion 52 will move to a position whereat the bias portion 52 is spaced a distance “d 2 ” from the inner surface of the opening 30 , the distance d 2 being a distance less than the distance d 1 . In response, the latch 50 will move inwardly as the bias portion 52 and latch portion 48 each pivot about the center support 42 . When the mechanism 40 is in the position whereat the latch 50 no longer engages the groove 4 of the tool holder 2 , the tool holder 2 can be removed from, or inserted into, from the tool holder receiving portion 26 of the tool pocket body 20 .
With reference to FIGS. 17-19, one alternative embodiment of the present invention is shown. Tool pocket body 20 , bushing 60 , plate 80 , bolts 90 , washers 92 , nuts 94 , and springs 96 are identical to those employed with the preferred embodiment hereof, and like reference numerals are intended to represent like components. However, in the present embodiment, the tool retention mechanism 140 has been modified. The main portion of mechanism 140 is again preferably made of plastic, as was mechanism 40 . However, to provide for longer wear of the latches 150 , each finger 146 includes a wear-resistant surface, for example, a V-shaped shield 157 which is sized and shaped to cover the wear surfaces of the latch 150 . The shields 157 are made of a metallic or other wear-resistant material, and each shield 157 includes one or more lips 158 which are used to securely each grip the latch 150 of latch portion 148 of one of the fingers 146 . One or more openings 156 may be provided on each latch portion 148 to receive lips 158 to attach the shield 157 . As shield 157 engages groove 4 of tool holder 2 , better component life is provided. Although the wear-resistant surfaces have been described as separate shields 157 which can be affixed to the latches 150 (and removed therefrom for replacement, if necessary, the same effect of which can be provided by constructing the mechanism 140 , or any portion thereof, out of a wear-resistant material, in which case, shields 157 are not necessary.
With reference to FIGS. 20-22, another alternative embodiment of the present invention is shown. Tool pocket body 20 , plate 80 , bolts 90 , washers 92 , nuts 94 , and springs 96 are identical to those employed with the preferred embodiment thereof and like reference numerals are intended to represent like parts, however, in the present embodiment, the fingers 246 are constructed of metal or other wear-resistant material. Because steel is the preferred material for the mechanism 240 according to the present embodiment, and because the stiffness of steel is significantly higher than the stiffness of most plastic materials, the entire tool retention mechanism can not be a unitary metal piece for the lever/fulcrum to function as described herein. Therefore, the metal retainers 240 comprise a pair of individual fingers 246 . Each finger 246 includes a throughbore 241 near the finger 246 center. Each finger 246 will pivot about its bore 241 . Each finger 246 includes a latch portion 248 to one side of bore 241 and a bias portion 252 to the opposed side of bore 241 . Toward the end of latch portion 248 away from bore 241 is a latch 250 . Toward the end of bias portion 252 away from bore 241 is a bore 253 which receives a pin 254 . While pin 254 could be formed as a unitary part of finger 246 , the manufacture is easier if pin 254 is a separate element.
Each latch 250 will function as latches 50 , 150 of the previous embodiments and each pin 254 will function as spring support tip 54 of the previous embodiments. To support this function, tool cage bushing 60 is modified to be a retainer support 260 and provide the fulcrum or pivot point for both fingers 246 . Opposed curved sides 268 , with a channel 270 therebetween, include a pair of aligned bores 269 , each pair of bores 269 going through both sides 268 . Fingers 246 are connected to support 260 using washers 243 and pins 245 . A pin 245 passes through one bore 269 in one side 268 , through a washer 243 , through bore 241 , through a washer 243 , and through the aligned bore 269 in the opposed side 268 . This provides for operation as explained with the prior embodiments, springs 96 being contained between pins 254 and respective tips 84 . Fingers 246 can pivot about pins 245 as fingers 46 , 146 pivot about center support 42 , as described in the prior embodiments.
With reference to FIG. 23, a tool retention mechanism 340 according to yet another alternative embodiment of the present invention includes many components in common with the tool retention mechanism 40 (FIG. 6) of the preferred embodiment hereof, and like reference numerals are intended to represent like components. However, the tool retention mechanism 340 according to the present embodiment includes more than one pair of opposing fingers 346 , for example, two pair of opposing fingers 346 providing four such fingers 346 spaced equidistantly around the support 342 with alignment members 44 being positioned between first and second pairs of fingers 346 . Of course, tool pocket body 20 , plate 80 , bushing 60 , and the components thereof, must all be modified to receive the mechanism 340 of the present embodiment, however, such modifications will be apparent to one of ordinary skill in the art upon reading the within description.
With reference to FIG. 24, a tool retention mechanism according to still another alternative embodiment of the present invention includes many components in common with the tool retention mechanism 40 (FIG. 6) of the preferred embodiment hereof, and like reference numerals are intended to represent like components. However, the tool retention mechanism 340 according to the present embodiment includes only one finger 446 , preferably spaced between the alignment members 44 . Although not depicted in the drawings, any number of fingers, including any odd number of fingers, can be provided spaced around the support, either equidistantly or otherwise, without departing from either the spirit or the scope of the present invention. In any such case, it will be apparent to one of ordinary skill in the art, upon reading the within description, how to modify the tool pocket body 20 , and its associated components, for the purpose of receiving the mechanism.
With reference to FIG. 25, a spring plate 580 according to one alternative embodiment of the present invention includes many components in common with the spring plate 80 (FIG. 14) according to the preferred embodiment hereof and like reference numerals are intended to represent like components. However, the spring plate 580 according to the present embodiment includes a continuous channel 584 extending across the plate 580 such that outermost ends thereof are disposed, relative to the outer periphery of the plate 580 , much like respective outermost ends of the channels 84 (FIG. 14) of the plate 80 (FIG. 14) according to the preferred embodiment hereof. However, the spring plate 580 of the present embodiment differs from the spring plate 80 (FIG. 14) of the preferred embodiment integrally-formed stops have been removed therefrom. Inward travel of the bias portions 52 (FIG. 5) would be limited either by a separate component (not shown) known to those of ordinary skill in the art) or by the material properties (i.e., stiffness) of the fingers 46 .
While the invention has been illustrated with reference to one or more preferred embodiments hereof, and such preferred embodiments have been described in considerable detail with reference to the drawings, it is not the intention of applicants that the invention be restricted to such detail.
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A cutting tool retention mechanism, for example, typically used to retain a tool holder in a tool pocket of a tool changer magazine. A horizontal machine tool apparatus typically contains a plurality of tool pockets attached to a movable tool changer magazine and the mechanism of the present inventions provides an affirmative mechanism for retaining tool holders so that they do not separate from their respective tool pockets unless removal is desired. More particularly, a pair of opposed pivotal fingers each include a latch which can engage with or disengage from the internal groove of a tool holder to perform this function. Spring bias can be provided to encourage this affirmative engagement of the latches with the internal groove.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This Continuation application claims the benefit of U.S. Ser. No. 13/046,138 filed Mar. 11, 2011, now pending, which claims the benefit of application U.S. Ser. No. 10/968,481 filed Oct. 19, 2004, now abandoned, which claims the benefit of U.S. Provisional Application Ser. No. 60/513,886, now expired, the entire disclosure of which is herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention related to a process for making sterile aripiprazole of desired particle size distribution and mean particle size which is especially adapted for use in preparing a controlled release formulation which releases aripiprazole over at least one week or more.
BACKGROUND OF THE INVENTION
[0003] U.S. provisional application No. 60/513,618, discloses a controlled release sterile injectable aripiprazole formulation in the form of a sterile suspension, and a method for preparing a sterile freeze-dried aripiprazole formulation (employed in forming the injectable formulation) which includes the steps of:
[0004] (a) preparing sterile bulk aripiprazole preferably having a desired particle size distribution and mean particle size within the range from about 5 to about 100 microns, more preferably from about 10 to about 90 microns,
[0005] (b) preparing a sterile vehicle for the sterile bulk aripiprazole,
[0006] (c) combining the sterile bulk aripiprazole and the sterile vehicle to form a sterile primary suspension,
[0007] (d) reducing the mean particle size of aripiprazole in the sterile primary suspension to within the range from about 0.05 to about 30 microns, to form a final sterile suspension, and
[0008] (e) freeze drying the final sterile suspension to form a sterile freeze-dried suspension of the aripiprazole of desired polymorphic form (anhydrous, monohydrate, or a mixture of both).
[0009] In carrying out the above method for preparing the freeze-dried aripiprazole formulation, it is required that everything be sterile so that sterile aripiprazole and sterile vehicle are combined aseptically to form a sterile suspension and that the sterile suspension be freeze-dried in a manner to form sterile freeze-dried powder or cake. Thus, an aseptic procedure is employed to produce sterile bulk aripiprazole of desired mean particle size, and particle size distribution, by crystallization methods as opposed to ball milling. The sterile bulk aripiprazole preferably prepared in step (a) by means of the impinging jet crystallization method, has a desired small particle size and narrow particle size distribution, high surface area, high chemical purity, and high stability due to improved crystal structure.
[0010] The impinging jet crystallization utilizes two jet streams that strike each other head-on. One of the streams carries a solution rich in the aripiprazole and the other carries an anti-solvent, such as water. The two streams strike each other which allows for rapid homogeneous mixing and supersaturation due to high turbulence and high intensity of micromixing upon impact. This immediate achievement of supersaturation initiates rapid nucleation. In general, the average crystal size of the aripiprazole decreases with increasing supersaturation and decreasing temperature of the anti-solvent. Therefore, in order to obtain the smallest particle size, it is advantageous to have the highest possible concentration of the aripiprazole rich solution and the lowest temperature of the anti-solvent.
[0011] The technique employed for forming sterile bulk aripiprazole is important since particle size of the aripiprazole formulation controls its release profile in the blood system over a period of one month.
[0012] It has been found that batch crystallization of aripiprazole produces particles 100 microns. However, in formulating the controlled release sterile aripiprazole injectable formulation discussed above, the particle size of the aripiprazole needs to be 95% 100 microns. In addition, a narrow particle size distribution is needed to maintain control of the release profile. Milling of batch aripiprazole is undesirable, as a broad particle size distribution will be obtained. Thus, it would be advantageous to employ a technique for preparing sterile bulk aripiprazole which can reduce particle size of aripiprazole to 95% 100 microns with a narrower particle size distribution than attainable employing batch crystallization.
[0013] U.S. Pat. No. 5,006,528 to Oshiro et al. discloses 7-[(4-phenylpiperazino)-butoxy] carbostyrils, which include aripiprazole, as dopaminergic neurotransmitter antagonists.
[0014] Aripiprazole which has the structure
[0000]
[0000] is an atypical antipsychotic agent useful in treating schizophrenia. It has poor aqueous solubility (<1 μg/mL at room temperature).
[0015] U.S. Pat. No. 6,267,989 to Liversidge, et al. discloses a method for preventing crystal growth and particle aggregation in nanoparticulate compositions wherein a nanoparticulate composition is reduced to an optimal effective average particle size employing aqueous milling techniques including ball milling.
[0016] U.S. Pat. No. 5,314,506 to Midler, et al. discloses a process for the direct crystallization of a pharmaceutical having high surface area particles of high purity and stability wherein impinging jet streams are employed to achieve high intensity micromixing of particles of the pharmaceutical followed by nucleation and direct production of small crystals.
[0017] U.S. Pat. No. 6,302,958 to Lindrud et al. discloses a method and apparatus for crystallizing submicron-sized crystals of a pharmaceutical composition employing sonication to provide ultrasonic energy in the immediate vicinity of impinging fluid drug and solvent streams so as to effect nucleation and the direct production of small crystals.
[0018] U.S. application Ser. No. 10/419,418, filed Apr. 21, 2003 by Chenkou Wei (attorney docket TU58 NP) which is based on U.S. Provisional Applications Nos. 60/376,414, filed Apr. 29, 2002 and 60/439,066, filed Jan. 9, 2003 entitled “Crystallization System Using Atomization” discloses a method for crystallizing a pharmaceutical by atomizing one solution and introducing the atomized solution into a vessel containing a second solution where the solutions are mixed to form a product, which does not require post-crystallization milling. This application is incorporated herein by reference.
[0019] U.S. application Ser. No. 10/419,647, filed Apr. 21, 2003 by Chenkou Wei (attorney docket TU59 NP) which is based on U.S. Provisional Applications Nos. 60/379,351, filed May 10, 2002 and 60/439,057, filed Jan. 9, 2003 entitled “Crystallization System Using Homogenization” discloses a process for crystallizing a chemical material from a first solution and a second solution wherein the first solution is atomized and introduced into a second solution, and the atomized solution and second solution are mixed to form the product. This application is incorporated herein by reference.
BRIEF DESCRIPTION OF THE INVENTION
[0020] In accordance with the present invention, there is provided a process for preparing sterile bulk aripiprazole of desired small particle size and narrow particle size distribution, preferably having an average particle size less than about 100 microns but preferably greater than 25 microns, which includes the steps of:
[0021] (a) providing a jet stream of a solution of aripiprazole in an organic solvent, preferably ethanol, preferably heated at a desired elevated temperature;
[0022] (b) providing a jet stream of anti-solvent, preferably water, which is capable of initiating precipitation of aripiprazole from solution, preferably said anti-solvent being at a desired temperature below the temperature of the solution of aripiprazole;
[0023] (c) causing the jet stream of solution of aripiprazole in solvent and the jet stream of anti-solvent to strike each other and impinge on one another to create high turbulence at their point of impact, each jet stream having sufficient linear velocity to achieve high intensity micromixing of each stream prior to nucleation, to produce a slurry of crystals of aripiprazole monohydrate; and
[0024] (d) recovering crystals of aripiprazole monohydrate of desired small particle size and narrow particle size distribution.
[0025] Prior to step (d) ultasonic energy may be provided, by means of a sonication probe, as described in U.S. Pat. No. 6,302,958, the disclosure of which is incorporated herein by reference, the tip of which is positioned within a gap defined between the two jet streams, to cause the impinging jet streams to achieve high intensity micromixing of fluids prior to nucleation.
[0026] In addition, in accordance with the present invention, a preferred process is provided for preparing sterile bulk aripiprazole of desired average particle size of less than about 100 microns, but preferably greater than 25 microns, and narrow particle size distribution, which includes the steps of:
[0027] (a) providing a jet stream of a solution of aripiprazole in ethanol heated at a temperature within the range from about 70 to about 85° C., preferably from about 75 to about 80° C.;
[0028] (b) providing a jet stream of deionized water which is at a temperature within the range from about 2 to about 40° C., preferably from about 20 to about 35° C.;
[0029] (c) causing the jet streams of solution of aripiprazole and water, each at a flow rate (where jet nozzles of 0.02 inch internal diameter are employed) within the range from about 0.20 to about 0.30 kg/min, preferably from about 0.22 to about 0.28 kg/min, to impinge on one another to create high turbulence at their point of impact to achieve high intensity micromixing of each stream prior to nucleation, and form a slurry of crystals of aripiprazole monohydrate; and
[0030] (d) recovering crystals of aripiprazole monohydrate having an average particle size less than 100 microns, but preferably greater than 25 microns, preferably about 95% of the crystals having a particle size less than 100 microns.
[0031] Prior to step (d) ultasonic energy may be provided, by means of a sonication probe, as described above, the tip of which is positioned within a gap defined between the two jet streams, to cause the impinging jet streams to achieve high intensity micromixing of fluids prior to nucleation.
[0032] In carrying out the above process of the invention, the volumetric ratio of solution of aripiprazole in organic solvent to anti-solvent is within the range from about 0.5:1 to about 1.5:1, preferably from about 0.9:1 to about 1.1:1.
[0033] The above processes may also be employed to prepare crystals of aripiprazole monohydrate having an average particle size of less than 25 microns.
[0034] The processes of the invention as described above employs jet streams which impinge on each other to achieve high intensity micromixing of the streams to enable formation of a homogeneous composition prior to the start of nucleation in a continuous crystallization process. Nucleation and precipitation are initiated utilizing the effect of antisolvent addition on the solubility of the aripiprazole in the solvent therefore.
[0035] The sonication steps disclosed above are carried out as described in U.S. Pat. No. 6,302,958.
[0036] The aripiprazole produced by the process of the invention may be employed in forming sterile bulk aripiprazole having a desired particle size distribution, preferably 10% <10 microns, 50% <35 microns and 95% <100 microns, and mean particle size within the range from about 25 to about 100 microns.
[0037] The sterile bulk aripiprazole prepared by the process of the invention may be used in forming a sterile-freeze dried aripiprazole formulation which may be suspended in water to form an injectable aripiprazole formulation as described in U.S. provisional Application No. 10/419,647.
[0038] Each of the above embodiments of the process of the invention are referred to as the impinging jet crystallization process of the invention.
[0039] The process of the invention employs impinging jet crystallization technology, an example of which is disclosed in U.S. Pat. No. 5,314,506 to Midler et al.
[0040] It will also be appreciated that the sterile bulk aripiprazole of desired small particle size and narrow particle size distribution as described above may be prepared employing the process and apparatus described and claimed in each of the Chendou Wei applications entitled “Crystallization System Using Atomization” and “Crystallization System Using Homogenization” described above and incorporated herein by reference.
BRIEF DESCRIPTION OF THE FIGURES
[0041] The accompanying FIGURE is a schematic representation of an impinging jet crystallization process flow diagram used in carrying out the process of the invention, which includes a crystallizer vessel.
DETAILED DESCRIPTION OF THE INVENTION
[0042] The process of the invention is illustrated in the following reaction scheme:
[0000]
[0043] In carrying out the process of the invention, low pyrogen aripiprazole starting material is employed to ensure that the sterile aripiprazole of desired particle size will be produced. The low pyrogen aripiprazole starting material may be either the anhydrous form or the monohydrate form. Either material will yield the desired monohydrate form from the impinging jet crystallization process of the invention.
[0044] The process of the invention employs two jet nozzles to create two impinging jet streams to achieve high intensity micromixing of the streams prior to nucleation and formation of crystals of aripiprazole monohydrate. The two impinging jet streams should be substantially diametrically opposed to one another with the nozzles directed to face each other. The jet nozzles will be aligned and positioned so that the fluid streams will impact head-on and will impinge. When the jet nozzles are properly aligned and appropriate flow rates chosen, the two streams will form a plane when impinged.
[0045] Each of the process streams, namely the aripiprazole-organic solvent stream and the anti-solvent stream will be sterilized. To sterilize the two process streams, both streams are preferably polish filtered and then sterile filtered through an appropriate size filter, such as a 0.2 micron filter. The aripiprazole stream should be filtered at an elevated temperature, for example, about 80° C., to prevent precipitation.
[0046] The temperature and composition of each solution are chosen so that 1) no material will crystallize upstream of the impinging jets, and 2) sufficient supersaturation will be developed in the impinging jets to cause nucleation. Micromixing creates temperature and compositional uniformity throughout the mixture prior to the start of nucleation.
[0047] To obtain the smallest particle size of aripiprazole, the highest possible concentration of aripiprazole in the organic solvent should be employed. Thus, the starting solution of aripiprazole in organic solvent, preferably ethanol, will contain from about 0.01 to about 0.1 kg/L aripiprazole, preferably from about 0.04 to about 0.06 kg/L aripiprazole. In a most preferred embodiment, the aripiprazole will be present in an amount of about 0.05 kg/L.
[0048] The organic solvent will preferably be ethanol, most preferably from about 92 to about 97% ethanol, with the remainder being water.
[0049] Other organic solvents, such as methanol, ethyl acetate, acetone, acetonitrile, acetic acid or isopropyl alcohol or mixtures of two or more thereof, or mixtures with water may be employed.
[0050] The anti-solvent will preferably be deionized water.
[0051] The two streams, namely, the stream of the solution of aripiprazole in the organic solvent and the stream of anti-solvent, are characterized as jet streams in that they will be made to strike each other head on at high linear velocities with a minimum of 5 m/s. The flow rates will be determined by the diameter of the jet nozzles employed to deliver the streams and the rate at which the streams are pumped through the nozzles. In a preferred embodiment, the flow rate of each of the stream of aripiprazole/solvent and the stream of antisolvent will be essentially the same, but will of course be in opposite directions.
[0052] The flow rates will be chosen so that proper impinging is achieved. For example, where jet nozzles of 0.02 inch internal diameter are employed, flow rates will be within the range from about 0.20 to about 0.30 kg/min, preferably from about 0.22 kg/min to about 0.28 kg/min, more preferably from about 0.24 kg/min to about 0.26 kg/min, and optimally about 0.25 kg/min.
[0053] The temperature of each of the streams is important in determining ultimate size of the particles of aripiprazole produced. Thus, the aripiprazole-solvent (preferably ethanol) stream should be heated at a temperature within the range from about 70 to about 85° C., preferably from about 75 to about 80° C. The anti-solvent stream (preferably water) should be at a temperature substantially less than the temperature of the aripiprazole-solvent stream, and within the range from about 2 to about 40° C., preferably from about 20 to about 35° C., and optimally about 30° C.
[0054] The two streams strike each other head-on, from opposite directions, to cause rapid homogeneous mixing and supersaturation due to high turbulence and high intensity of mixing upon impact. The immediate achievement of supersaturation initiates rapid nucleation. In general, the average crystal size decreases with increasing supersaturation and decreasing temperature of the anti-solvent. The smallest particle size of aripiprazole is obtained employing the highest possible concentration of the aripiprazole solution and the lowest temperature of the anti-solvent. Sonication is utilized where even smaller particles are desired.
DESCRIPTION OF THE FIGURE
[0055] Referring to the accompanying FIGURE, an impinging jet crystallization process flow diagram and crystallizer vessel used in carrying out the process of the invention are shown which includes a jacketed impingement crystallization vessel 10 . There are two jacketed-vessels 12 , 14 that flank the impingement vessel 10 to the left and right which contain the aripiprazole-rich solution ( 12 ) and the anti-solvent ( 14 ), respectively. Both of these side vessels 12 , 14 are spaced apart from the impingement vessel 10 . Impinging jet nozzles 16 , 18 , each having a 0.02-inch diameter, are spaced 10 mm apart. The impingement vessel 10 may include agitator 11 and a sonicator (as employed in U.S. Pat. No. 6,302,958), if desired, not shown for drawing clarity. Outlet 31 of impingement vessel 10 is connected to receiving vessel 32 , via line 33 . Overflow line 35 links impingement vessel 10 and line 33 and aids in maintaining a constant volume in impingement vessel 10 .
[0056] The above description is of the sterile portion of the flow diagram. The non-sterile portion as shown includes a vessel 34 for holding a solution of aripiprazole in ethanol, preferably 95% ethanol, which is pumped via pump 36 through polish filter 38 and sterile filter 40 into vessel 12 and processed as described above.
[0057] The jet nozzles 16 , 18 should be placed so that the fluid streams they emit will impinge, inside the stirred impingement vessel 10 or inside a separate jet chamber (not shown) which is linked directly to the vessel 10 . The fluid jets must impinge to create an immediate high turbulence impact. The two jet nozzles are preferably arranged so that they are substantially diametrically opposed to each other with their outlet tips directed to face each other; i.e., the two jet nozzles are at or close to a 180 degree angle to each other from an overhead view. Preferably, each jet outlet nozzle can have a slight downward angle from the horizontal, for example, about 10 degrees, to help the flowing material move down and out of the chamber.
[0058] Likewise, two jet nozzles placed directly inside the stirred impingement vessel 10 are preferably arranged so that they are substantially diametrically opposed to each other with their outlet tips directed to face each other. When the jet nozzles are so placed, each nozzle can have a slight upward or downward angle from the horizontal of from 0 degrees up to about 15 degrees, but preferably the two nozzles have just enough downward angle from the horizontal (ca. 13 degrees) to ensure that the fluid stream of one will not enter the outlet hole of the opposite nozzle.
[0059] Jet nozzle 16 is used to transport aripiprazole solution into the vessel 10 (or separate jet chamber) and the other jet 18 is used to similarly transport water. The distance between the nozzle tips inside the jet chamber or vessel 10 should be such that the hydro-dynamic form of each fluid jet stream remains essentially intact up to the point of impingement. Therefore, the maximum distance between the nozzle tips will vary depending on the linear velocity of the fluids inside the jet nozzles. To obtain good results for generally non-viscous fluids, linear velocity in the jet nozzles should be at least about 5 meters/sec., more preferably above 10 meters/sec., and most preferably between about 20 to 25 meters/sec., although the upper limit of linear velocity is only limited by the practical difficulties involved in achieving it. Linear velocity and flow rate can both be controlled by various known methods, such as altering the diameter of the entry tube and/or that of the nozzle outlet tip, and/or varying the strength of the external force that moves the fluid into and through the nozzle. Each jet apparatus can be manipulated independently to attain a desired final fluid composition ratio. When the desired flow ratio of one jet to the other differs from unity, preferably the difference is compensated for by appropriate sizing of the entry tubes. For example, if a 4:1 volumetric ratio of feed solution to anti-solvent is desired, the entry tube delivering feed solution should be twice the diameter of the entry tube delivering anti-solvent. When the jet streams impinge inside a jet chamber, residence time for the fluid inside the jet chamber is typically very short, i.e., less than ten seconds.
[0060] Stirring in the vessel is provided by standard agitators 11 , preferably Rushton 10 turbines, Intermig impellers, or other agitators suitable for stirring a slurry suspension. Any impeller providing good circulation inside the vessel may be used. However, when the jet streams are arranged to impinge directly inside the stirred vessel, an agitator that does not interfere with the space occupied by the impinging jet streams inside the vessel is preferred, especially, e.g., a Rushton turbine. Impinging jet streams inside the vessel are most preferably placed in the effluent stream of the agitator, and the height of the liquid in the stirred vessel 10 when operated in continuous mode (i.e., flow in equals flow out, constant volume maintained), is most preferably between about two to four times the height of the impeller.
[0061] The crystallization is preferably run in a continuous process and the appropriate residence time for the completion of crystal digestion is attained by adjusting the volume capacity of the stirred vessel, but the mixture can be held up in the vessel for any desired length of age time if batchwise processing is desired.
[0062] Manual seeding can be done at any point in the system, e.g., in the stirred vessel 10 , the transfer line or the jet chamber itself. In some situations, the continuous jet process may be “self-seeding”, i.e., the first crystals to form inside the jet chamber (if used), the transfer line (if used) or the stirred vessel 10 serve as seed for the material that flows through thereafter.
[0063] The micromixed material must be highly supersaturated to attain the beneficial results of the jet crystallization process. Aside from thermoregulated initiation of nucleation, temperature variation also affects product results when anti-solvent is used to initiate nucleation because of its effect on supersaturation. Generally, good results can be achieved using a volumetric ratio of aripiprazole to anti-solvent that provides a high degree of supersaturation in the jet chamber in a temperature range of about 24° C. to 70° C., although the temperature upper limit is limited only by the chosen solvent's boiling point.
[0064] An example of the impingement vessel which may be employed is disclosed in U.S. Pat. No. 5,314,506 to Midler et al. and in U.S. Pat. No. 6,302,958 to Lindrud et al. which are incorporated herein by reference.
[0065] To prepare a 100-gram batch of aripiprazole monohydrate, a 100 grams of aripiprazole anhydrous N1 is charged into a 4-L vessel 12 and dissolved in 2 L of 95% ethanol at 75 to 80° C. The clear solution is then transferred to the product-rich 2-L jacketed vessel 10 and maintained at 75 to 80° C. In the anti-solvent vessel 14 , 2 L of deionized (DI) water is then charged and heated to 28 to 32° C. When both liquids are at the desired temperatures, the two streams are pumped simultaneously via pumps 20 and 22 through mass flow meters 24 , 26 , respectively, and sterile filters 28 , 30 , respectively, through the 0.02-inch internal diameter nozzles 16 , 18 and impinge at a rate of 0.22 to 0.28 kg/min to produce the monohydrate crystals. The crystals are continuously transferred to receiving vessel 32 to maintain a constant volume in the impingement vessel 10 . It takes approximately 5 to 7 minutes to impinge a 100-gram batch. The slurry is cooled to 20 to 25° C., filtered, and washed with 200 mL of deionized water. The cake is then dried at 35° C. under vacuum to obtain approximately 100 grams of aripiprazole monohydrate, H0, with a Karl Fisher % (KF %) of ca. 4% w/w.
EXAMPLES
[0066] The following working Examples represent preferred embodiments of the present invention.
Example 1
[0067] Sterile bulk active pharmaceutical ingredient (API) aripiprazole was prepared using impinging crystallization with sonication employing an apparatus set up as shown in the attached FIGURE.
[0068] The following procedure was employed to form a sterile bulk aripiprazole.
[0069] 1. Charge 100 g of aripiprazole in a 4 L flask 34 .
[0070] 2. Add 2 L of 95% ethanol.
[0071] 3. Heat the suspension to 80° C. until it becomes a clear solution.
[0072] 4. Transfer the hot aripiprazole solution to a 2 L jacketed vessel 12 and maintain at 75-80° C.
[0073] 5. Charge 2 L of deionized (DI) water to a 2 L jacketed vessel 14 .
[0074] 6. Cool the DI water to 2° C.
[0075] 7. Add 100 mL of 95% ethanol and 100 mL of DI water to the impinging vessel 10 and cool to 2° C.
[0076] 8. Initiate sonication (Sonication is provided by a 0.5 inch probe with 120 W power output employed as described in U.S. Pat. No. 6,302,958).
[0077] 9. Pump the aripiprazole solution through a 0.02 inch diameter nozzle 16 at 0.25 kg/min and impinge it with the 2° C. water pumped at 0.25 kg/min through a 0.02 inch diameter nozzle 18 .
[0078] 10. Sonicate the newly formed crystal slurry in the impinge vessel 10 while continuously transferring the crystals to a receiving vessel 32 to maintain a constant volume in the impingement vessel 10 .
[0079] 11. Cool the slurry to 20 to 25° C. at the end of impingement.
[0080] 12. Filter the slurry.
[0081] 13. Wash the cake with 200 mL of DI water.
[0082] 14. Dry the wet cake at 35° C. under vacuum to obtain 97.9 g of aripiprazole with a KF of 4.0% w/w, with reduced particle size (95% <100 microns).
Example 2
[0083] Sterile bulk API aripiprazole was prepared using impinging jet crystallization and an apparatus set up as shown in the accompanying FIGURE.
[0084] The following procedure was employed to form a sterile bulk aripiprazole:
[0085] 1. Suspend 100 g of aripiprazole in 2000 mL of 95% ethanol. Heat the suspension to 80° C. until it becomes a clear solution.
[0086] 2. Polish filter the aripiprazole solution into a holding vessel 12 and maintain at 80° C.
[0087] 3. Polish filter 2000 mL water to another holding vessel 14 and heat to 80° C.
[0088] 4. Pump the aripiprazole solution through a 0.02 inch diameter nozzle 16 at 0.25 kg/min and impinge it with the 30° C. water pumped at 0.25 kg/min through a 0.02 inch diameter nozzle 18 to form a crystal slurry which is collected in an impingement vessel 10 .
[0089] 5. Agitate the newly formed crystal slurry in the impingement vessel 10 while continuously transferring it to a receiver 32 to maintain a constant volume in the impingement vessel 10 .
[0090] 6. At the end of impingement, cool the slurry in the receiver 32 to room temperature.
[0091] 7. Filter the slurry.
[0092] 8. Dry the wet cake at 35° C. under vacuum to yielding 100 g (96% recovery) of aripiprazole with reduced particle size (95% <100 microns).
Example 3
[0093] An aripiprazole injectable aqueous suspension (200 mg aripiprazole/2 mL, 200 mg/vial) was prepared as follows.
[0094] The following ingredients were added to a 3 L glass jacketed vessel maintained at 15° C. (±5° C.) to form a sterile primary suspension:
[0000]
Aripiprazole (prepared by impinging jet
100 g
crystallization as described in Example 2):
Carboxymethylcellulose, Sodium Salt 7L2P
9.0 g
Mannitol
45 g
Sodium Phosphate, Monobasic
0.8 g
Sodium Hydroxide Solution, 1N
q.s. to adjust pH to 7.0
Water, USP
q.s. to 1000 g
[0095] The sterile suspension was mixed at 500-1000 rpm for about 0.5 hour and then at 300-500 rpm for an additional 1 hour under 20″ Hg (±5″Hg) vacuum.
[0096] 2.5 mL of the above suspension were aseptically filled into sterilized vials which were then aseptically partially stoppered with sterilized stoppers. The vials were aseptically transferred to a freeze dryer and lyophilized according to the following cycle:
[0097] (a) thermal treatment: freeze product at −40° C. over 0.1-1 h and keep at −40° C. for at least 6 h,
[0098] (b) cool the condenser to −50° C. or below,
[0099] (c) primary drying: lower chamber pressure to approximately 100 microns Hg and increase product temperature to −5° C. over approximately 2 h; continue primary drying at −5° C. and 100 microns Hg for at least 48 h,
[0100] (d) stopper the vials under atmospheric pressure or partial vacuum using sterile nitrogen or air and remove from the freeze dryer,
[0101] (e) seal the vials with the appropriate seals and label.
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A process is provided for making sterile aripiprazole having an average particle size less than 100 microns but preferably greater than 25 microns employing an impinging jet crystallization procedure. The resulting bulk aripiprazole of desired particle size may be used to form a sterile freeze-dried aripiprazole formulation, which upon constitution with water and intramuscular injection releases aripiprazole over a period of at least about one week and up to about eight weeks.
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The present invention relates to a bone anchor, in particular, but not exclusively, to a bone anchor for graft fixation such as tendon or ligament fixation.
BACKGROUND OF THE INVENTION
Due to increasing involvement of people with active sport, injuries are becoming increasingly common where tissues such as ligaments or tendons tear or detach from bone. Surgical techniques have been developed to reconstruct such torn soft tissues and to re-attach them to the relevant bone. One of the most common types of such injuries is tearing of the Anterior Cruciate Ligament (ACL). The Anterior Cruciate Ligament connects the femur to the tibia at the centre of the knee joint. Reconstruction of such tissues generally involves replacement with a graft such as autologous or artificial tendon. An autologous tendon graft may be taken from the patients patellar tendon or, alternatively, the semitendinosus may be utilised. A typical fixation technique involves the use of a circular button fixation device which is located on the outside of the femur above the knee. As this is some distance from the site where the graft will be utilised in the knee joint, sutures are used to attach the graft to the femur button. The main disadvantage of this technique is that incisions need to be made through the skin and quadriceps muscle resulting in trauma to the leg and a cosmetically undesirable procedure. U.S. Pat. No. 5,645,588 describes an improved technique whereby the ligament anchor may be threaded through a femoral tunnel formed through the femur from the centre of the knee but such still involves the use of sutures attached directly to the fixation device on the outside of the femur above the knee and through which the graft is looped before passing out of the femoral tunnel before being secured to the tibia. Using such techniques inevitably involves the introduction of potential sources of loosening of the graft by way of stretching of the suture. This can cause movement in the graft during subsequent patient mobility which hinders the healing and grafting process. Furthermore, the use of sutures involves the tying of knots which themselves result in some subsequent stretch in the suture, increasing the likelihood that the graft will have inappropriate tension for its intended purpose. The suture itself may also fail under the high tensile forces to which it is subjected during use. PCT/US97/22061 attempts to solve this problem by providing an interference fit insertion element with a proximal apperture through which a graft may be threaded or attached. The technique involves securement of the interference end of the device into the central cancellous area of the bone. Unfortunately, this softer area of the bone may not provide sufficient anchoring of the device to resist the tensions to which the graft is subject in use.
U.S. Pat. No. 5037422 also relates to the anchoring of sutures for securement of a suture to a bore hole in a bone. The device is shown secured to the cancellous bone. The device is for use in soft tissue fixation to the outside of the bone and not fixation within the bore hole itself.
Futhermore, it is not suitable for graft fixation and is only applicable to sutures.
A device for graft fixation using sutures is described in EP 0 619 982 where the anchor includes a body and a plurality of barbs located in axially aligned, circumferentially spaced relation to each other about the body. The barbs have a normal configuration wherein they extend rearwardly and radially outwardly from the anchor body to outer ends which are normally located outside a longitudinal projection of the largest geometric cross-section of the body transverse to its longitudinal axis. The device utilises sutures and suffers from the drawbacks previously outlined. It also relies upon interference between the barbs and the soft cancellous bone area.
SUMMARY OF THE INVENTION
According to the present invention there is provided a bone anchor suitable for soft tissue-bone fixation comprising an anchoring member, the anchoring member having a head portion at the distal end thereof and supporting means at the proximal end thereof operable to be urged against the inside surface of the cortical bone, wherein soft tissue locating means are located on the exterior of at least the said head portion.
Advantageously, by having soft tissue locating means on the exterior of the head portion, the soft tissue may be securely located over the exterior of the head to anchor the soft tissue in position. Compression force may then be applied from the trailing ends of the soft tissue urging the support means against the inside surface of the cortical bone through which the hole has been drilled.
A further advantage of the locating means is that it allows the soft tissue to be anchored directly by the anchoring member without the need for interconnecting sutures.
To carry out its function of being urged against the inside surface of the cortical bone in the region around the hole that has been drilled, in use, at least a part of the supporting means is preferably wider or capable of being made wider than the hole that has been drilled.
Preferably, access means are provided in the body of the anchoring member to allow the soft tissue access from the exterior of the member to the hole in the bone.
The access means may be in the form of one or more apertures but, preferably, the supporting means is in the form of a number of legs depending from the head portion and a guide means or spacing between adjacent legs provides access from the exterior of the anchoring member to the hole in the bone.
Preferably, the locating means extends, at least partially, down the outside of the sides of the anchoring member to guide the elongate soft tissue and, preferably, urge it against the walls of the bone hole. Advantageously, this encourages grafting of the soft tissue to the surrounding bone.
Preferably, at least the lowermost portion of the supporting means at the proximal end of the anchoring member extends outwardly to a greater extent than the head portion.
The supporting means may be inwardly radially resiliently deformable at least at the said lowermost portion thereof, so that by compressing the sides of the supporting means radially inwardly, a lowermost portion which is wider than the bone hole may be eased therethrough and, upon release of the compression, the supporting means may then expand inside the hole so that the supporting means may then be urged back against the bone so that the bottom surface at proximal end of the supporting means abuts against the inside surface of the cortical bone in the region around the hole.
The legs may be thickened on the outside thereof at the proximal end to provide the wider lowermost portion of the anchor. Preferably, the anchor member is hollow and the thickness of the bottom surface at the proximal end thereof is such that, in use, the outermost portion of the surface is urged against the inside surface of the cortical bone around the region of the hole whereas the innermost portion of the surface projects over the hole. In this manner, when the proximal end comprises the ends of a number of legs, the gaps between adjacent legs provide access to the hole for tissue guided between adjacent legs. Alternatively, or in addition, the supporting means may be outwardly expandable, preferably, by use of expansion means.
Preferably, the supporting means may be expanded by means of a wedge means or an expansion tool Preferably, the supporting means comprise a number of legs depending from the head portion and the expansion tool or wedge means may be located between the legs to urge the legs radially outwardly with respect to the bone hole. The wedge means may be driven into the anchor means to urge the legs radially outward with respect to the hole. The wedge means may be left in the anchor after use. The wedge means may be in the form of a peg but any suitable shape which could be accommodated by the anchor between the legs may be employed.
Preferably, at least three legs depend from the head portion, more preferably, at least four legs, most preferably, four legs depend from the head portion. The legs may merge together above the lowermost portion and be spaced apart only at the proximal end of the anchoring member.
Preferably, the wedge means is narrower than the hole drilled so that, in use, access to the hole is possible radially outward of the wedge means.
Preferably, the locating means comprises a recessed portion over the distal end of the anchoring member which is suitable to securely locate elongate soft tissue such as tendon, ligament or substitutes therefor. Preferably, the locating means comprises a guide means across the distal end for the elongate soft tissue. Preferably, the recessed portion forms a guide portion for the said elongate soft-tissue. Preferably, there are two such guide means or portions which, preferably, cross each other at the centre of the outside of the said head portion. Preferably, the said two guide portions are substantially at right angles.
The head portion may comprise the distal ends of the legs where the latter merge together at the said distal ends thereof.
Typically, a guide channel is at least partially formed between adjacent legs. At the proximal end, where the legs separate, the channel may be formed by the adjacent sides of neighbouring legs and the wedge means between the said legs.
The head portion may be formed by the merging of the said legs. Preferably, by the merging of at least three such legs, more preferably by the merging of at least four such legs, most preferably, by the merging of four such legs. Preferably, the legs are equidistant.
The recessed portion may be formed by the top surface of the legs, at the distal end thereof. Preferably the top surface of each leg is angled downwardly toward the centre of the head portion to thereby provide the said recessed portion which prevents elongate soft tissue located over the head from sliding off the head in use.
Preferably, the wedge means may be secured in the anchoring member by suitable means to prevent it coming out in use. In some embodiments, the wedge means and inside surface of the legs co-operate in a rib and groove arrangement. The groove may be located on the legs or on the wedge means but to ease entry of the wedge between the legs, the rib is generally located around the wedge means at the proximal end thereof and corresponding grooves are found on the inside of the legs at the proximal end thereof
Preferably, elongate guides extend down the outside of the bone anchor to guide elongate soft tissue, preferably, the guides are recessed into the sides of the bone anchor.
Preferably, the area between the sides of adjacent legs forms an elongate guide to guide the elongate soft tissue from the head portion to the bone hole.
Preferably, the guide is designed to only partially accommodate the full thickness of the elongate soft tissue, so that, in use, the latter is urged against the walls of the hole to encourage grafting thereof.
Preferably, the anchoring member is designed so that a compression force applied at the head portion causes the legs to splay outwardly. Preferably, the bottom surface of the proximal end of the anchoring member legs are distally angled toward the centre line of the anchoring member so that outward splaying of the said legs causes the angle to diminish until the said bottom surface lies substantially in the same plane as the cortical bone against which it abuts. Advantageously, in use, this causes the part of the proximal end in contact with bone to lie flat against the inside surface of the bone for added strength and security. Preferably, in use, the radially outermost part of the bottom surface abuts the region of the inside surface of the cortical bone around the hole and the innermost part extends over the hole in the bone to provide with the adjacent leg an exit hole for the elongate soft tissue and to urge the soft tissue against the cortical bone of the hole to facilitate grafting.
Examples of elongate soft tissue for use with the invention include ligament or tendon, in particular, reconstructed ligament or tendon.
The invention extends to a method of soft tissue-bone fixation utilising the bone anchor. In particular, ligament or tendon fixation at a suitable joint such as the knee, elbow or shoulder. The invention is particularly advantageous in reconstruction of the Anterior Cruciate Ligament (ACL) in the knee or the posterior cruciate ligament (PCL) in the knee. In particular, femoral fixation of the reconstructed ligament. Especially, fixation at the intercondylar notch by mounting the bone anchor on the interior surface of the cortical bone at the intercondylar notch.
According to a second aspect of the present invention there is provided a method of anchoring a graft in a bone comprising the steps of:
forming a tunnel or opening in the bone to a predetermined depth;
securing the graft to the bone anchor so that the trailing ends of the graft extend below the proximal end of the anchor;
inserting the anchor and graft in the tunnel or opening;
and pulling the graft trailing ends to urge the proximal surface of the anchor into contact with the inside surface of the cortical bone around the region of the hole.
Preferably, by pulling the trailing ends, the graft is urged into contact with the walls of the hole.
According to a further aspect there is provided a method of anchoring a bone anchor comprising the steps of:
forming a tunnel or opening in the bone to a predetermined depth;
securing soft-tissue to the anchor;
mounting the bone anchor on the inside surface of the cortical bone;
employing compression means to urge the bone anchor against the said inside surface to provide soft-tissue anchoring.
Preferably, the soft-tissue is elongate and is secured to the anchor so that its trailing ends extend below the proximal end of the anchor.
Preferably, the compression is applied by tensioning the said soft-tissue trailing ends.
Preferably, the soft-tissue is a ligament or tendon graft, more preferably, an ACL or PCL graft.
Preferably, the bone anchor is mounted on the inside surface of the cortical bone at the intercondylar femoral notch, preferably, on the inside surface or distal surface of the cortical bone immediately adjacent the wall of the hole drilled therethrough. The bone anchor may have a plurality of simultaneous mounting points, preferably, at least two, more preferably at least three, most preferably, at least four. Preferably, the mounting points are equally circumferentially spaced with respect to the round hole. Preferably, the mounting points are provided by proximal mounting surfaces at the ends of legs of the bone anchor.
Preferably, the graft is secured to the bone anchor by locating the graft over the outside of a bone anchor according to the first aspect of the invention by placing the graft thereover via the locating means.
Preferably, the method includes the step of locating the graft along the sides of the anchor, preferably, by passing it down elongate guide means located on the side thereof.
Preferably, the method includes the step of expanding the walls of the anchor in the tunnel using wedge means or an expansion tool. Preferably, the wedge is urged up the hollow centre of the anchor to urge the sides outwardly into contact with the walls of the hole and to preferably, provide sufficient contact between the proximal surface of the anchor and the inside surface of the cortical bone so that the anchor is mounted on the said inside surface of the cortical bone.
Preferably, the method includes locating at least two elongate grafts in this manner, preferably, substantially at right angles to each other.
Preferably, the bone anchor comprises bio-compatible materials. For instance, the material may be bio-absorbable material or a non-absorbable permanent material. Such absorbable materials may include trimethylene carbonate copolymers, polylactic acid and polyglycolic acid. Examples of non-absorbable materials include polyethylene, polypropylene, polyester and acetal homopolymers. Alternatively, copolymers of any of the foregoing may be utilised.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention will now be described by way of example, with reference to the accompanying drawings in which:
FIG. 1 a is a plan view of a bone anchor in accordance with the first invention;
FIG. 1 b is a detail of a peg securing groove in accordance with the present invention;
FIG. 1 c is a front elevation of the bone anchor of FIG. 1 a;
FIG. 1 d is a perspective view of the bone anchor;
FIG. 1 e is a cross section along a line K—K of figure 1 a;
FIG. 1 f is a cross section along line P—P of FIG. 1 a;
FIG. 1 g shows a possible tendon profile of a tendon located over the bone anchor;
FIG. 2 a is a peg according to the present invention;
FIG. 2 b is a detailed view of part of the rib at the proximal end of the peg of FIG. 2 a.
FIG. 3 is a cross-section through a bone anchor mounted on the inside surface of the cortical bone; and
FIG. 4 shows a graft reconstruction of an ACL.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, a bone anchor 2 comprises four elongate coextensive legs which are arranged in cruciform in plan view. Each leg has a generally non uniform rectilinear section. The legs are merged together at the upper distal end 4 of the bone anchor but separate as they extend to the proximal end 6 of the bone anchor.
After separating the inside faces 8 ( a-d ) of the legs radiates outwardly as it extends towards the proximal end 6 so that a wedge receiving socket 10 is formed by the space between the legs on the inside of the bone anchor 2 . The exterior surfaces 12 ( a-d ) of each leg are arcuate in section to closely accommodate the bore hole profile. The main part of this surface of the leg extends parallel with the corresponding surface on the opposed leg. However, the surface extends radially outwardly at the proximal end 6 of the bone anchor 2 to form a thickened radially outermost portion 32 of each leg and extends radially inwardly at the distal end 4 of the bone anchor 2 . The lower surface 14 ( a-d ) of each leg at the proximal end 6 thereof is angled distally towards the centre line of the bone anchor so that a flat surface is presented to an underlying bone surface when the legs 20 - 26 splay outwardly under compression forces acting at the distal end 4 of the bone anchor 2 . The compression force is provided by elongate grafts which are located over the distal end 4 and guided between adjacent legs of the bone anchor. At the distal end 4 of each leg 20 - 26 , the leg upper end surface angles proximally towards the centre of the bone anchor. In this manner, a recess is provided at the distal end 4 of the bone anchor.
The sides 28 , 30 of each leg extend parallel with each ocher and are generally planar along the whole of their length. However, the sides are thickened at the proximal end 6 of the bone anchor by the outwardly thickened portion 32 which also extends circumferentially at the lateral edges thereof. At the distal end of the legs, the sides angle inwardly to meet each other in an apex 34 . The line of the apex itself is angled proximally towards the centre of the bone anchor as previously described.
Due to the shape of the bone anchor described, two reconstructed ligaments or tendons may be located cross wise over the distal end 4 of the bone anchor 2 so that the trailing ends thereof are guided down towards the bone outlet between adjacent legs. In this way, the reconstructed ligament or tendon is securely held in position between adjacent legs on opposed sides of the bone anchor and in the recess across the head of the bone anchor. The other reconstructed ligament or tendon is similarly located at right angles to the first reconstructed ligament or tendon. The trailing ends of the reconstructed ligaments or tendons may then pass out through the bone hole at the proximal end of the legs. By putting the trailing ends of the ligaments so fixated under tension, a compression force is applied to the bone anchor at the distal end thereof. This causes the legs 20 - 26 to splay outwardly to urge the legs into firmer engagement with the bore hole. As the proximal end of the legs is thickened, a proportion of the bottom surface 14 thereof is urged against the inside surface of the cortical bone through which the hole has been drilled. The splaying of the legs also causes the distally angled bottom surface 14 to come into the plane of the inside surface of the cortical bone providing a flat base for anchoring against the bone.
By locating the reconstructed graft on the outside of the bone anchor, the graft is encouraged to graft onto the walls of the bore hole and the cortical bone at the entrance to the tunnel. Furthermore, by increasing tension in the graft, which may occur during subsequent use by the patient, the bone anchor is urged outwardly with respect to the bore hole and the inside surface of the cortical bone causing more pronounced fixation.
Referring to FIG. 1 g , the tendon profile located between adjacent legs 20 , 26 is shown to follow the profile of the bore hole. By carefully constructing the replacement graft and/or the dimensions of the bone anchor, the tendon profile 40 may be urged radially outwardly into the bore hole and cortical bone at the outlet causing a greater likelihood of graft fixation. FIG. 2 a shows a peg 50 which is designed to be close fitting with the peg receiving cavity 10 formed between the inside surfaces of the legs 20 - 26 . In use, after bone anchor and ligament fixation, the peg may be urged into the peg receiving cavity 10 . A circumferencial rib 52 is formed near the base of the peg 50 and a corresponding close fitting groove 54 is formed at corresponding heights on the inside surface of each leg 20 - 26 . As the peg is urged further up the peg receiving cavity 10 the rib 52 eventually slots into the grooves 54 formed on the inside of each leg so that the peg will not-subsequently become dislodged. The peg provides two advantages in that it prevents the legs collapsing inwardly and also may force the legs outwardly to the radial extent to which they were designed.
Referring to FIGS. 3 and 4, a bone anchor 60 of the type previously described with respect to FIGS. 1 and 2 is shown in cross section with reconstructed anterior crucimate ligaments 88 in position. One method of attaching a graft is that used in reconstructing the Anterior Cruciate Ligament (ACL) or the Posterior Cruciate Ligament (PCL). Initially, notchplasty is carried out at the intercondylar notch. This technique is described in U.S. Pat. No. 5139520 (Rosenberg), which is incorporated herein by reference, and is known to those skilled in the art. Typically, a drill guide is used to form a tibial channel 68 . The isometric position required at the femoral surface is located using conventional surgical techniques and a closed end socket 70 is formed in the femur extending from the intercondylar notch at the angle required for ACL fixation. The length of the socket is relatively short and of the order of 2-3 cm. A pair of reconstructed ligaments are then located over the bone anchor as previously described. The bone anchor with the ligaments in position is then inserted into the intercondylar socket 70 as depicted in FIG. 3 . Conventional techniques may then be carried out to secure the trailing ends 72 , 74 at the tibia.
Referring to FIG. 3, the bone anchor 76 is of the same construction as that previously described with respect to FIGS. 1 and 2. The proximal surfaces 78 of the bone anchor 76 abut at the radially outermost portion of the surface against the inside surface 80 of the cortical bone 82 through which hole 84 has been drilled. The radially innermost portion of the surface of the proximal end 78 extends over the hole 84 . The bone anchor 76 is shown prior to insertion of the expansion peg (not shown) which is to be fully inserted in an expansion peg socket 86 formed between the inside surfaces of the legs under the head portion 94 . The effect of the insertion of the expansion peg is to cause the proximal ends 78 of the bone anchor 76 to expand radially and increase the proportion of the proximal end surface 78 which abuts against the s inside surface 80 of the cortical bone 82 . Furthermore, during the surgical operation, the reconstructed ACL ligament 88 is tensioned to the required level which causes the legs to radially expand and thus further secures the bone anchor 76 in position. As is most clearly seen in FIG. 3, the effect of channelling the reconstructed ligament 88 around the outside surface of the bone anchor 76 causes the ligament to come into direct contact with the cancellous bone 90 and cortical bone 92 encouraging the grafting process. Furthermore, due to the absence of sutures securing the reconstructed ligament 88 to the bone anchor 76 , there is a reduced risk of longitudinal movement of the reconstructed ligament 88 during use further increasing the likelihood that the graft will take. As a further advantage, the absence of sutures also prevent failure of the ligament anchor during use.
The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.
All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.
Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
The invention is not restricted to the details of the foregoing embodiment (s). The invention extend to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
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The invention describes a bone anchor 76 comprising a head region 94 and supporting legs 78 and a method for soft tissue-bone grafting using the said bone anchor 76 . A hole 84 is drilled through cortical bone 82 forming a socket 70 in a cancellous bone 90 , and the bone anchor 76 is inserted therein thereby trapping ligaments 88 a and 88 b between the radially outermost portion of the anchor 76 and the inside surface of the socket 70 . An optional expansion peg (not shown) is inserted into a hole 86 within the bone anchor 76 , thereby causing the proximal ends of the legs 70 of the bone anchor 76 to expand radially causing the ligaments 88 a and 88 b to closely abut the cancellous bone 90 thereby encouraging the grafting process.
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BACKGROUND
For purposes of enhancing the production of a hydrocarbon (oil or gas) from a hydrocarbon-bearing reservoir, a hydraulic fracture operation may be conducted to induce fractures in the reservoir rock. With hydraulic fracturing, a fracturing fluid is pumped downhole to create a downhole hydraulic pressure that causes a network of fractures to form in the reservoir rock. A fracture pack (proppant, for example) may be communicated downhole with the fracturing fluid for purposes of depositing the pack inside the fractures to hold the fractures open when the hydraulic pressure is released. To observe the progress, geometry and extent of an ongoing fracturing operation, hydraulic fracture monitoring (HFM) may be employed. With passive micro-seismic HFM, an array of geophones may be deployed on the surface, in a neighboring well or in the well to be fractured and used to map microseismic events, which are created by the fracturing process.
SUMMARY
The summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.
In an example implementation, an apparatus usable with a well includes an explosive pellet that is adapted to be communicated into the well via a fluid and includes an explosive material that is adapted to be detonated downhole in the well. The apparatus further includes an encapsulant to encapsulate the explosive pellet to inhibit unintended detonation of the explosive material. The encapsulant is adapted to be at least partially removed from the explosive pellet in response to the explosive pellet being communicated into the well.
In another example implementation, a technique that is usable with a well includes pumping a fluid into the well to communicate an explosive pellet into the well and detonating the explosive pellet downhole in the well. The technique includes using an encapsulant to encapsulate the explosive pellet to inhibit unintended detonation of the explosive material; and at least partially removing the encapsulant in response to communicating the explosive pellet into the well.
In yet another example implementation, a technique that is usable with a well includes providing a device adapted to launch ball sealers into the well and encapsulating an explosive pellet with an encapsulant to cause the encapsulated explosive pellet to have a form factor that is substantially the same as a ball sealer form factor. The technique includes using the device to communicate the explosive pellet into the well.
Advantages and other features will become apparent from the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a well system according to an example implementation.
FIG. 2 is a schematic cross-sectional view of an explosive pellet according to an example implementation.
FIG. 3 is a perspective view of an encapsulated explosive pellet according to an example implementation.
FIG. 4 is a schematic cross-sectional view taken along line 4 - 4 of FIG. 3 according to an example implementation.
FIG. 5 is a schematic cross-sectional view of a portion of a well illustrating the use of a restriction in downhole equipment to remove an outer layer of an encapsulated explosive pellet according to an example implementation.
FIGS. 6 , 8 , 10 and 12 are schematic cross-sectional views of encapsulated explosive pellets according to further example implementations.
FIGS. 7 , 9 , 11 and 13 are flow diagrams depicting techniques to construct and use encapsulated explosive pellets according to example implementations.
DETAILED DESCRIPTION
In the following description, numerous details are set forth to provide an understanding of features of various embodiments. However, it will be understood by those skilled in the art that the subject matter that is set forth in the claims may be practiced without these details and that numerous variations or modifications from the described embodiments are possible.
As used herein, terms, such as “up” and “down”; “upper” and “lower”; “upwardly” and downwardly”; “upstream” and “downstream”; “above” and “below”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments. However, when applied to equipment and methods for use in environments that are deviated or horizontal, such terms may refer to a left to right, right to left, or other relationship as appropriate.
Although passive micro-seismic hydraulic fracture monitoring (HFM) may be relatively useful in providing information about the geometry and extent of fractures, the resolution and overall quality of the HFM data may be enhanced, in accordance with example implementations disclosed herein, through the use of relatively small explosive pellets that are pumped into the fractures. More specifically, systems and techniques are disclosed herein for purposes of encapsulating an explosive pellet and deploying the encapsulated explosive pellet in a well. The encapsulated explosive pellet may be used to enhance HFM, as well as be used for other purposes, such as stimulating the well, providing a triggering mechanism for other devices, functioning as acoustic sources, etc. For the specific example application of HFM, increased accuracy may be achieved in HFM by introducing explosive pellets into the fractures that are created by the hydraulic fracturing and monitoring the acoustic energies (using geophones, for example) generated by the pellets when they explode. As examples, the explosive pellets may be constructed to be detonated downhole by the temperatures and/or stresses in the downhole environment, such as the stresses or temperatures that are experienced inside the downhole fracture network.
As disclosed herein, the explosive pellets are encapsulated, which imparts certain safety characteristics. In this manner, the encapsulation mitigates, if not prevents, unintended stresses on the pellets during the handling, storage, transportation and conveyance into the well of the pellets, which have the potential of causing unintended pellet detonation. The encapsulation also enhances deployment of the explosive pellets into the well, as the encapsulation may be used to transform the form factor of the explosive pellet to the form factor of a ball sealer or other convenient shape, thereby allowing the use of a conventional ball sealer launcher or similar devices to deploy encapsulated explosive pellets into the well. Moreover, as disclosed herein, the encapsulant is constructed to be readily removed, or released, when the explosive pellet is released into the well or at least when the downhole pellet approaches the fracture network, for purposes of allowing the encapsulation to provide the aforementioned storage, transportation and delivery features, as well as allow the pellet to perform its intended downhole function.
Turning now to a more specific example of the use of encapsulated explosive pellets for HFM, referring to FIG. 1 , a well system 5 includes a wellbore 12 that extends into a particular example zone, or stage 50 , which has been perforated (as shown by perforation tunnels 60 ) and fractured to some degree (as shown by exemplary fractures 62 ). The well system 5 may include HFM monitoring equipment (not shown in FIG. 1 ) for purposes of monitoring the progress of the hydraulic fracturing. More specifically, as depicted in FIG. 1 , the fracturing fluid may be pumped directly into the wellbore 12 through the central passageway of a casing string 20 , and encapsulated explosive pellets 10 may be communicated with the fracturing fluid into the perforated zone of the well 50 . In an alternate scenario, the hydraulic fracturing fluid and the encapsulated explosive pellets may be communicated into the wellbore 12 through a tubing string (not depicted in FIG. 1 ) that extends from the Earth surface E to a position just above the perforated zone of the well 50 .
For this example, the wellbore 12 is “cased,” or lined by the casing string 20 , which supports the wellbore 12 . To this end, the casing string 20 includes perforation openings 54 that correspond to the perforation tunnels 60 and may be formed by the shaped charge perforation jets (produced by a perforating gun) that form the tunnels 60 . In further implementations, the casing string 20 may pre-perforated; may have sleeve valves that are opened to establish hydraulic communication; or may be formed using an abrasive fluid jetting tool. In another example, the well could be open-hole in the zone of interest.
As depicted in FIG. 1 , the explosive pellets 10 may be communicated into the well (via directly through the casing, for example, or through a central passageway of tubing string positioned from the surface to just above the perforated zone of the well 50 ) by pumping a fracturing fluid supplied by a fluid source 6 (at the Earth surface E) via an Earth surface E-disposed pump 7 . For this example, in preparation to be delivered into the well, the encapsulated explosive pellets 10 are stored at the Earth surface E inside a ball sealer launcher 9 , which is constructed to be operated to deliver the pellets 10 into the well. In this manner, as further disclosed herein, in accordance with example implementations, the encapsulated explosive pellet 10 has a form factor (i.e., dimensions, or geometry) that corresponds to the form factor of a ball sealer (e.g., the encapsulated explosive pellet 10 has outer dimensions and geometry that are consistent with the outer dimensions of a ball sealer), and as such, a conventional ball sealer launcher 9 , or another device that is constructed to deliver, or launch objects having a given form factor that differs from the form factor (i.e., the outer dimensions) of the inner pellet, may be used for purposes of deploying the encapsulated explosive pellets 10 into the well, in accordance with example implementations.
As shown in FIG. 1 , in accordance with example implementations, the ball sealer launcher 9 , or an equivalent device, is disposed downstream from the pump 7 so that the deployed encapsulated explosive pellets 10 (deployed in a flow F downstream of the pump 7 ) are not communicated through the flow path of the pump 7 . When deployed into the well, the encapsulated explosive pellets 10 travel downhole, for example, are communicated into the well through the casing 20 or through a central tubing string positioned from the surface to just above the perforated zone of the well 50 , the encapsulating materials are removed, the inner explosive pellets are translated to the perforated zone of the well 50 , and the explosive pellets follow the fluid flow lines into the perforation tunnels 60 .
Referring to FIG. 3 , in accordance with an example implementation, the encapsulated explosive pellet 10 includes an inner, elongated explosive pellet 100 , which is surrounded by an encapsulant 140 that imparts a generally spherical shape (as an example) for the encapsulated explosive pellet 10 . Referring to FIG. 2 in conjunction with FIG. 3 , in accordance with an example implementation, the inner explosive pellet 100 may be formed from an explosive casing, or housing 110 , which contains, for example, an initiator 120 and secondary explosives 116 and 118 which are disposed on either side of the initiator 120 .
The housing 110 of the explosive pellet 100 may be made of any suitable material including metals and metal alloys, such as stainless steel, aluminum, or the like. As depicted in FIG. 2 , the housing 110 may be elongated in the general form of an open circular cylinder (as an example) that is closed by an end cap; and the housing 110 may have a length ranging from a low of about 0.5 centimeters (cm), about 1.0 cm, about 1.5 cm, or about 2.0 cm to a high of about 2.5 cm, about 3.0 cm, about 4.0 cm, about 5.0 cm, or more. For example, the length can be about 2.5 cm to about 4.0 cm. The housing 110 may have an outer cross-sectional diameter ranging from a low of about 0.3 cm, about 0.6 cm, about 0.7 cm, about 0.8 cm, or about 0.9 cm to a high of about 1.1 cm, about 1.2 cm, about 1.3 cm, about 1.4 cm, about 1.5 cm, or more. For example, the outer diameter of the housing 110 may be about 0.7 cm to about 1.0 cm. The housing 110 may have an inner cross-sectional diameter ranging from a low of about 0.2 cm, about 0.4 cm, about 0.5 cm, about 0.6 cm, or about 0.7 cm to a high of about 0.8 cm, about 0.9 cm, about 1.0 cm, about 1.1 cm, about 1.2 cm, or more. For example, the inner diameter may be about 0.5 cm to about 0.7 cm. Accordingly, the thickness of the wall of the housing 110 may range from a low of about 0.025 cm, about 0.05 cm about 0.1 cm, or about 0.2 cm to a high of about 0.3 cm, about 0.4 cm, about 0.5 cm, or more. For example, the thickness of the wall of the housing 110 can be about 0.05 cm to about 0.2 cm.
When the housing 110 is sufficiently stressed in the downhole environment, the effect of the resulting stress ignites the initiator 120 of the pellet 100 , which causes the initiator 120 to burn and build up a sufficient pressure to initiate the secondary explosives 116 and 118 . The initiations of the secondary explosives 116 and 118 , in turn, initiate corresponding adjacent primary explosives 112 and 114 . It is noted that the explosive pellet 100 that is depicted in FIG. 2 is merely an example, as other designs of the explosive pellet may be used, in accordance with further implementations. Details of various example implementations for the explosive pellet may be found, in, for example, U.S. patent application Ser. No. 13/485,546, entitled, “EXPLOSIVE PELLET,” which was filed on May 31, 2012, and is hereby incorporated by reference in its entirety.
Referring to FIG. 4 in conjunction with FIG. 3 , in accordance with an example implementation, the encapsulant 140 ( FIG. 3 ) may be formed from an inert material 154 (a material that does not react with the material of the explosive pellet housing, for example) and an outer, dissolvable layer 150 . In general, the inert material 154 provides support to impart a spherical shape to the encapsulated explosive pellet 10 (cause the form factor of the encapsulated explosive pellet 10 to conform to the form factor of a ball sealer, for example), and the dissolvable, outer layer 150 of the encapsulated explosive pellet 10 surrounds the inert material 154 to provide a release mechanism i.e., a removable mechanism that allows disintegration or otherwise removal of the inert material 154 so that the inner explosive pellet 100 may be released to perform its intended downhole function.
In accordance with some implementations, the outer layer 150 is dissolvable in fracturing fluid. To prevent premature dissolving of the outer layer 150 , the encapsulated explosive pellet 10 may be initially stored in a “compatible” fluid 8 (see FIG. 1 ) inside an interior space 11 of the ball launcher 9 , in accordance with example implementations. In other words, the portion of the ball launcher 9 containing stored encapsulated explosive pellets 10 may be filled, in accordance with example implementations, with a fluid that does not dissolve or react with the outer layer 150 of the pellet 10 (i.e., the pellets 10 may be stored in a fluid in which the outer layer 150 is insoluble).
As examples, in accordance with some implementations, the inert material 154 may be one or more of the following: ceramic proppant; sand proppant; resin coated proppant; sand, in general; silica; rock salt (either potassium chloride, sodium chloride); a polymer material; or a combination of one or more of these materials. Moreover, the dissolvable outer layer 150 may be one or more of the following materials: polyacrylamide (PA); polyacrylamide copolymers; polylactic acid (PLA); polyglycolic acid (PGA) polyvinyl alcohol (PVOH); a polyvinyl alcohol copolymer; a methyl methacrylate; an acrylic acid copolymer; or any combination of one or more of these materials.
In a further implementation, the outer layer 150 may be a non-dissolvable layer, i.e., a layer that is formed from a material that does not react or dissolve in the presence of a well fluid or fluid that is introduced into the well. In this regard, for these implementations, the outer layer 150 may be removed to expose the inert material 154 by the tearing or erosion of the outer layer 150 . For example, in accordance with some implementations, a restriction in well equipment (a restriction in the casing to which the fracturing fluid is pumped, for example) may be sized appropriately to restrict flow of the encapsulated explosive pellet 10 .
Thus, as depicted in FIG. 5 , a given encapsulated explosive pellet 10 may flow along a flow path 160 from a position 10 ′ to a position 10 ″ at which the pellet 10 lodges in a casing perforation opening 54 . In other words, the opening 54 has an effective inner diameter that is smaller than the outer diameter of the encapsulated explosive pellet 10 . Due to the encapsulated explosive pellet 10 becoming lodged in such an opening 54 , the outer layer 150 eventually tears or erodes so that the inert material 154 (without the outer layer 150 ) passes through the opening 54 and thereafter disintegrates as depicted at reference numeral 164 , to release the inner explosive pellet 100 .
The restriction to tear or erode the outer layer 150 may also be in the form of a screen that has openings that are sized smaller than the diameter of the encapsulated explosive pellet 10 . Regardless of the particular form, the flow restriction retains, or holds, the encapsulated explosive pellet 10 in place while a downhole fluid flow tears or erodes the outer layer 150 . In further implementations, the downhole equipment may be constructed so that an outer knife-type edge in a flow restriction serves to tear open the outer layer 150 .
In further implementations, the outer layer 150 may be a non-dissolvable layer, which is eroded or torn due to the encapsulated explosive pellet 10 being sized substantially small to not pass through the perforation tunnel 50 (see FIG. 1 ). Therefore, for these implementations, the encapsulated explosive pellet 10 lodges in the perforation tunnel 50 , until the outer layer 150 is removed, which causes the eventual release of the inner explosive pellet 100 . Thus, many variations are contemplated, which are within the scope of the appended claims.
In further implementations, the outer layer 150 may be a material that has a relatively low temperature melting point. For example, in accordance with some example implementations, the outer layer 150 may be a relatively low melting-temperature polymer, which allows the release of the inert material 154 as the encapsulated explosive pellet 10 travels downhole in the wellbore where the temperature increases accordingly with depth. The polymer that forms the outer layer 150 is compatible with the fracturing fluid inside the ball launcher 9 . In further implementations, the well system 10 (see FIG. 1 ) may include a heating element (not shown) that is disposed downstream of the ball launcher 9 for purposes of intentionally supplying sufficient heat to melt the outer layer 150 , as the encapsulated explosive pellet 10 is introduced into the well.
In further implementations, the outer layer 150 may be designed to be collapsible at the pressures experienced downhole in the well. For example, in accordance with some implementations, the outer layer 150 may have a sufficient thickness to be stable for the pressure used in the ball launcher 9 but may be collapsible at higher pressures, such as the hydrostatic pressures that are present downhole in the well.
As a more specific example, in accordance with some implementations, an encapsulated explosive pellet 170 that is depicted in FIG. 6 may be used. The encapsulated explosive pellet 170 has the same general design as the encapsulated explosive pellet 10 , with like reference numbers being used to designate similar components, except that the pellet 170 has an outer layer 174 (replacing the outer layer 150 ) that is formed from a non-dissolvable material 175 and has at least one rupture disk 176 (a relatively thinner portion of the material 175 or another relatively thin material, as examples) that is constructed to be breached, or rupture, at downhole pressures.
Thus, referring to FIG. 7 , in accordance with example implementations, a technique 200 may be used for purposes of encapsulating an explosive pellet and using the encapsulated explosive pellet in a well. Pursuant to the technique 200 , an explosive pellet is surrounded (block 204 ) with an inert material. The inert material may be surrounded (block 208 ) with an outer layer that is selected from one of the following: a dissolvable outer layer; an outer layer constructed to be removed by erosion; an outer layer constructed to be removed by contact force; an outer layer having a relatively low temperature melting point; and an outer layer that is constructed to collapse at wellbore pressure. The encapsulated explosive pellet may be pumped downhole into the well, pursuant to block 212 , where the encapsulant is at least partially removed to allow the explosive pellet to perform its intended function.
Referring to FIG. 8 , in accordance with further implementations, an encapsulated explosive pellet 300 may be formed by surrounding an explosive pellet 100 with an encapsulating material 304 that encapsulates the explosive pellet 100 and is bonded together by a dissolvable binder material. For this example, the encapsulated explosive pellet 300 does not have an outer layer that surrounds the inert material 304 . As an example, the encapsulating material 304 may be formed mostly of an inert material (fracturing sand, for example), which is bonded together using a dissolvable adhesive, or resin. The encapsulating material 304 may be relatively porous, so that the adhesive/resin may dissolve rapidly in the well to release the explosive pellet 100 . For these implementations, the encapsulated explosive pellet 300 may be stored in the ball launcher 9 using a compatible fluid.
Thus, referring to FIG. 9 , in accordance with an example implementation, a technique 320 includes surrounding (block 324 ) an explosive pellet with an inert material and holding, or bonding, the inert material together with a binder, pursuant to block 328 . The resulting encapsulated explosive pellet may then be pumped into the well, pursuant to block 330 .
In accordance with further implementations, the inert material 304 of FIG. 8 may be held together by a non-dissolvable material. For these implementations, the inert material, such as fracturing sand or resin-coated proppant, or a thermoplastic treated with a partial solvent, may be held together using a non-dissolvable adhesive. The resulting encapsulated mass is relatively brittle and weakly bonded and therefore, may be disaggregated to liberate the inner explosive pellet 100 when flowing through a restriction, as discussed above.
In accordance with further implementations, the inert material 304 of FIG. 8 may be held together by a dissolvable material. For these implementations, the inert material, such as fracturing sand or resin-coated proppant, or a thermoplastic treated with a partial solvent, may be held together using a dissolvable adhesive. The resulting encapsulated mass stays bonded while inside of the ball sealer launcher 9 or other device by use of a fluid 8 in which the bonding adhesive is not soluble, but the bonding adhesive begins dissolving in the well when in contact with the well fluids.
As a more specific example, in accordance with some implementations, the encapsulated explosive pellet 300 may be formed by embedding the explosive pellet 100 inside a 20/40 ceramic proppant that is coated with a resin and is placed inside a mold. Using the mold, the ceramic proppant may then be compressed to 1000 pounds per square inch (psi) and heated to 200° Fahrenheit (F) to form the encapsulated explosive pellet. As another variation, the above-described process may be used with the addition that fibers, such as polyactic acid fibers, may be added to the resin-coated ceramic proppant before the above-described application of heat and pressure. As another example, the encapsulated explosive pellet 300 may be formed by pouring a mixture of 20/40 sand and polyactic acid fibers into a mold (where the sand and fibers surround an inner explosive pellet 100 ) and compressing this mixture to 1000 psi. As another variation, a 20/40 ceramic proppant without a resin may be compressed in a mold about the explosive pellet 100 to 1000 psi.
Referring to FIG. 10 , in accordance with further implementations, an encapsulated explosive pellet 350 may be formed from a relatively loose inert material 360 that surrounds the explosive pellet 10 . The inert material 360 is surrounded by an outer layer 354 that is formed from an inert material that is bonded together by a dissolvable material. In this manner, the material 360 may be formed mostly of an inert material, such as fracturing sand; and the outer layer 354 may be formed from fracturing sand or resin-coated proppant or a thermal plastic treated with a partial solvent, which is bonded together using a dissolvable adhesive. The resulting outer layer 354 is relatively brittle, weakly bonded and may be disaggregated to liberate the explosive pellet 100 when flowing through a restriction, as discussed above.
Thus, referring to FIG. 11 , in accordance with some implementations, a technique 400 includes surrounding (block 404 ) an explosive pellet with an inert material and surrounding (block 408 ) the inert material with an outer layer that has an inert material with a dissolvable material. Pursuant to the technique 400 , the encapsulated explosive pellet may then be pumped into the well, pursuant to block 412 .
As yet another example, FIG. 12 depicts an encapsulated explosive pellet 420 in accordance with example implementations. The encapsulated explosive pellet 420 includes an explosive pellet 100 that is encapsulated by a dissolvable material 424 . In this manner, when the encapsulated explosive pellet 420 is introduced into the well, the material 424 begins to dissolve. In accordance with some implementations, the encapsulated explosive pellet 420 may be stored in a compatible fluid inside the ball launcher 9 .
In further implementations, the dissolvable material 424 may be any of the following materials: a surfactant, a polymer, a wax, a plasticizer, an asphalt, a resin or any combination thereof.
Thus, referring to FIG. 13 , in accordance with example implementations, a technique 430 includes surrounding (block 432 ) an explosive pellet with one of the following materials: a surfactant a polymer, a wax, a plasticizer, an asphalt, a resin or any combination thereof. The technique includes pumping (block 436 ) the encapsulated explosive pellet into a well.
While a limited number of examples have been disclosed herein, those skilled in the art, having the benefit of this disclosure, will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations
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An apparatus usable with a well includes an explosive pellet that is adapted to be communicated into the well via a fluid and includes an explosive material that is adapted to be detonated downhole in the well. The apparatus further includes an encapsulant to encapsulate the explosive pellet to inhibit unintended detonation of the explosive material. The encapsulant is adapted to be at least partially removed from the explosive pellet in response to the explosive pellet being communicated into the well.
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